S54 Vanos Procedure (E46 M3)

S54 Vanos Procedure
The following information is provided for reference purposes only and should be used at your own risk.
In no event shall Beisan Systems, LLC, or its members, be held liable for incidental, consequential, or special loss or damages of any kind, however caused.

Introduction

“Vanos” refers to BMW’s variable valve timing system.The design and shape of Vanos units vary depending on the car’s year, model, and engine type. The Vanos being discussed is BMW part # 11-36-7-838-161. It is a double Vanos system, meaning it adjusts the timing of both the intake and exhaust valves. This Vanos unit belongs to the BMW 6-cylinder S54 engine, which powers the M3 E46 (2000-2006), Z3 E36 M Roadster & M Coup (2000-2002), Z4 E85 M3.2 Roadster (2005-2008), and Z4 E86 M3.2 Coup (2006-2008).

S54 Vanos Procedure

A common and significant issue occurs when the exhaust camshaft sprocket hub Vanos oil pump driver tabs break. These hubs feature two tabs, and either one or both can break.

Like other performance engine Vanos units, this Vanos unit uses an oil pump to generate high oil pressure, which is essential for optimal Vanos operation. This high pressure facilitates rapid and precise adjustment of the Vanos and engine timing. In this system, the exhaust camshaft drives the oil pump. Specifically, the eccentric oil pump driver positions the Vanos exhaust piston concentrically with the camshaft.

Thus, two drivers, located 180 degrees apart, balance the drive.

The Vanos includes an oil pump disk with two holes, and the exhaust hub has two driver tabs that insert into the oil pump disk holes. One or both of the driver tabs can break, leading to Vanos malfunction and engine fault codes. A broken tab can either stay lodged in the Vanos oil pump disk hole or drop into the oil pan. In rare cases, the tab can engage the chain and sprockets, causing engine damage.

The oil pump driver tab breaks due to excessive rotational pressure force or rattling hitting force. Inspecting the Vanos oil pump disk holes reveals wall indentations at the rotational and counter-rotational tab engagement positions. The counter-rotational indentations indicate a rattling hitting movement. A dynamic hitting movement can also generate significantly higher forces than a pressure force.

The Vanos piston seals and static seal O-rings (excluding the small O-ring on the oil pressure restrictor) incorporate the correct materials, so they do not fail prematurely. However, over time and with use, the piston seal O-rings undergo notable compression set (flattening), and the Teflon rings experience wear (loss of material). These effects can degrade performance.

The static seal O-rings also undergo compression set and could eventually leak. Therefore, a replacement seal solution is necessary for this Vanos.

Beisan Systems (bee-saan) offers a Vanos seals/O-rings repair kit, available at www.beisansystems.com/products. This kit includes a Vanos replacement set of Teflon rings and Viton O-rings made from OEM-equivalent materials.

The following repair procedure also covers the installation of the Beisan S54 Vanos sealing plate repair kit and rebuilt Vanos solenoid coil pack. For a discussion of these products and their associated failure modes, see the Beisan S54 Vanos solenoid procedure.

Symptoms (S54 Vanos Procedure)

Fault Codes:

Intake Vanos Fault Codes:

P0010 (BMW xx, 0xxx): Vanos intake solenoid circuit
P0011 (BMW 67, 0x43): Vanos intake timing over-advanced
P0012 (BMW 72, 0x48): Vanos intake timing over-retarded
Pxxxx (BMW 184, 0xB8): Vanos intake position control
P1525 (BMW xx, 0xxx): Vanos intake solenoid open circuit

Exhaust Vanos Fault Codes:

P1531 (BMW xx, 0xxx): Vanos exhaust solenoid open circuit

Unfortunately, the engine timing remains in the same position as when the failure occurred. As a result, the engine will likely perform better at low RPM and worse at high RPM, or worse at low RPM and better at high RPM. Engine misfire with fault codes may also occur.

P0014 (BMW 22, 0x16): Vanos exhaust timing over-advance

P0015 (BMW 21, 0x15): Vanos exhaust timing over-retarded

Pxxxx (BMW 185, 0xB9): Vanos exhaust position control

Diagnosis

When you see a circuit code, it likely indicates that the solenoid coil pack has failed.

The above codes, other than the circuit codes, can occur when the Vanos oil pump driver tab(s) breaks or the Vanos solenoid coil pack fails. Therefore, you must differentiate between the two potential failures.

A simple, though not conclusive, method for differentiating between the two failures is to reset the fault codes, start the engine, and let it idle. If the oil pump driver tabs break, the system generates fault codes and activates the check engine light within a few minutes.

The solenoid coil pack failure is often intermittent, and it will require some driving before the fault codes and check engine light appear. Unfortunately, there are cases where the solenoid coil pack can fail significantly, causing the fault codes and check engine light to appear at idle after the reset. Furthermore, in some cases, only one of the oil pump driver tabs will break. In such cases, the fault codes and check engine light will not appear at idle, and driving will be necessary for them to appear.

A definitive method for determining which of the two failures exists is to remove the valve cover and inspect the oil pump driver tabs. If one or both break, they cause the problem. If the tabs are intact, then the problem is most likely the solenoid coil pack.

Repair Procedure

The following is an E46 M3 Vanos oil pump disk, sealing plate rings, Vanos seals, solenoid coil pack, R&R (remove and replace) procedure.

Repair time: 5 hours mechanic, 7+ hours DIY.

Valve adjustment repair can be combined with this repair. However, only perform the valve adjustment repair after the Vanos system is fully mounted on the engine head.

