Euro S50 Single Vanos (Euro E36 M3)

In no event shall Beisan Systems, LLC or its members be liable for incidental, consequential, or special loss or damages of any kind however caused.

Introduction

• The vanos discussed here is BMW part # 11-31-1-402-428. In fact , it’s a single vanos, which means that only the intake valve timing is varied.
• Furthermore , this vanos unit is part of the BMW 6-cylinder engine Euro S50B30.
• Notably, this engine was used exclusively in one car model: the 3-series Euro E36 M3, which BMW produced from 1993 to 1995

This vanos has been experiencing a failure. Diagnostics show that the failure primarily results from the deterioration of the vanos intake rod seal. Further analysis confirms that the cup seal is made of Buna rubber (Buna-N, NBR, Nitrile). While Buna is a very common rubber material, it has limitations in temperature and chemical resistance. Unfortunately it is fairing quite badly in the vanos/engine environment. The seal hardens, shrinks, and develops flat surfaces. This deterioration is causing the seal to lose its functional characteristics and thus cause the vanos to fail. BMW has engaged with experts regarding other Vanos failures in the past but has chosen not to address the issues, stating, “We will not pursue further development.” BMW does not provide the vanos rod seal as a separate part.

You can replace the Buna rod seal with a Viton rubber rod seal. Viton (FKM, Fluorocarbon) has similar functional characteristics to Buna, but has much higher temperature and chemical resistance characteristics. But an even better solution is to replace the rod seal with a Teflon equivalent. Teflon (PTFE filled) has a much lower friction property and is more appropriate for dynamic sealing than rubber.

The material is compatible with the engine environment and is a standard choice for this rod cup seal design. In addition, an O-ring is inserted into the cup to provide energizing support for the Teflon. Moreover, Viton is the best material for the O-ring to withstand the engine environment.

The vanos intake piston seal can also in some cases experience a problem.

• This seal consists of a Teflon ring and a machined Viton rubber backing ring. Over time , it can lean to one side, causing the Teflon ring to wear unevenly.
• This issue is caused by two main factors. First , the failure of the rod seal leads to leakage from an oil chamber on one side of the piston seal. As a result , the oil chamber on the opposite side of the piston seal presses against the seal, tilting it.

Second, the piston seal cavity is too wide, which allows the seal to tilt. This issue is caused by the introduction of a paper gasket between the two piston parts, which widens the cavity. This paper gasket functions to maintain the piston parts from spinning during assembly, but has no function after assembly.
You can solve the piston seal problem by replacing the rod seal with a more reliable seal that prevents oil chamber leaks. Additionally, removing the paper gasket restores the piston seal cavity to the correct width and eliminates the excess space.

The vanos solenoid O-rings also fail and in some cases and cause external oil leak.

• These O-rings are made from Buna, and over time , they tend to harden and flatten.
• Although replacing the O-rings with Viton O-rings has been attempted, it has proven ineffective, as the Viton O-rings shred due to the high oil pressure.
• In response to these challenges , BMW has redesigned the solenoid O-rings specifically for the S62 engine (E39 M5) vanos unit.
• Interestingly , the S62 vanos solenoids are identical to those used in the Euro S50 vanos system, meaning they share the same O-rings.

The new S62 solenoid O-rings are not only made from Viton but also have multiple facets. These facets function to divert oil flow away from the O-ring, preventing it from shredding. Furthermore, the new S62 vanos solenoid O-rings feature the correct design and are suitable for use with this vanos solenoid. Please note that these O-rings are purchased directly from BMW and are not included in the Beisan seals kit.

The Euro S50 Sin

gle Vanos also has multiple O-rings used for static sealing. The O-rings, with the exception of one, are made from Viton, which is the correct material. But over time they experience compression set (flattening) and need replacement.

The static sealing O-rings can be replaced with a set of Viton O-rings.

Additionally, a vanos seals/O-rings repair kit can be acquired through Beisan Systems (bee-saan) at www.beisansystems.com/products. This kit includes a vanos(Euro S50 Single Vanos) replacement intake rod Teflon cup seal with an inserted Viton O-ring, an intake piston seal consisting of a Teflon ring and a machined Viton rubber ring, and a replacement set of static Viton O-rings.

Symptoms

Cars experience:
Overall loss of torque and power, particularly in the lower RPM range, < 3k. Bogging then surging at 3k RPM. Symptoms include uneven power distribution and RPM transition, along with engine hesitations in the lower RPM range (below 3k). Additionally, there is a louder idle, intermittent idle RPM hiccups, and difficulty with takeoffs. Loss of power and bogging when AC on. Increased fuel consumption.&lt;br /&gt;Repairing the vanos(Euro S50 Single Vanos) seals provides:
Overall increase in torque and power, particularly in the lower RPM range, < 3k.Resolution of bogging then surging at 3k RPM.

• One of the key benefits is the smooth and even distribution of power, which ensures a seamless RPM transition.
• Additionally , engine hesitations in the lower RPM range (below 3k) are resolved, leading to a more responsive driving experience.
• Furthermore , the engine achieves a quiet and stable idle, contributing to a more refined performance.
• Finally , takeoffs become smooth and effortless, enhancing overall driving comfort.

Improved performance when AC on. Reduced fuel consumption.

Diagnosis 

In general, a diagnosis is not necessary. The vanos Buna intake rod seal deteriorates in 20k miles (32k kilometers). Thus essentially all the cars with this vanos have deteriorated intake rod seal and a failing vanos.

Repair Procedure  

The following is a Euro E36 M3 single vanos seals R&R (remove and replace) procedure.

The valve cover gaskets and bolt grommets on the Euro S50 engine are made from Viton, which ensures they do not fail and therefore do not require replacement.

• On average , the repair time is about 5 hours for a professional mechanic, whereas a DIY repair may take 7 or more hours.
• In terms of materials , you’ll need parts, tools, and shop supplies to complete the job.
• Specifically , parts with a part number pattern like xx-xx-x-xxx-xxx are BMW parts, and as such , they can be acquired directly from a BMW dealership.
• However , Beisan Systems only provides the vanos(Euro S50 Single Vanos) seals repair kit, so additional components may need to be sourced separately .

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Euro S50 single vanos seals repair kit (BS031) $60/each (www.beisansystems.com)

The parts list includes two large solenoid O-rings (part number 11-36-7-830-828), priced at $2.29 each, along with two small solenoid O-rings (part number 11-36-7-830-829), priced at $3.38 each.

Notably , these solenoid O-rings are sourced by BMW from the S62 (E39 M5) Vanos system. Furthermore , they have been redesigned with multiple facets, which serve to prevent shredding under high oil pressure.

As a result , these upgraded O-rings offer improved durability and reliability, ensuring optimal performance in demanding conditions.

Additionally, they are made from Viton, allowing them to withstand high engine temperatures and synthetic oil effectively.

First , you will need a Euro S50 Single Vanos oil filter (part number 11-36-1-401-973), which is priced at $16.27 each. Additionally , ensure you have a Vanos oil filter washer (part number 07-11-9-963-073), priced at just $0.09 each.

Next , make sure to include a Vanos solenoid cover gasket (part number 11-31-1-318-323) in your parts list, which is priced at $14.64 each.

By gathering these components beforehand , you can ensure a smooth and efficient repair process without unnecessary interruptions.

Finally, the required parts include an intake splined shaft and a piston self-locking nut (11-36-1-313-170), each priced at $5.42.

To begin, gather the following tools:

• 2 x putty-knife (small, medium) and a hammer (not shown).
• Additionally, prepare a strait pick, hook pick, 90-degree pick, razor knife, and small medium nose pliers.

Next, ensure you have the following wrenches:

• 24mm combo wrench, 22mm combo wrench, 12mm combo wrench, 10mm combo wrench, and 7mm combo wrench.

Then, collect these tools:

• Flathead screwdriver (medium head), tack lifter, magnet pickup, and a medium mirror.

For socket work, prepare the following:

• 24mm socket 1/2″ (not shown), 10mm socket 3/8″, 4mm socket (6-point) 1/4″, 6mm hex bit socket 3/8″, 5mm hex bit socket 3/8″, 4mm hex bit socket 3/8″, 1/2″ to 3/8″ socket adapter, and 3/8″ to 1/4″ socket adapter.

Furthermore, have these ratchets ready:

• 1/2″ ratchet, 3/8″ ratchet, 1/4″ ratchet, 1/2″ long-arm ratchet, and 3/8″ long-arm ratchet.

Also, include a 3/8″ socket extension (short).

Finally, ensure you have a torque wrench capable of 5 Nm (4 ft-lb) and 12 Nm (9 ft-lb).

First , you will need a BMW crankshaft turning socket (part number 83-30-0-491-056), which is priced at $68.04 each. This specialized tool is essential for safely and accurately turning the crankshaft during maintenance or repairs.

By ensuring you have this tool on hand , you can avoid potential delays and ensure a smooth workflow while working on the engine.

However, you can substitute this tool with a 36mm 12-point socket (1/2″.

For mechanical fan removal, gather the following tools:

• A 32mm combo wrench,
• A BMW water pump pulley holder (83-30-0-491-046) priced at $37.76 each, and
• A handheld sledgehammer (3lb).

Additionally, note that aftermarket vendors, including eBay, often offer the water pump pulley holder. It is typically listed under its original BMW part number, 115030. You can also often find it in a combination tool set that includes a 32mm slim open wrench.

• To prepare for the repair , gather the necessary supplies, including paper towels, a water-based cleaner (such as Simple Green diluted 1:10), brake cleaner, spray lubricant, and assembly oil (lubricant oil).
• Additionally , ensure you have a parts plate and gasket sealant on hand, as these will be essential for the process.
• Before beginning , it’s important to note that the car engine must be cold to safely perform the repair procedure.

• Furthermore, keep in mind that “Right” and “Left” refer to the car’s orientation as viewed from the front while facing the hood.

• To start the disassembly , begin with the removal of the fan and shroud.
• Specifically , for the Euro E36 M3, follow the steps for fan and shroud removal.
• Next , proceed with the removal of the valve cover, which is a critical step in accessing the internal components.

Detach the Engine Top Cover:
First, begin by eliminating the 4 cover mounting bolts using a 5mm hex bit socket (3/8″) and a 3/8″ ratchet .

Once the bolts are removed, carefully lift the cover away from the engine, ensuring that you avoid any contact with surrounding components to prevent damage.

By following these steps in order, you can safely and efficiently remove the engine top cover without causing any unintended issues.

Disconnect Ignition Coils Electrical Cable Connectors:
Start by locating the ignition coils. For each coil, pull up on the coil connector’s metal lock to release it, and then pull off the electrical cable connector.

• Detach the Coil Electrical Cables Mounting Bracket:
  Begin by locating the bracket’s 2 mounting nuts. Then, use a 10mm socket (3/8″), a 3/8″ ratchet, and an extension to loosen and remove the nuts.After removing the nuts, carefully lift the bracket off the mounting studs.

First , remove the coil cables’ rear boot rubber block from the valve cover. Once it is detached , rotate the cables, bracket, and boot to the side. Next , carefully wedge the boot between the air conditioning valve stem and the upper cable harness boot.

By following these steps in order , you can ensure that the components are safely repositioned without causing any damage or interference.

• To begin , remove the coils by first removing the two mounting nuts at each coil using a 10mm socket, 3/8″ ratchet, and extension.
• Next , pull up and out on all the coils to detach them completely from their positions.
• As a reminder , maintain the coil/cylinder association during removal, as this will ensure proper alignment during reinstallation.

This is not necessary, but is good practice.

• To begin , detach the valve cover ground wire from the rear valve cover by first eliminating the mounting nut using a 10mm socket (3/8″) and a 3/8″ ratchet.
• Once the nut is removed , carefully withdraw the ground wire from the valve cover stud.
• Finally , set the ground wire to the rear of the work area to keep it out of the way during subsequent steps.

Start by locating the 16 bolts around the perimeter of the valve cover. Then, using a 10mm socket (3/8″), a 3/8″ ratchet, and an extension, remove all 16 bolts along with their grommets. For easier removal, use a tack lifter to help pry out the grommets if necessary.

• Note that the rear center bolt has limited access, which makes it more challenging to remove.
• To address this , use a 10mm socket (3/8″), a 1/2″ ratchet, and a 1/2″ to 3/8″ socket adapter with an extension.
• Additionally , a tack lifter can assist in this step, making the process easier and more efficient

Additionally, note that the front center bolt is shorter than the others.

Remove the 4 Valve Cover Mounting Bolts with Grommets:
First, locate the 4 bolts at the center of the valve cover. Then, using a 10mm socket (3/8″), a 3/8″ ratchet, and an extension, remove the bolts along with their grommets. If needed, use a tack lifter to help pry out the grommets.

Note: These bolts are shorter than the others.