Thus perform valve adjustment repair just before removing Vanos or just after installing Vanos. This is referenced in the procedure.

Parts, Tools, and Shop Supplies

BMW parts, identifiable by the part number pattern xx-xx-x-xxx-xxx, are available for purchase at your local BMW dealership.

Beisan Systems specializes in providing components for Vanos repair, including the oil pump disk, sealing plate repair kit, seals repair kit, and rebuilt solenoid coil pack.

S54 Vanos Procedure
The S54 Vanos oil pump disk (BS025) is priced at $150 with a $300 refundable core charge (available at www.beisansystems.com). The S54 Vanos sealing plate repair kit (BS024) is available for $10 each (also at www.beisansystems.com).

1% of Vanos units will have a .001mm oversized cap that may stick in the side cylinder of a Beisan new oil pump disk. If you encounter this issue, polish the side cylinder for 30 seconds using 400-grit sandpaper and a 1/4″ socket extension. This action will remove .0005mm of material, allowing the oversized cap to fit properly.

Beisan Systems will refund the $300 core charge (deposit) if you return the original, undamaged oil pump disk within 90 days of the purchase date.

Ensure you wrap the oil pump disk carefully to protect it from damage. Include your name and the transaction date in the return package.

S54 rebuilt Vanos solenoid coil pack (BS023) $200 + $300 refundable core charge (www.beisansystems.com)
Note: Rebuilt solenoid coil pack includes Vanos oil pressure restrictor O-rings.

Beisan Systems will refund the $300 core charge (deposit) if you return the original undamaged solenoid coil pack within 90 days of the purchase date.

Wrap the coil pack to protect it from damage.
Include name and date on purchase transaction in return package.

S54 Vanos Procedure
S54 Vanos seals repair kit (BS021) $60/each
Note: Seals repair kit includes Vanos oil pressure restrictor O-rings.

S54 Vanos Procedure
Vanos gasket (11-36-7-831-938) $11.69/each
2 x valve cover stud grommet (11-12-1-437-395) $1.17/each, 2 x oil drain hose crush washer (07-11-9-963-129) $0.11/each
2 x Vanos oil accumulator pipe crush washer (07-11-9-963-072) $0.11/each, cable strap (zip tie)
Vanos oil filter (11-36-1-401-971) $9.66/each (not shown). Note: You do not need to replace the oil filter. Instead, you can spray clean it using brake cleaner.

Note: The S54 engine valve cover gaskets and bolt grommets (except for the front two corner grommets) are made from Viton, so they do not wear out and do not require replacement. However, the front two corner grommets are made from Buna, which wears out over time and needs replacement. These are included in the list above.

S54 Vanos Procedure
Tools Required:

First, gather 2 x putty knives (small and medium), a straight pick tool (small), and a 90-degree pick tool (small).

Next, ensure you have pliers (medium), medium nose pliers (small), cutters (small), and a razor knife (small).

Additionally, prepare a 24mm combo wrench, 22mm combo wrench, 10mm combo/ratcheting wrench, and a 7mm combo wrench.

Furthermore, include a flathead screwdriver (large), a Phillips screwdriver, a tack lifter, a magnet pickup, and a medium mirror.

For sockets, you’ll need a 32mm socket (1/2″), 17mm socket (3/8″), 14mm socket (3/8″), 13mm socket (3/8″), 10mm socket (3/8″), 10mm deep socket (3/8″), and a 5mm hex bit socket (3/8″).

Also, prepare an 8mm socket (1/4″), an E-5 Torx or 4mm socket (1/4″), a T30 Torx bit socket (1/4″), a T25 Torx bit socket (1/4″), and a 3/8″ to 1/4″ socket adapter.

For ratchets, include a 1/2″ long-arm ratchet, a 3/8″ ratchet, a 3/8″ medium-arm ratchet, a 1/4″ ratchet, and a 1/4″ socket driver.

Moreover, gather a 1/2″ socket extension (short), a 3/8″ socket extension (short), and a 1/4″ socket extension (short and medium).

Lastly, ensure you have a 3/8″ torque wrench (10 Nm [7 ft-lb], 40 Nm [29.5 ft-lb]) and retaining ring pliers (medium internal) (Craftsman part # 947412, $25).

S54 Vanos Procedure
BMW Crankshaft Turning Socket (83-30-0-491-056):

Price: $68.04 each
Note: You can substitute this with a 36mm 12-point socket (1/2″).
Alternatively, you can use a 32mm 1/2″ socket combined with a 1/2″ extra short extension.

Additional Notes:

For later production S54 engines: These engines come with an adapter featuring a 27mm hex.

For early production S54 engines: These engines have 4 Torx bolts that require a special tool or a 36mm 12-point socket.

S54 Vanos Procedure
Mechanical Fan Removal Tools:

32mm combo wrench
BMW water pump pulley holder (83-30-0-491-046): $37.76 each
Handheld sledge hammer (3lb)

Note:

It is frequently sold as part of a combination tool set that includes a 32mm slim open wrench.

The water pump pulley holder is also available from aftermarket vendors, often listed on eBay.

It is commonly listed under its original BMW part number 115030.

Strong magnet(s) (Harbor Freight Craft Magnet Blocks (2 pc) part #98406, $1.50)

Note: Strong magnet, or multiple magnets to multiply strength, is needed to open Vanos solenoid valves for cleaning

Supplies and Tools:

3Bond Drei Sealant (BS0SS): $19.90 (available at www.beisansystems.com)
Paper towels
Water-based cleaner (e.g., Simple Green diluted 1:10)
Brake cleaner
Spray lubricant
Parts plate
Assembly oil (lubricant oil)
Medium plastic bag
400-grit sandpaper (not shown)

Repair Instructions:

Preparation:

Ensure the car engine is cold before starting the repair procedure.