• To begin , remove the valve cover from the engine head by inserting a blade (medium putty-knife) between the valve cover gasket and the engine head.
• Next , pry up at all accessible locations along the front end to break the gasket bond.
• Additionally , be sure to focus on breaking the gasket sealant bond at the front corners, as these areas tend to adhere more strongly.

Repeat blade insertion and prying until cover gasket seize breaks and cover lifts.

• You might need to apply notable prying force at the front center to break the seize.
• Note: If the valve cover cannot be removed, double-check that the 16 perimeter bolts and 4 center bolts of the valve cover have been removed.

Remove the Valve Cover:
First, carefully lift up and remove the valve cover from the engine head.

Next, remove the valve cover perimeter gasket.

Finally, take out the valve cover spark plug well gaskets.

Removal of vanos

Locate 4 center torx bolts on crankshaft pulley (mirror).

• To begin , position the crankshaft turning socket onto the crankshaft pulley by aligning it with the four center Torx bolts.
• For better visibility , use a mirror to ensure proper placement of the socket before tightening.

• Next , mount the ratchet onto the crankshaft turning socket, ensuring a secure connection.
• For this step , use a 1/2″ long-arm ratchet to provide better leverage and control during operation.

If manual transmission, place transmission in neutral. This allows turning of crankshaft.
Turn crankshaft pulley clockwise until cylinder 1 intake and exhaust cams point to each other at ~45 degree angle (crankshaft turning socket / 1/2″ long-arm ratchet).
Note that turning the crankshaft counterclockwise is acceptable.

• To start , inspect the TDC (top dead center) timing marks on the engine timing cover and the crankshaft harmonic balancer, which are located at approximately the 11 o’clock position. For better visibility , use a mirror to clearly see the marks.
• Following that , adjust the crankshaft pulley to align the TDC timing marks, ensuring precise movement by using the crankshaft turning socket and a 1/2″ long-arm ratchet.
• Finally, make sure the pointer on the timing cover aligns with the single mark on the harmonic balancer, as this alignment is critical for accurate timing.

If the timing cover timing mark is not visible, clean the cover with brake cleaner and towels to reveal the mark. Additionally, if the timing marks on the harmonic balancer are not visible, they may be concealed behind the water pump pulley.

Turn crankshaft pulley counter clockwise.
Note: Precise alignment is not necessary.

Detach the VANOS Electrical Connectors Cover by first locating the cover’s 2 mounting nuts. Then, using a 10mm socket (3/8″) and a 3/8″ ratchet, remove the nuts. Afterward, once the nuts are removed, carefully remove the cover.

To disconnect the VANOS solenoid 2 electrical cable connectors, first press in the connector wire clip. Then, pull off the connector.

First , take a double-length, double-layer towel and carefully insert it under the VANOS. Next , position the towel so that it rests securely on the thermostat and the radiator lower hose.

By doing this , you can provide effective protection for surrounding components and prevent any potential damage or contamination during the process.

Remove the VANOS oil accumulator pipe by first removing the oil pipe mounting bolt with a 12mm open wrench. Afterward, pull the oil pipe out from the VANOS and set it above the VANOS (as shown in the next picture).

Slightly loosen vanos oil pressure restrictor (22mm open wrench).
Note: Pressure restrictor work will be performed at bench. Loosening is easier to perform while vanos is mounted.

• To start , pry the upper solenoid out of the VANOS body by leveraging against the VANOS body itself. For this step , use a medium-head flathead screwdriver to carefully pry the solenoid from the mid-body groove.
• If needed , make several attempts from different positions to fully remove the solenoid, as it may require extra effort to loosen.
• However , be sure not to leverage against the solenoid circuit board, as it is delicate and can be easily damaged.
• Once the solenoid is free , proceed to remove it completely from the VANOS.

• To begin , pry the lower solenoid out of the VANOS body by leveraging against the VANOS body itself. For this step , use a medium-head flathead screwdriver to carefully pry the solenoid from the mid-body groove.
• If necessary , try multiple positions to successfully remove the solenoid, as it may require additional effort to fully loosen.
• However , avoid leveraging against the solenoid circuit board, as it is fragile and can be easily damaged.
• Once the solenoid is free , take it out of the VANOS and set it aside for inspection or replacement.

Insert towels in vanos solenoid chambers to protect oil passages from debris contamination (towels).

Exhaust camshaft groove on first guide bearing will be roughly aligned with groove on first bearing cover (picture).

Fully retard intake camshaft timing.
Place open wrench (24mm combo wrench) on intake camshaft hex at front of camshaft.
Rotate intake camshaft counter clockwise to adjustment end position. If camshaft resistant to rotation rock camshaft back and forth to release seize.
Note: Rotating camshaft is most effective when standing at exhaust side of car.
Camshaft groove on first guide bearing will be roughly aligned with groove on first bearing cover (picture).

Note: Camshaft adjustment causes full camshaft timing retard. This causes splined shaft and vanos piston forward positioning. This facilitates access for disconnecting splined shaft from vanos piston in coming step.

h=”512″ height=”384″ />
lass=”yoast-text-mark” />&amp;amp;gt;/>Remove vanos(Euro S50 Single Vanos) intake cylinder cover bolts.
Remove cover 6 mounting bolts (4mm hex bit socket 3/8″ / 3/8″ ratchet).
Note: If bolt not removed previously, paint drop will be found at bolt head base and cover. This is used in car assembly to verify bolt is fully tightened with toque wrench.

Remove intake cylinder cover.
Pry cover at multiple locations to remove cover evenly (small putty-knife).
Note: Orient blade with edge ramp side to vanos body. This orientation is more effective.
Note: Cover resistance is due to cover sealing O-ring.

Remove vanos intake piston mounting nut.
Initially loosen nut by counter holding splined shaft stud and unscrewing nut (7mm box wrench, 4mm socket (6-point) 1/4″ / 1/4″ ratchet).
Once nut is loosened, unscrew nut by counter holding nut and screwing splined shaft stud (7mm box wrench, 4mm socket (6 point) 1/4″ / 1/4″ ratchet).
When nut is close to end of shaft and shaft can no longer be held with tool, counter hold piston/shaft by hand and unscrew nut (fingers, 7mm box wrench).

Consider using a 6-point socket, as a 12-point socket is susceptible to stripping the shaft hex. Additionally, be sure to use the box end of the wrench, as an open wrench is prone to stripping the nut hex.

• Referring to the picture , locate the TDC sensor positioned in the VANOS bridge.
• For Step 1 , use a 5mm hex bit socket and a 3/8″ ratchet to remove the three sensor plate mounting bolts. Once the bolts are loosened , take care not to lose any components, as they are small and easily misplaced.
• Moving on to Step 2 , next, carefully take off the sensor plate along with the sensor and set it aside. This step is crucial , as it ensures the parts are safely removed and ready for the next stage of the process.

Step 3: Next, remove the nine Vanos mounting bolts—five upper and four lower—using the same 5mm hex bit socket and 3/8″ ratchet.

Note: Upper right and left end bolts are long. Right bolt is fully threaded and left bolt is partially threaded.
Note: Lower second bolt from right also mounts vanos ground wire.

Remove vanos bridge bolts.
Remove vanos bridge 4 mounting bolts (6mm hex bit socket 3/8″ / 3/8″ long-arm ratchet).
Note: Center 2 bolts are long and outer 2 bolts are short.

Remove vanos bridge.
Wiggle vanos bridge while pulling up to remove vanos bridge from engine head.
Note: Gasket sealant at base of bridge acts as adhesive mounting bridge to engine head. Wiggling bridge helps break sealant bond.

Caution: When removing vanos, exhaust oil pump driver must be held in place on vanos then removed. Otherwise driver will fall in oil pan.

While holding the exhaust oil pump driver on the Vanos, carefully pry the Vanos forward off the engine head.
Use a medium putty knife to pry between the Vanos and the engine head at the top right and left ends.
Rotate evenly between each side as you pry until the Vanos releases and separates from the engine head.
Note: Vanos resistance is due to vanos intake and exhaust head sealing O-rings.

Pull the VANOS forward off the head and remove the exhaust oil pump driver.

Note: After the VANOS comes off the engine head, it will be suspended on the intake splined shaft.

Caution: Once the VANOS is pulled off the engine head, it should not be remounted without installing and aligning the exhaust side VANOS oil pump driver. Because a misalignment combined with pressure from the VANOS mounting bolts will cause breakage of the VANOS bridge

Remove vanos from engine head by removing vanos intake piston from intake splined shaft stud.
Lift up vanos. Wiggle and pull forward on vanos to remove vanos intake piston from intake splined shaft stud.
Note: Splined shaft stud inserted in piston has O-ring at center which mates with piston inner diameter. Resistance to removal is due to this O-ring.

Take vanos to work bench.
Clean outside of vanos to remove dirt and sludge (brake cleaner & towels).

Installation of vanos seals

During following seals installation procedure, great care should be taken to not drop and damage vanos components. Perform work over table, so if part is dropped it will fall to table top.

Note: Try to not disturb vanos oil pump rotational position. Oil pump is currently aligned to mate with exhaust camshaft oil pump driver.

Installation of vanos intake seals

Remove intake piston from intake cylinder.
Press piston from vanos inboard side to remove piston from vanos outboard side (finger).

Remove intake cylinder cover from vanos inboard side.
Remove 5 mounting bolts (4mm hex bit socket 3/8″ / 3/8″ ratchet).

Eliminate intake cylinder cover.
Pry cover at multiple locations to evenly remove cover (small putty-knife).
Note: Orient blade with edge ramp side to vanos body. This orientation is more effective.
Note: Cover resistance is due to cover sealing O-ring.

Remove intake cover washer (fingers).

Remove intake cylinder form vanos housing.
Press intake cylinder from vanos inboard side to remove it from vanos outboard side. (24mm 1/2″ socket).
If cylinder resistant, hit press tool to knock out cylinder (1/2″ ratchet head side).

Remove intake cylinder sealing O-ring.
Pry O-ring from cylinder groove and remove from cylinder (hook pick).

Clean intake cylinder (brake cleaner & towels).
Clean intake cylinder vanos housing (brake cleaner & towels).

Install new O-ring on intake cylinder.
Insert new O-ring in cylinder groove on one end and stretch other end over cylinder and drop into groove (fingers).
Lightly lubricate O-ring to ease cylinder installation (assembly oil).

Note: Intake cylinder O-ring is one of two identical O-rings. Second identical O-ring is intake inboard cover O-ring.

Lightly lubricate intake cylinder vanos housing to ease cylinder installation (assembly oil).
Insert intake cylinder into vanos housing from vanos outboard side.
Rotate cylinder in vanos to align cylinder cutouts with vanos housing oil access holes at sides of vanos cylinder housing.
Turn vanos inboard side down to keep cylinder in housing.

Remove intake cylinder outboard cover sealing O-ring.
Pry O-ring from cover groove and remove from cover (hook pick).

Clean intake cylinder cover (brake cleaner & towels).

Note: Do not install new cover O-ring at this time. Cover will be easier to install and remove in next step without cover O-ring.

Install and then remove intake cylinder outboard cover.
Align cover bolt holes to vanos body bolts holes.
Install cover 6 mounting bolts (4mm hex bit socket 3/8″).
Tighten bolts evenly in multiple passes.
Note: Tightening cover bolts presses intake cylinder into vanos housing.
Remove cover 6 mounting bolts (4mm hex bit socket 3/8″).
Remove cylinder cover.

Install new O-ring on intake cylinder cover.
Insert new O-ring in cover groove on one end and stretch other end over cover and drop into groove (fingers).
Lightly lubricate O-ring to ease cover installation (assembly oil).

Note: Intake cylinder cover O-ring is larger of three remaining similar O-rings that fit cover.

Remove intake rod seal from intake inboard cylinder cover.
Pry rod seal from cover outboard side to remove it from cover inboard side (strait pick).

Remove intake cylinder inboard cover sealing O-ring.
Pry O-ring from cover groove and remove from cover (hook pick).

Clean intake cylinder inboard cover (brake cleaner & towels).

Install new O-ring on intake cylinder inboard cover.
Insert O-ring in cover groove on one end and stretch other end over cover and drop into groove (fingers).
Lightly lubricate O-ring to ease cover installation (assembly oil).

Install new intake rod seal into intake cylinder inboard cover.
Insert seal into housing on one side and press seal into housing on opposite side.
Once seal inserts into housing, press seal fully into housing along its perimeter (thumb).
Seal should fully insert into housing (picture).
Press O-ring into rod seal to verify O-ring full insertion.

Disconnect intake piston end cap from main piston body (hands).

Remove intake piston seal from intake piston cap.
Pry piston seal from piston cap (small putty-knife).
Note: Orient putty-knife with edge ramp side to piston cap wall. This orientation is more effective.