Note: Right and left denotations are based on the car’s front orientation (as viewed from the hood).

Removal:

Remove the fan and shroud.

E46 M3 fan & shroud removal

Removal of cabin filter housing

E46 M3 cabin filter housing removal

Removal of suspension cross brace

If present, remove suspension cross brace from engine bay.

Remove 2 mounting nuts at left and right end of suspension cross brace (13mm socket 3/8″ / 3/8″ medium-arm ratchet).

Remove suspension cross brace from engine bay.

Removal of valve cover

Steps to Remove the Engine Top Cover:

Remove the Engine Top Cover:
Firstly, take off the engine top cover.

Remove the 6 Cover Mounting Caps:
Next, use a 10mm socket (3/8″) with a 3/8″ ratchet and extension to loosen and remove the mounting caps.

Disconnect the Ventilation Hose:
Afterwards, locate the ventilation hose at the rear top of the cover. Then, press in the side clips of the hose connector and gently pull up to disconnect it.

Remove the Oil Fill Cap:
Subsequently, take off the oil fill cap and set it aside.

Lift and Remove the Top Cover:
Finally, lift and remove the top cover.

Carefully lift the cables and ventilation hose, then remove the top cover.

Reinstall the oil fill cap:

Once the cover is removed, reinstall the oil fill cap to prevent debris from entering the engine.

To begin, uninstall all components attached to the brackets at the rear of the valve cover. Next, remove the O2 sensor connectors. Following that, detach the O2 sensor cable mounting clips. Subsequently, remove the rubber block. Finally, detach the cable mounting clip.

Remove coil harness ground strap mounting bolt at valve cover exhaust side (13mm socket 3/8″ / 3/8″ ratchet).

Remove O2 sensors connector bracket at top of valve cover.
Press in clip tabs at front and rear right of bracket and pull off bracket.

Remove coil harness rail 2 mounting bolts (8mm socket 1/4″ / 1/4″ ratchet & extension).

Remove coils electrical cable connectors.
For each coil, pull up and back on coil connector pivot lock until cable connector is thrust out and disconnected.
First, remove all cable connectors from the coils, as shown in the picture. Then, place the O2 sensor connector bracket, coil harness rail, and cable connectors to the exhaust side of the valve cover.

Firstly, remove all six sparkplug coils.
Next, for each coil, wiggle it vigorously from side to side and pull upward with force to remove it.
Please note that the coils require significant force to be pulled out.
Finally, ensure you maintain the coil/cylinder association for reinstallation.

This is not necessary, but is good practice.

First, remove the 15 valve cover mounting bolts/studs, along with their washers and rubber grommets. These include the two front corner studs, the one front center bolt, and the six bolts on each side. Use a 10mm socket and a 10mm deep socket with a 3/8″ drive ratchet and extension, and a tack lifter.

Firstly, remove the oil drain hose mounting bolt at the exhaust side of the valve cover. In addition, place the O2 sensors connector bracket and coil harness rail and cable connectors at the top of the valve cover. Finally, remove the oil hose mounting banjo bolt (17mm socket 3/8″ / 3/8″ medium-arm ratchet).
Catch crush washer at cover side of hose fitting while removing bolt. Place finger at each side bottom of fitting and remove bolt.
Discard removed crush washer and crush washer on bolt.
Place O2 sensors connector bracket and coil harness rail and cable connectors to exhaust side of valve cover.

Release valve cover from engine head.
Insert a blade (medium putty-knife) between the valve cover gasket and the engine head, and then pry up at all accessible locations on the front end to break the gasket bond. Specifically, be sure to break the gasket sealant bond at the front corners.

Rewrites.
Repeat blade insertion and prying until cover gasket seize breaks and cover lifts. Notable prying might be needed at front center to break seize.
Note: If valve cover can not be removed, double check valve cover 15 bolts/studs have been removed.

Lift up and remove the valve cover from the engine head. After that, place the rear cable rubber block to the rear of the valve cover. Lift up the valve cover’s right side above the black fuel injector rail. Next, lift up the cables and hose, and lift up and bring forward the valve cover. Finally, oust the valve cover.

Expel valve cover perimeter gasket.
Discard valve cover 6 sparkplug well gaskets.

Valve adjustment repair can be performed at this point in the procedure.

Setting of timing to TDC

Assess tool needed for turning crankshaft.
Inspect crankshaft pulley turning bolt(s) (mirror).
If 4 torx bolts are found use special torx socket. If hex bolt fond use 32mm socket.

First, if the vehicle has a manual transmission, place it in neutral. This will allow the crankshaft to turn freely. Then, turn the crankshaft pulley clockwise until the cylinder 1 intake and exhaust cams point toward each other at an approximate 45-degree angle. Use a crankshaft turning socket with a 1/2″ drive, a 1/2″ long-arm ratchet, and a short extension for this step. Note: Turning the crankshaft counterclockwise is also acceptable.

First, inspect the TDC (top dead center) timing marks on the engine timing cover and crankshaft harmonic balancer. These marks should be located at approximately the 11 o’clock position (use a mirror for better visibility). Next, adjust the crankshaft pulley to precisely align the TDC timing marks. Use a crankshaft turning socket with a 1/2″ drive, a 1/2″ long-arm ratchet, and a short extension for this adjustment. Note: The pointer on the timing cover bracket should align with the single mark on the harmonic balancer. Important: While precise alignment is desirable, it is not absolutely critical at this stage.