Remove paper gasket from intake piston or piston cap.
Pry off and scrape off paper gasket as necessary from piston or piston cap (strait pick).
Fully remove all paper gasket.

Note: Paper gasket excessively widens piston seal groove allowing seal to tilt in groove and wear unevenly. Gasket only seems to function to better seat piston cap before mounting. This is not needed.

Install new piston seal rubber ring on piston cap shaft (fingers).
Fully insert rubber ring onto piston cap (fingers).

Stretch intake piston new Teflon ring.
Place Teflon ring on piston shaft and pick tool on Teflon ring (90 degree pick) (picture).
Leverage pick tool against piston and tilt pick tool to stretch out Teflon ring (90 degree pick).
Perform Teflon ring stretching at multiple locations along Teflon ring until Teflon ring notably stretches.
Note: Teflon ring needs to stretch sufficiently to install over piston seal rubber ring in next step.
Note: You can attempt stretching the Teflon ring multiple times and then proceed with the next installation step.

Install piston seal Teflon ring onto piston seal rubber ring.
If Teflon ring is too small, repeat previous Teflon ring stretching step.
Continue stretching and attempting to install Teflon ring until it installs.
Do not over stretch Teflon ring. Stretch only sufficiently to install.
Fully insert Teflon ring onto rubber ring.

Mount intake piston cap onto intake piston.

Insert intake piston seal end into intake cylinder outboard side.
Lightly lubricate cylinder entry inner wall and piston Teflon ring (assembly oil).
Wiggle piston and press strait into cylinder.
Verify Teflon ring is inserting into cylinder at all perimeter locations. Reposition piston and reattempt insertion to facilitate Teflon ring full perimeter insertion.
Once all Teflon ring perimeter inserts into cylinder, wiggle piston and press strait into cylinder to fully insert Teflon ring into cylinder.

Note: The cylinder entry features a chamfer, which allows the stretched Teflon ring to be gathered and inserted into the cylinder.

Maintain piston in cylinder for 1 minute then remove.
This period allows Teflon ring to be compressed (resized) close to original size.
Remove piston from cylinder.
Note Teflon ring has decreased in diameter.

Remove piston cap from piston.
Place piston cap, shaft first, into intake cylinder outboard end.

Insert piston cap into cylinder by pressing with piston cap end.
Press cap ~1/3 down cylinder.

Place intake piston vertically with cap end down.

Slide intake cylinder cover washer onto piston.

Insert intake cylinder cover with new rod seal onto piston.
Lightly lubricate piston and rod seal inner Teflon lip (assembly oil).
Press cover strait onto piston without tilting.
Press cover over piston until ~10mm of piston is protruding from cover (next picture).

Clean vanos intake cylinder inboard side cover mating surfaces and cover mounting bolts (brake cleaner & towels).

Insert intake piston, cap end first, into intake cylinder inboard side.
Slide cylinder cover washer up to cover.
Insert piston into cylinder.
Mount piston to piston cap by pressing on piston and piston cap from both ends of cylinder (finger, hand).

Mount intake cylinder cover washer onto cylinder.
Fully seat washer.

Mount intake cylinder cover onto vanos body.
Rotate cover/piston to align cover holes with vanos body holes (picture).
Brace piston from vanos outboard side (finger) and press cover down piston and onto vanos body.
Rotate cover/piston to align cover holes with vanos body holes (picture).
Press cover onto vanos body.
If present, cover alignment small pin hole will insert onto vanos body alignment pin.

Install intake cover 5 mounting bolts (4mm hex bit socket 3/8″ / 3/8″ ratchet).
Tighten bolts evenly to draw cover evenly to vanos body.
Note: If top end of cover not inserting hit with object to insert (ratchet handle)
Fully tighten, 6 Nm (4.5 ft-lb) (4mm hex bit socket 3/8″ / 3/8″ torque wrench).
Note: Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

Installation of vanos oil pump cover O-rings

Get rid of vanos oil pump cover from vanos outboard side.
cover 8 mounting bolts (4mm hex bit socket 3/8″ / 3/8″ ratchet).

Remove oil pump cover.
Insert blade between vanos body and cover to lift cover at perimeter (small putty-knife & hammer).
Initially insert blade at best access location (picture).
Note: Orient blade with edge ramp side to vanos body. This orientation is more effective.

Once cover is lifted at perimeter, pry cover at multiple locations to evenly remove cover (small putty-knife).
Note: Cover resistance is due to cover sealing O-ring.

Remove oil pump cover oil feed sealing O-ring.
Pry O-ring from face groove and remove from vanos (hook pick).

Clean O-ring face groove (brake cleaner & towels).

Install new O-ring on oil pump cover oil feed sealing face.
Insert new O-ring in face groove (fingers).

Note: Oil pump oil feed O-ring is similar in size to oil pressure restrictor small O-ring. Oil feed O-ring is slightly thicker in cross section than oil pressure restrictor small O-ring.
Note: Oil pump oil feed O-ring is one of two identical O-rings. Second identical O-ring is vanos inboard oil feed O-ring.

Remove oil pump cover sealing O-ring.
Pry O-ring from cover groove and remove from cover (hook pick).

Clean oil pump cover (brake cleaner & towels).

Install new O-ring on oil pump cover.
Insert O-ring in cover groove on one end and stretch other end over cover and drop into groove (fingers).
Lightly lubricate O-ring to ease cover installation (assembly oil).

Install oil pump cover on vanos.
Orient cover to align cover oil feed ridge with vanos oil feed hole (picture).
Align cover bolt holes to vanos body bolts holes.
Press cover onto vanos body.

Install oil pump cover 8 mounting bolts (4mm hex bit socket 3/8″ / 3/8″ ratchet).
Tighten bolts evenly to draw cover evenly to vanos body.
Fully tighten, 6 Nm (4.5 ft-lb) (4mm hex bit socket 3/8″ / 3/8″ torque wrench).
Note: Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

Remove vanos inboard intake head sealing O-ring.
Pry O-ring from housing groove and remove from vanos (hook pick).

Clean O-ring housing groove (brake cleaner & towels).

Install new O-ring on vanos(Euro S50 Single Vanos) inboard intake head sealing housing.
Insert new O-ring in housing groove on one end and stretch other end over housing and drop into groove (fingers). Lightly lubricate O-ring to ease vanos installation (assembly oil).

Note: Inboard intake head sealing O-ring is one of two identical O-rings. Second identical O-ring is inboard exhaust head sealing O-ring.