S54 Vanos Service Procedure

Vanos solenoid removal relieves Vanos hydraulics and allows manipulation of Vanos and engine timing without need for air compressor and expensive electrical switches. This method is also easier to perform, clearer to understand, and less problematic.

Remove Vanos solenoid electrical cable connector at Vanos bottom left.
Press in connector side clips and pull/pry off connector (tack lifter).
If present, pull off and discard cable strap.

Cover lower radiator hose to protect belts from oil leakage (towels).

If installing Vanos seals repair kit or rebuilt Vanos solenoid coil pack, slightly loosen Vanos oil pressure restrictor (22mm open wrench).
Note: Pressure restrictor work will be performed at bench. Loosening is easier to perform while solenoid is mounted.

Remove Vanos solenoid 5 mounting bolts; 3 upper and 2 lower (5mm hex bit socket 3/8″ / 3/8″ ratchet & extension).
Loosen bolts evenly and support solenoid as it drops from Vanos.

Remove solenoid with sealing plate from engine bay.

Retarding of camshaft timing

Maintain cover over lower radiator hose during following camshaft adjustment as oil will leak from Vanos bottom (towels).

Fully retard exhaust camshaft timing.
Place open wrench (24mm combo wrench) on exhaust camshaft hex at front of camshaft.
Rotate exhaust camshaft counter clockwise to adjustment end position. If camshaft resistant to rotation rock camshaft back and forth to release seize.
Camshaft rotation is most effective when standing at the exhaust side of the car.
Note: The splined shaft becomes visible, protruding from the front of the sprocket hub, when the camshaft reaches the adjustment end position.

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.

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.
Message: Camshaft rotation is most effective when standing at exhaust side of car.
Statement: Splined shaft can be seen protruding from sprocket hub front when camshaft is at adjustment end position.

Remark: Camshaft adjustment causes full camshaft timing retard. As a result, this causes splined shaft and Vanos piston forward positioning. This, in turn, facilitates access for disconnecting the splined shaft from the Vanos piston in the coming step.

When intake and exhaust camshafts are fully retarded holes in the camshafts between cylinder 2 & 3 will point up perpendicularly to engine head.

Remove covers from lower radiator hose (towels).
Wipe clean bottom of Vanos (towels).

Removal of Vanos

To begin, clear the camshaft chain guide of any obstructions. Following that, extract the two mounting bolts securing the chain guide. Use a 5mm hex bit socket with a 3/8″ drive and a 3/8″ ratchet for this step. Lastly, remove the chain guide completely.

Cover cavities between Vanos and sprockets to keep bolts from falling down in next step (towels).

Detach the Vanos bracket. First, unscrew the two Vanos bracket mounting bolts using a 10mm socket (3/8″ ratchet & extension). Once the bolts are removed, take off the Vanos bracket. Finally, note the Vanos bracket mounting orientation.

Remove covers (towels).

To begin, eliminate the oil accumulator pipe from the Vanos system. Following that, remove the banjo bolt that secures the oil pipe. Use a 14mm socket with a 3/8″ drive and a 3/8″ ratchet for this step. Lastly, discard the crush washers situated on either side of the pipe fitting.

Locate oil accumulator pipe bracket mounting bolt under radiator lower hose (mirror).

Take out oil accumulator pipe bracket mounting bolt (10mm socket 3/8″ / 3/8″ ratchet & extension).

Move oil accumulator pipe to rear.

Cover lower radiator hose to protect belts from oil leakage in next steps (towels).

Remove Vanos 5 mounting bolts; 2 top corner and 3 lower (10mm socket & 5mm hex bit socket 3/8″ / 3/8″ ratchet & extension).

Pry Vanos forward off engine head.
Pry between the Vanos and the engine head at the Vanos top right and left ends using a medium putty knife. Then, insert the blade between the Vanos and engine head, and hit the blade to press in and separate the Vanos from the engine head (medium putty-knife & hand).
Pry Vanos evenly rotating between each side until Vanos releases and separates from engine head.

To begin, pull the Vanos assembly forward, extending it as far as it will go. Note: Be aware that once the Vanos is separated from the engine head, it will remain suspended by the intake and exhaust splined shafts. Caution: It is imperative that the Vanos not be reinstalled onto the engine head without proper alignment of the exhaust-side Vanos oil pump and the camshaft oil pump driver.

Firstly, install the Vanos solenoid long mounting bolts into the top right and left mounting holes on the Vanos to support it on the engine head (refer to the picture).
Next, insert the bolts into the head by hand, turning them only a few times.
Finally, disconnect the Vanos pistons from the splined shaft studs.

Cover cavities below sprockets to keep tools from falling into cavities (towels).

Rotate Vanos intake piston to allow tool access to splined shaft stud flats (10mm open wrench).

Disconnect Vanos intake piston from intake splined shaft stud.
Counter hold splined shaft stud and unscrew Vanos piston; left hand thread (7mm open wrench, 10mm open wrench).
Note: Piston and shaft stud are left hand thread, thus unscrew by turning piston tool (10mm open wrench) from left to right (clockwise) (car front orientation).
Note: As needed, rotate piston tool (10mm open wrench) at every turn to facilitate tool access.

Rotate Vanos exhaust piston to allow tool access to splined shaft stud flats (10mm open wrench).