Pry O-ring from housing groove and remove from vanos (hook pick).

Clean O-ring housing groove (brake cleaner & towels).

Install new O-ring on vanos(Euro S50 Single Vanos) inboard exhaust head sealing housing.
Insert new O-ring in housing groove on one end and stretch other end over housing and drop into groove (fingers).
Lightly lubricate O-ring to ease vanos installation (assembly oil).

Remove vanos inboard oil feed head sealing O-ring.
Pry O-ring from face groove and remove from vanos (hook pick).

Clean O-ring face groove (brake cleaner & towels).

Install new O-ring on vanos inboard oil feed head sealing face.
Insert new O-ring in face groove (fingers).

Note: Inboard oil feed O-ring is similar in size to oil pressure restrictor small O-ring. Oil feed O-ring is slightly thicker in cross section than oil pressure restrictor small O-ring.

Unscrew oil pressure restrictor from vanos body (hand).
Drain and discard oil from vanos.

Clean restrictor and vanos restrictor area (brake cleaner & towels).

Cut cross section of small O-ring on pressure restrictor (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Note: Take care to not cut or damage adjacent plastic washer. Plastic washer has cut cross section.

Remove cut O-ring from pressure restrictor.

Remove large O-ring from pressure restrictor (90 degree pick).

Clean pressure restrictor O-ring grooves (brake cleaner & towels).

Install new large O-ring on pressure restrictor. Roll O-ring onto pressure restrictor until O-ring drops into base groove.
Install small O-ring on pressure restrictor. Roll O-ring onto pressure restrictor until O-ring drops into groove.
Note: White washer should be positioned in groove on side of regulator large end (picture).
Lightly lubricate O-rings to ease pressure restrictor installation (assembly oil).

Screw pressure restrictor into vanos body (hand).
Note: Pressure restrictor will be tightened once vanos is mounted on engine.

Remove intake splined shaft stud O-ring.
Pry O-ring from stud groove and remove from stud (90 degree pick).

Clean splined shaft stud (brake cleaner & towels).

Note: If installing rattle kit, delay splined shaft O-ring installation until after rattle kit installation.
Install new O-ring on intake splined shaft stud.
Insert new O-ring on splined shaft stud and roll O-ring down stud and drop into groove (fingers).
Lightly lubricate O-ring to ease vanos installation (assembly oil).

For both solenoids, perform following O-rings removal and install.

Cut cross section of solenoid small and large O-rings (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Note: Do not press into solenoid as this nicks sealing surface.
Rotate blade in O-ring after cutting to note any remaining uncut O-ring (razor knife).
Remove cut O-rings from solenoid.

Clean solenoid (brake cleaner & towels).

Install new small and large O-rings on solenoid (fingers).
O-rings should not be twisted in final position.<br />Lightly lubricate O-rings to ease solenoid installation (assembly oil).

Repeat O-rings removal and install for second solenoid.

Remove vanos oil filter and washer (5mm hex bit socket 3/8″ / 3/8″ ratchet).

Clean vanos(Euro S50 Single Vanos) outer face at oil filter hole (brake cleaner & towels).

Install vanos new oil filter and washer (5mm hex bit socket 3/8″ / 3/8″ ratchet).
Fully tighten, 12 Nm (9 ft-lb) (5mm hex bit socket 3/8″ / 3/8″ torque wrench).

Remove towels from vanos(Euro S50 Single Vanos) solenoid chambers.
Clean vanos solenoid chambers (brake cleaner &amp; towels).&amp;lt;br /&amp;gt;Clean vanos solenoid housing and cover matting surfaces (brake cleaner & towels).Insert new clean towels in vanos solenoid chambers to protect oil passages from debris contamination (towels).

Perform rattle procedure

If performing rattle repair continue at this point with rattle procedure, Euro S50 Single Vanos Rattle Procedure

Cleaning of parts

Note: When cleaning parts, spray cleaning compound on towel then wipe component with towel. Components can also be placed in small container and sprayed with cleaning compound then individually wiped with towel.

Clean all mounting bolts, nuts, washers (brake cleaner & towels).

Clean vanos matting surfaces; solenoid cover and bolts, intake cylinder outboard housing and cover bolts, inboard face (brake cleaner & towels).
Note: Do not rotate vanos exhaust oil pump.

vanos bridge polished surfaces; top gasket surface, arches, base bottom (remove old sealant) (brake cleaner & towels).

head matting surfaces; sparkplug well, top perimeter and front half-moons, front polished surfaces (brake cleaner & towels).

Clean vanos ground wire and valve cover ground wire (brake cleaner & towels).

Clean coils mounting contact surfaces (at coils) (brake cleaner & towels).

Remove valve cover gaskets from valve cover.
Clean valve cover gaskets (brake & towels). Note: Euro S50 valve cover gaskets are made of Viton and thus can withstand brake cleaner. Brake cleaner will allow for removing oil from gaskets.
Clean valve cover mating surfaces; inner gasket, bolt access holes, all studs (brake cleaner & towels).

Installation of vanos

Slightly advance intake camshaft position.

Rotate intake camshaft slightly clockwise (24mm open wrench).
Align intake timing grooves so camshaft bearing groove is slightly left of bearing cover groove (car rear orientation) (picture). If camshaft resistant to rotation rock camshaft back and forth to release seize.
Note: Rotating camshaft is most effective when standing at exhaust side of car.
Note: This step insures vanos(Euro S50 Single Vanos) intake piston/splined shaft stud do not protrude too far and obstruct mounting of vanos intake cylinder cover.

Inspect TDC (top dead center) timing marks on engine timing cover and crankshaft harmonic balancer at ~11 o’clock position (mirror).
If needed, adjust crankshaft pulley to align TDC timing marks (crankshaft turning socket / 1/2″ long-arm ratchet).
Note: Precise alignment is not necessary.

If crankshaft adjusted, double check and readjust camshafts timing as above.

After above camshaft adjustment, intake splined shaft will be slightly more recessed into sprocket (picture).

s ground wire forward and position end under vanos solenoid cable connector bracket.
Note: This allows installing vanos on engine head without ground wire being caught between vanos and engine head.

Verify vanos inboard side is clean and ready for installation.
As needed, wipe down vanos inboard surfaces (brake cleaner & towels).
Note: Do not rotate vanos(Euro S50 Single Vanos) exhaust oil pump.

Install vanos on engine head.
Insert vanos intake piston onto intake splined shaft stud.
Stop when resistance is met.