Disconnect Vanos exhaust piston from exhaust splined shaft stud.
Counter hold splined shaft stud and unscrew Vanos piston; left hand thread (7mm open wrench, 10mm open wrench).
Note: Piston and shaft stud are left hand thread, thus unscrew by turning piston tool (10mm open wrench) from left to right (clockwise) (car front orientation).
Note: As needed, rotate piston tool (10mm open wrench) at every turn to facilitate tool access.

Remove sprocket cavity covers.

Unscrew solenoid long bolts at Vanos top corners from engine head while supporting Vanos.
Remove Vanos and take to work bench.

Note rotational position of Vanos oil pump holes.
This position is necessary for reinstalling Vanos and matting it with oil pump driver tabs.

Replacement of Vanos oil pump disk

Perform following work on table to prevent parts from falling and being damaged.

Remove oil pump retaining ring.
Compress ring at end holes and remove ring form Vanos (retaining ring pliers).

Remove oil pump retaining washer.
Pry out washer from inner perimeter and pull out (90 degree pick).

Inspect mounting position of pump disk outer bearing ring to outer radial bearing.
Note bearing ring protrudes out slightly higher than outer radial bearing.

Install clear plastic bag over Vanos oil pump side.

Turn Vanos down and hit end of Vanos on table to dislodge oil pump disk from Vanos.

Remove plastic bag from Vanos with oil pump disk, caps and springs, and bearing ring.
Note: If bearing ring still in Vanos (picture), remove bearing ring from Vanos (90 degree pick).

Remove spring pads from oil pump 4 side holes.
Insert tool in pad center hole and pry out pad (straight pick).

Insert old oil pump disk on exhaust sprocket hub and rotate back and forth to assess amount of play between oil pump holes and exhaust hub tabs.
Perform same with new oil pump disk. Be sure to use newly drilled and marked holes.
New disk holes significantly reduce hole to tab play and thus prevent hitting and tab breaking.

Clean oil pump components and verify inventory (brake cleaner & towels).
Components include: retaining ring, retaining washer, bearing ring, 4 x cap, 4 x spring, 4 x spring pad.

Check fit of oil pump caps in new Beisan oil pump disk. 1% of Vanos units will have a .001mm diameter oversized cap that will stick in a Beisan new oil pump disk side cylinder. If this is encountered, a 30 second polishing of a side cylinder with 400 grit sandpaper and 1/4″ socket extension will remove .0005mm material and accommodate the oversized cap. The polished cylinder will now accommodate the oversized cap.

Install 4 spring pads in oil pump side holes.
Insert tool in pad protruding nipple center hole and insert pad to bottom of side hole (straight pick).

Caution: Spring pads must be installed in correct orientation. Pad protruding nipple must point out.

Install 4 springs in oil pump side holes.
Insert spring on side hole.

Place 4 caps on oil pump side hole springs.
Install cap on spring.

Set up the pump disk with caps and springs in the bearing ring.

Next, slightly insert the 4 caps and springs into the oil pump disk side holes using your fingers (as shown in the picture).

Then, lift the disk with the caps slightly inserted and place it over the bearing ring.

After that, press in all the caps and insert the disk with the caps into the bearing ring.

Once the caps are inserted into the ring, hold the disk down and pull the ring up slightly to position the caps at the ring’s center groove.

Finally, lightly lubricate the pump disk’s center bushing with assembly oil.

Clean Vanos oil pump housing (brake cleaner & towels).
Lightly lubricate Vanos center shaft side and outer radial bearing to ease pump installation (assembly oil).

Initially install oil pump disk on oil pump shaft.
Tilt pump side to side as needed to insert onto shaft.
Only initially insert and seat disk onto shaft. Do not insert further.

First, press the bearing ring to the right side to align it and insert it into the radial bearing (using your fingers).

Once the bearing ring aligns with the radial bearing, slightly press down on the bearing ring to insert it into the radial bearing.

Next, press down on the bearing ring to fully insert it into the radial bearing. As a result, the oil pump disk will slide down the center shaft as the bearing ring lowers.

First, press down on the bearing ring at multiple locations to ensure full insertion (using a 90-degree pick).

Once fully pressed down and released, the bearing ring will come back up slightly to align with the disk caps.

Finally, check the position of the bearing ring’s top relative to the radial bearing’s top along the perimeter to verify full bearing ring insertion (using your finger).
Note bearing ring will protrude out slightly further than radial bearing.

Lightly lubricate each pump cap (assembly oil).
Turn pump disk and lubricate each cap as it becomes exposed on right side.

Turn pump disk and verify smooth operation.
Adjust and lubricate components as necessary.

Install retaining washer in oil pump housing.

Initially insert retaining ring in oil pump housing.

Compress retaining ring and insert into oil pump housing ring groove (retaining ring pliers).

Visually verify retaining ring is inserted into housing ring groove.

Turn pump disk and verify smooth operation.

Note: Oil pump rotates counterclockwise in normal operation. If rotated in this direction air can be heard compressed and released. In engine operation this will be oil compressed and released. Function of oil pump is to compress oil to high pressure. It is then regulated down to 100 bar (1,450 psi).

Replacement of Vanos sealing plate rubber rings

Clean vanos sealing plate (brake cleaner & towels).

Cut rubber rings from sealing plate (razor knife).
Make radial cut from rubber ring inner diameter to sealing plate hole perimeter, then cut along sealing plate hole perimeter.
Note: Cutting motion facilitates cutting.
Once rubber ring is removed cut out remaining rubber at sealing plate hole perimeter.
Note: Cutting some metal from sealing plate is normal and acceptable.
Note: It is not necessary to remove all rubber from hole perimeter.

Clean sealing plate rubber ring hole perimeter surfaces (brake cleaner & towels).

Insert new O-rings into corresponding size sealing plate rubber ring holes.
Note: O-rings fit with slight interference (larger) in holes and thus will maintain their mounted position.
Note: O-rings will adjust position and fit correctly once sealing plate is installed.

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.

Installation of Vanos intake seals

Dispose of Vanos intake cylinder cover.
Discard cover 3 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).

Remove intake cylinder cover.
Pry cover at multiple locations to evenly remove cover (small putty-knife).
As necessary, strike blade between cover and Vanos body to initially break seize.
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 piston from intake cylinder.
Press piston from Vanos inboard side to remove piston from Vanos outboard side (1/4″ socket extension).

Cut cross section of intake piston end seal Teflon ring (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Rotate blade in seal after cutting to note any remaining uncut seal (razor knife).

Remove cut Teflon ring from piston grove.

S54 Vanos Service Procedure

When seal removal is complete, piston seal groove will have exposed metal with no seals.

Clean intake piston (brake cleaner & towels).

Insert intake piston end seal new O-ring in piston seal groove at one end and stretch other end over piston and drop into seal groove (fingers).
Center O-ring in seal groove (straight pick).

Insert intake piston end seal new Teflon ring in piston seal groove at one end and stretch other end over piston and drop into seal groove (fingers).
Stretch Teflon ring at multiple location along Teflon ring before final stretch over piston and into groove (fingers).

Inserting the Intake Piston into the Cylinder
First, insert the large end of the intake piston into the intake cylinder. Next, lightly lubricate the inner wall of the cylinder entry and the piston’s Teflon ring using assembly oil. Then, wiggle the piston slightly and press it straight into the cylinder.

Ensuring Proper Teflon Ring Insertion
Afterward, verify that the Teflon ring is inserting into the cylinder at all perimeter locations. If necessary, reposition the piston and try again to ensure the Teflon ring inserts fully along its entire perimeter. Once the Teflon ring is properly aligned, continue wiggling the piston and pressing it straight into the cylinder to fully seat the Teflon ring.

Additional Notes
Finally, keep in mind that the cylinder entry has a chamfer. This chamfer allows the stretched Teflon ring to be collected and guided smoothly into the cylinder during insertion.

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.

First, record the intake rod seal on the intake cylinder, located just inside the cylinder’s inboard side. Additionally, note that the picture shown is of a different Vanos system and depicts burnt sludge buildup.

Pry out intake rod seal Teflon ring from intake cylinder seal groove.
Pry Teflon ring from front to rear to dislodge from seal cavity, then pull Teflon ring out of cylinder (90 degree pick).

Investigate out intake rod seal O-ring from intake cylinder seal groove.
Pry O-ring from rear to front to dislodge from seal cavity, then pull O-ring out of cylinder (90 degree pick).

Crimp and hold the new O-ring for the intake rod seal at approximately the middle using medium nose pliers. However, be sure to hold the O-ring without twisting it, as it must remain straight for insertion in the next step.

Insert intake rod seal new O-ring into cylinder seal groove bottom (picture).
Then press down on O-ring and insert O-ring top into seal groove top.
Release O-ring holding tool and O-ring will insert into seal groove.
Press against O-ring remaining protruding section to fully insert into seal groove (medium nose pliers).

Press Intake rod seal new Teflon ring side into middle of Teflon ring and hold at crimped section (picture) (medium nose pliers).

Insert the new Teflon ring for the intake rod seal into the bottom of the cylinder seal groove, as shown in the picture. Then, release the Teflon ring from the holding tool, and it will seat itself into the seal groove.

Carefully press the remaining protruding section of the Teflon ring to fully seat it in the seal groove, using medium nose pliers. Afterward, smooth the Teflon ring by gently pressing along the bent section from side to side with the side of the medium nose pliers.

Insert the small end of the intake piston into the inboard side of the intake cylinder. Lightly lubricate the piston and the cylinder rod seal Teflon ring with assembly oil. Then, while wiggling the piston slightly, press it straight into the cylinder.

Maintain piston in cylinder for 1 minute then remove.
Allow this period for the Teflon ring to rebound (resize) close to its original dimensions. Afterward, remove the piston from the cylinder. Note that the Teflon ring should have returned to its original shape.

Insert the small end of the intake piston first into the outboard side of the intake cylinder and press the piston fully into the cylinder. Next, clean the Vanos intake cylinder outboard side cover mating surfaces and cover mounting bolts using brake cleaner and towels.

Remove intake cylinder cover sealing O-ring.
Pry O-ring from cover groove and remove from cover (90 degree pick).

Clean intake cylinder cover (brake cleaner & towels).

Install new O-ring on intake cylinder 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 intake cylinder cover on Vanos.
Orient cover to align cover holes with Vanos holes. Cover is asymmetric and only one orientation aligns.
Install intake cylinder cover 3 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).
Tighten bolts evenly to draw cover evenly to Vanos body.
Fully tighten, 10 Nm (7 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.

Installation of vanos exhaust seals

Exclude Vanos exhaust cylinder cover.
Extract cover 3 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).

Erase exhaust cylinder cover.
Pry cover at multiple locations to evenly remove cover (small putty-knife).
As necessary, strike blade between cover and Vanos body to initially break seize.
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 exhaust piston from exhaust cylinder.
Press piston from Vanos inboard side to remove piston from Vanos outboard side (1/4″ socket extension).

Cut cross section of exhaust piston middle seal Teflon ring (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Rotate blade in seal after cutting to note any remaining uncut seal (razor knife).