[picture]
Install exhaust oil pump driver on vanos oil pump and rotate as needed to align with exhaust sprocket driver.
Hold driver in position while inserting vanos in next step.

Insert thumb into vanos intake cylinder and press on piston.
Lift up vanos. Wiggle and press vanos onto engine head.
Rotate vanos oil pump and driver as needed to align and insert driver into exhaust sprocket driver.
Note: Intake splined shaft stud O-ring will seize on piston inner walls and prevent insertion. Wiggling and pressing vanos helps release O-ring seize and facilitates vanos advance.
Note: When vanos advances, splined shaft stud will come through piston front center hole (picture).
Stop advancing vanos once splined shaft stud protrudes from vanos intake piston and oil pump driver mates with exhaust sprocket driver. Vanos should not be fully mounted.

Apply thin layer of sealant to vanos bridge bottom base surfaces.
Allow sealant to solidify for ~2 minutes before mounting bridge.

Install vanos bridge onto engine head.
Orient bridge with large arch on exhaust side (picture).
Insert bridge bottom side dowel holes (small) onto engine head dowels.
Fully seat bridge onto engine head.

Install vanos bridge 4 mounting bolts (6mm hex bit socket 3/8″ / 3/8″ ratchet).
Note: Center 2 bolts are long and outer 2 bolts are short.
Fully tighten, 10 Nm (7 ft-lb) (6mm hex bit socket 3/8″ / 3/8″ torque wrench).
Note: Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

Wipe excess sealant from vanos bridge base perimeter (finger).

Note: Engine head half-moons and vanos bridge arches combine to create cavities for vanos inboard intake and exhaust protrusions to insert into. Vanos intake and exhaust protrusion O-rings seal engine oil from leaking externally.

Place thumb on vanos intake piston to keep from falling out of cylinder.
Lift up vanos. Wiggle and press vanos onto engine head.
Note: Intake splined shaft stud O-ring will seize on piston inner walls and prevent insertion. Wiggling and pressing vanos helps release O-ring seize and facilitates vanos advance.
Note: When vanos advances, splined shaft stud will come through piston front center hole (picture).

Press vanos onto engine head until vanos O-rings reach head / bridge and resistance is encountered.
Note: Vanos O-rings will insert partially into head / bridge.

Initially thread vanos 9 mounting bolts, 5 upper and 4 lower.
Note: Upper right and left end bolts are long. Right bolt is fully threaded and left bolt is partially threaded.
Note: Lower second bolt from right mounts vanos ground wire.

Tighten vanos 9 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).
Tighten bolts evenly in multiple passes to draw vanos slowly and evenly to engine head and vanos bridge.
Vanos O-rings will insert into engine head and vanos bridge.
Vanos will fully mate with engine head.

Caution: This is a critical step. If vanos oil pump is not correctly aligned with exhaust camshaft drive damage can occur. Tighten bolts evenly and note any resistance to bolt tightening and vanos insertion. If bolts are tighter on exhaust side and vanos is not inserting, stop. Remove vanos from engine head and repeat procedure for vanos oil pump alignment.

Fully tighten vanos 9 mounting bolts, 8 Nm (6 ft-lb) (5mm hex bit socket 3/8″ / 3/8″ torque wrench).
Note: Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

[picture]
Place TDC sensor in vanos bridge.
Install sensor plate with sensor on bridge.
Install sensor plate 3 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).
Fully tighten plate 3 mounting bolts, 8 Nm (6 ft-lb) (5mm hex bit socket 3/8″ / 3/8″ torque wrench).
Note: Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

Press on vanos intake piston end cap at multiple locations to fully seat cap on piston.
Clean piston cap and splined shaft stud (brake cleaner & towels).

Initially install vanos intake piston / splined shaft new mounting nut.
Screw nut on splined shaft stud (fingers).
Counter hold piston/shaft by hand and screw nut (fingers, 7mm box wrench).
Note: Nut can only be slightly installed on shaft. This allows slight section of shaft stud to protrude from nut and allow counter holding shaft in next step.

Fully mount nut by counter holding shaft stud and screwing on nut (4mm socket (6 point) 1/4″ / 1/4″ ratchet, 7mm open wrench).
Note: At first, shaft tool (4mm socket) will only barely mount on splined shaft end.

Fully tighten nut, 9 Nm (6.5 ft-lb) (7mm box wrench, 4mm socket (6 point) 1/4″ w/ 3/8″ to 1/4″ socket adapter / 3/8″ torque wrench).
Memo: It is critical to use a 6-point socket, as a 12-point socket can strip the shaft hex..
Note: Be sure to use wrench box end, as open wrench is susceptible to stripping nut

Note: The intake piston end is slightly recessed into the intake cylinder. This is due to slight advance (clockwise) adjustment of intake camshaft. This assures piston / splined shaft stud do not interfere with cylinder cover installation.
Install vanos intake cylinder cover.
Orient cover with side slight indent to vanos oil filter cap (picture right).
Press cover onto vanos body.

Next, install the vanos(Euro S50 Single Vanos) intake cover using the 6 mounting bolts and a 4mm hex bit socket with a 3/8″ ratchet. Tighten the bolts evenly to draw the cover evenly to the vanos body.

Then, fully tighten the bolts to 5 Nm (4 ft-lb) using a 4mm hex bit socket and a 3/8″ torque wrench.

Installed the rattle kit, verify the engine timing by following the procedure outlined in the rattle kit instructions.

By following these steps carefully, you can ensure proper installation and avoid any potential issues.

Verification of engine timing

If you installed the rattle kit, verify the engine timing using the procedure outlined in the rattle procedure.
Euro S50 Single Vanos Rattle Procedure

Installation of solenoids

First </strong>, place the solenoid cover gasket onto the solenoid cover mating surface. Next , align the gasket carefully with the housing surface and bolt holes to ensure proper positioning. Once aligned , press the gasket firmly onto the surface to bind it with the sealant, ensuring that it adheres securely to the housing surface.Tighten bolts evenly to draw cover evenly to vanos body.

Press solenoids to insert fully into chambers.
Rotate solenoids if necessary to align further.

Press on solenoids to verify full insertion.

Next, apply multiple thin dots of sealant along the solenoid cover mating surface using your finger or a sealant applicator.

First, place the solenoid cover gasket onto the solenoid cover mating surface. Then, align the gasket with the housing surface and bolt holes. Finally, press the gasket to bind it with the sealant, ensuring it stays securely on the housing surface.