Remove cut Teflon ring from piston grove.

Cut cross section of exhaust piston middle seal O-ring (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Rotate blade in seal after cutting to note any remaining uncut seal (razor knife).

Remove cut O-ring from piston grove.

Cut cross section of exhaust piston end seal Teflon ring (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Rotate blade in seal after cutting to note any remaining uncut seal (razor knife).

Remove cut Teflon ring from piston grove.

Cut cross section of exhaust piston end seal O-ring (razor knife).
Note: Rocking of blade while pressing helps create cutting motion.
Rotate blade in seal after cutting to note any remaining uncut seal (razor knife).

Remove cut O-ring from piston grove.

When seals removal is complete, piston seal grooves will have exposed metal with no seals.

Clean exhaust piston (brake cleaner & towels).

Mount exhaust piston middle seal O-ring onto exhaust piston small end and roll O-ring along piston and drop into seal groove (fingers).
Center O-ring in seal groove (straight pick).

Mount the exhaust piston middle seal Teflon ring onto the small end of the exhaust piston.
Insert the pick tool between the Teflon ring and the piston (use a 90-degree pick) (see the picture).
Leverage the pick tool against the piston and tilt it to stretch the Teflon ring.
Stretch the Teflon ring at multiple locations along its length until it notably stretches.
Note: The Teflon ring must stretch sufficiently to slide over the larger diameter of the piston.

Place exhaust piston vertically with large end down.
Press down on Teflon ring from top end to press Teflon ring onto piston larger diameter (fingers/nails).
Move Teflon ring evenly along piston (picture).
Note: If Teflon ring difficult to press down repeat previous Teflon ring stretching step.

Slide Teflon ring down exhaust piston to seal groove rim (fingers/nails) (picture).

Press down on Teflon ring from top end to press Teflon ring onto piston seal groove rim and drop Teflon ring into seal groove (fingers/nails).
Move Teflon ring evenly along piston (picture).

Note: It has been found that it is practical to first compress this small Teflon ring as next step and insert it into the exhaust cylinder for a few minutes, as shown a few steps below.
After that continue here with the ring on the piston bottom.

Insert exhaust piston end seal O-ring in piston seal groove at one end and stretch other end over piston and drop into seal groove (fingers).
Center O-ring in seal groove (straight pick).

Insert exhaust piston end seal Teflon ring in piston seal groove at one end and stretch other end over piston and drop into seal groove (fingers).
Stretch Teflon ring at multiple location along Teflon ring before final stretch over piston and into groove (fingers).

Insert exhaust piston large end into exhaust cylinder outboard side.
Lightly lubricate cylinder entry inner wall and piston Teflon ring (assembly oil).
Wiggle piston and press straight 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 straight into cylinder to fully insert Teflon ring into cylinder.
Note: Cylinder entry has chamfer which allows for stretched Teflon ring to be collected and inserted into cylinder.

Place small hose clamp around exhaust piston middle seal Teflon ring (small hose clamp).
Tighten clamp until it seats on piston (Philips).
Note: Only lightly tighten clamp on piston.

Note: Mounting clamp on piston middle seal Teflon ring will compress Teflon ring to close to original size and allow piston insertion in next step.

Remove hose clamp from exhaust piston (Philips).
Note Teflon ring has compressed.
Note: Clamp will leave slight crease on Teflon surface. This crease will rectify once Teflon ring is heated in engine.

Lightly lubricate exhaust piston middle seal Teflon ring (assembly oil).
Insert exhaust piston small end into exhaust cylinder outboard side.

Place flat object on exhaust piston end (small putty-knife handle).
Press in on piston with moderate pressure until piston inserts into cylinder (picture).
Note: During this step piston middle seal Teflon ring is being inserted into exhaust smaller cylinder. Cylinder entry has chamfer which will allow for stretched Teflon ring to be collected and inserted into 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 by pressing piston from inboard side.
Note Teflon ring has decreased in diameter.

Insert exhaust piston small end first into exhaust cylinder outboard side and press piston fully into cylinder.

Clean Vanos exhaust cylinder outboard side cover mating surfaces and cover mounting bolts (brake cleaner & towels).

Remove exhaust cylinder cover sealing O-ring.
Pry O-ring from cover groove and remove from cover (90 degree pick).

Clean exhaust cylinder cover (brake cleaner & towels).

Install new O-ring on exhaust cylinder 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 exhaust cylinder cover on Vanos.
Orient cover to align cover holes with Vanos holes. Cover is asymmetric and only one orientation aligns.
Install exhaust cover 3 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).
Tighten bolts evenly to draw cover evenly to Vanos body.
Fully tighten, 10 Nm (7 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.

Remove Vanos oil flow regulator from Vanos.
Rotate regulator to break seize then pull regulator from Vanos.

Remove regulator small O-ring.
Pry O-ring from regulator groove and remove from regulator (90 degree pick).

Remove regulator large O-ring.
Pry O-ring from regulator groove and remove from regulator (90 degree pick).

Clean oil flow regulator (brake cleaner & towels).
Spray through end port to flush out any debris (brake cleaner). Not: Do not use compressed air as it can damage filter.
Verify oil flow regulator valve is moving smoothly. Press and release wider brown component at end of regulator (above picture). It should insert with some resistance and spring back when released. Movement should be smooth.