Next, mount the solenoid cover and secure it with the 4 mounting bolts. Note: Some alignment of the bolts with the cover gasket may be necessary.

Initially tighten solenoid cover 4 bolts (4mm hex bit socket / hand).
Next, fully tighten to 8 Nm (6 ft-lb) using a 4mm hex bit socket with a 3/8″ ratchet and a 3/8″ torque wrench. Note: Tighten the bolts evenly in multiple passes and verify that you have fully tightened all bolts in the final pass.

Next, insert the solenoid electrical cable connectors into the connector brackets under the vanos. Note: The brackets key the connectors, so you can insert them in only one orientation.

Next, connect the vanos(Euro S50 Single Vanos) electrical cable connectors to the vanos solenoid cable connectors in the connector brackets. Note: Ensure that the right connector’s metal clip is facing down, while the left connector’s metal clip is facing outward.

Press in connectors until wire clip snaps into place.

Next, install the vanos electrical connectors cover. Align the cover and then install it onto the connector bracket studs,

Next, mount the cover with 2 nuts using a 10mm socket and 3/8″ ratchet.

6″&gt;Then, lightly tighten them.

Next, fully tighten the vanos oil pressure restrictor to approximately 14 Nm (by feel) using a 22mm open wrench.

Next, install the vanos oil accumulator pipe. Afterward, pull the oil pipe to the side and insert it into the vanos(Euro S50 Single Vanos) oil pipe hole. Then, screw on the oil pipe mounting bolt using a 12mm open wrench. Finally, fully tighten the bolt to 20 Nm (by feel) with the 12mm open wrench.

Proceed with the installation of the valve cover.

First, mount the valve cover perimeter gasket and sparkplug well gaskets on the engine head. Then, orient the sparkplug well gaskets with the end bolt hole facing the front (as shown in the picture), and ensure the perimeter ridges are facing down.

Install valve cover on engine head.
Align valve cover with engine head and gaskets and lay valve cover on engine head.
Adjust valve cover perimeter gasket so each valve cover gasket bolt hole aligns with associate valve cover perimeter bolt hole.

Install the 20 valve cover mounting bolts: 16 perimeter bolts and 4 center bolts, using a 10mm socket with a 3/8″ ratchet and extension.

Note: The front center (VANOS bridge) bolt and the 4 center bolts are shorter. Ensure proper placement for these shorter bolts.

Note: The rear center bolt has limited access, so use a 10mm socket with a 3/8″ ratchet and a 1/2″ to 3/8″ socket adapter (extension).

Tighten the bolts evenly, working back and forth to ensure even pressure distribution across the cover.

Tighten until bolts bottom out on head.
Fully tighten, 8Nm (6 ft-lb) (10mm socket 3/8″ / 3/8″ torque wrench & extension).

First , locate the valve cover ground wire and position it onto the rear-most stud of the valve cover, as shown in the picture. Next , secure the ground wire by attaching the nut to the stud. Then , use a 10mm socket with a 3/8″ ratchet to tighten the nut firmly.

Install Each Coil into Original Spark Plug Well:

To begin , position each coil into its original spark plug well, ensuring proper alignment. Once properly aligned , secure the coil by mounting it with the two nuts provided. Then , use a 10mm socket with a 3/8″ ratchet and extension to tighten the nuts.

As you proceed, rotate the nuts alternately to ensure the coil is mounted evenly. This step is crucial because uneven pressure could lead to improper seating or damage. Therefore , take care to double-check the tightness and alignment before completing the installation

Finally, check that you have securely mounted and properly aligned all coils before proceeding to the next steps

Note: Coil boot will not fully insert onto sparkplug during initial mount. This is normal.
Fully tighten, 10Nm (7 ft-lb) (10mm socket 3/8″ / 3/8″ torque wrench & extension).

Rotate Coils Cables/Bracket/Boot Back onto Valve Cover:
First, carefully rotate the coil cables, bracket, and boot back into their original position on the valve cover. Make sure to properly align all components before proceeding.

Next, you will need to mount the rear boot rubber block of the coil cables onto the valve cover. In order to do this , slide the rubber block into the valve cover slot from the top, as demonstrated in the picture. Once you properly align it, make sure it is securely in place before moving on to the next step.

Make sure to fully seat the block in the slot to prevent any movement or dislodging during operation.

Finally, double-check that all components are securely in place and properly aligned before moving on to the next steps

Secure Coil Cables Mounting Bracket:
First, position the coil cables mounting bracket onto the two mounting studs. Make sure to properly align the bracket with the studs before proceeding.

Next, proceed by installing the two mounting nuts onto the studs. Then , use a 10mm socket with a 3/8″ ratchet and extension to tighten the nuts securely. Tighten the nuts evenly to avoid any misalignment or damage.

Make sure to firmly attach the bracket to prevent any movement during operation.

Finally, double-check that you have tightly secured the bracket and properly positioned the coil cables before moving on to the next steps.

Install Coil Cables Electrical Connectors:
First, begin by working on each coil individually. For each coil, start by gently lifting up on the metal lock of the connector. Then, press the cable’s electrical connector firmly into place to ensure a secure connection. Afterward, push down on the metal lock to secure the connector in position and make sure it locks tightly.

Next, once you have installed all the connectors, carefully route the coil cables as needed. In particular , make sure to position the cables away from moving parts, heat sources, or sharp edges so that you can avoid damage or interference. Additionally , double-check the routing to ensure everything is secure and properly aligned.

Finally, double-check that you have properly seated all connectors and safely routed the cables before moving on to the next steps.

Install Engine Top Cover:
First , align the engine cover and carefully place it over the valve cover. Then , ensure that the rear left side of the cover mounts over the coil cables boot rubber block. Once you have properly positioned it, press down firmly on the rear of the cover in order to fully secure the block in place.

Finally, double-check that you have aligned and secured everything before moving on to the next step.

Then, proceed to install the four mounting bolts using a 5mm hex bit socket with a 3/8″ ratchet .

Finally, securely tighten the bolts to firmly attach the cover and prepare it for operation.

By following these steps, you can correctly and safely install the engine top cover.

Installation of fan & shroud

Euro E36 M3 fan & shroud installation

Post repair procedures

Allow sealant to dry a minimum of one hour before driving car.

Check and replenish engine oil.
Drive car, then park car and let engine oil settle.
Remove oil dipstick; wipe dipstick end; fully reinsert dipstick; remove dipstick again; read oil marking. If oil is low add needed (small) amount of new oil at oil fill cap at valve cover.

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