Install new small O-ring on regulator.
Insert O-ring in regulator groove on one end and stretch other end over regulator and drop into groove (fingers).
Lightly lubricate O-ring to ease Vanos installation (assembly oil).
Note: Oil regulator small O-ring is similar in size to Vanos solenoid oil pressure restrictor small O-ring. Oil regulator O-ring is slightly thicker in cross section than oil pressure restrictor small O-ring.

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

Orient regulator with overflow holes to sides of Vanos (picture) and fully insert regulator into Vanos.

Remaining two O-rings in seals kit are for oil pressure restrictor and their installation is covered in the next solenoid section.

Replacement of solenoid coil pack, pressure restrictor O-rings, and oil filter

Remove coil pack 4 mounting bolts (E-5 torx or 4mm socket 1/4″ / 1/4″ ratchet).

Pull off coil pack (black) from valve body (silver).

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

Cleaning of solenoid valves

Spray cleaner into all valve body available holes to clear out oil (brake cleaner).

Mount magnet on each valve shaft of valve body to open valve, then spray cleaner in corresponding valve small hole on opposite side of valve body (brake cleaner).
Continue to spray cleaner into valve hole until cleaner runs clean from valve body.
Perform valve opening and cleaning process for 4 valves.

Once valves cleaned, each valve internal piston should be heard easily moving and clicking when magnet is applied on and off valve shaft.

Pull off oil filter from pressure restrictor (pliers).

Note: Oil filter replacement is not a requirement. Oil filter can be spray cleaned (brake cleaner).

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 already has cross section cut which is needed for installation.
Remove cut O-ring from pressure restrictor.

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

Clean pressure restrictor (brake cleaner & towels).
Install new large O-ring on pressure restrictor. Roll O-ring onto pressure restrictor till O-ring drops into base groove.
Install small O-ring on pressure restrictor. Roll O-ring onto pressure restrictor till O-ring drops into groove.
Install new oil filter on pressure restrictor. Press filter small hole end onto pressure restrictor end stud.

Screw pressure restrictor into valve body (hand).
Note: Pressure restrictor will be tightened once solenoid is mounted on Vanos.

Mount new coil pack on valve body.
Align coil pack holes with valve body studs and mount.

Install coil pack 4 mounting bolts (E-5 torx or 4mm socket 1/4″ / 1/4″ ratchet).
Tighten bolts evenly in multiple passes.
Fully tighten, 4 Nm (3 ft-lb) (E-5 torx or 4mm socket 1/4″ w/ 3/8″ to 1/4″ socket adapter / 3/8″ torque wrench).
Note: Bolts can be tightened lightly by feel. Do not over tighten.

Cleaning of parts

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

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

Wipe Vanos matting surfaces; solenoid (both Vanos and solenoid), head gasket (brake cleaner & towels).

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

Wash coil harness ground wire (brake cleaner & towels).

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

Polish valve cover gaskets (brake cleaner & towels). Note: S54 valve cover gaskets and bolt grommets 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, exhaust side ground wire hole, exhaust side oil drain hole (brake cleaner & towels).

Perform rattle procedure

If performing rattle procedure, do so at this time.
S54 Vanos Rattle Procedure

Installation of Vanos

Rotate Vanos oil pump to approximate position found when Vanos was first removed.
This position will locate oil pump holes close to oil pump driver tabs position on exhaust sprocket hub. This facilitates easier alignment and installation.
Note: Pump disk new smaller holes to be used are marked black.

If Vanos top corner alignment dowels remained on Vanos place Vanos gasket on Vanos.
Place gasket on Vanos with gasket ridge to Vanos. Gasket two lower tabs will point to Vanos (picture).

If Vanos top corner alignment dowels remained on engine head place Vanos gasket on engine head.
Place gasket on head with gasket ridge to Vanos (front). Gasket two lower tabs will point to Vanos (front) (picture).

Mount Vanos onto engine head with solenoid 2 long bolts at Vanos top corners.
Screw solenoid long bolts into engine head just a few turns.

Connecting of Vanos pistons to splined shaft studs

Cover cavities below sprockets to keep tools from falling down (towels).

Rotate intake splined shaft stud to facilitate tool access to stud flats (fingers).
Mount splined shaft stud tool (7mm open wrench).

Install pliers on Vanos intake piston hex (medium nose pliers).
Lift up Vanos and pull Vanos intake piston onto splined shaft stud (medium nose pliers).
While pressing piston onto splined shaft, counter hold splined shaft stud and thread piston onto splined shaft stud one rotation; left hand thread (medium nose pliers / 7mm open wrench).
Note: Piston and shaft stud are left hand thread, thus screw by turning piston tool (medium nose pliers) from right to left (counter clockwise) (car front orientation).

Thread intake piston onto splined shaft stud; left hand thread (10mm open wrench / 7mm open wrench).
Note: Piston and shaft stud are left hand thread, thus screw by turning piston tool (10mm open wrench) from right to left (counter clockwise) (car front orientation).
Note: As needed, rotate piston tool (10mm open wrench) at every turn to facilitate tool access.
Lightly tighten; left hand thread (10mm open wrench / 7mm open wrench).
Note: Due to left hand thread, it is not necessary to over tighten joint.

Rotate exhaust splined shaft stud to facilitate tool access to stud flats (fingers).
Mount splined shaft stud tool (7mm open wrench).

Install pliers on Vanos exhaust piston (medium nose pliers).
Pull Vanos exhaust piston onto splined shaft stud (medium nose pliers).
While pressing piston onto splined shaft, counter hold splined shaft stud and thread piston onto splined shaft stud one rotation; left hand thread (medium nose pliers / 7mm open wrench).
Note: Piston and shaft stud are left hand thread, thus screw by turning piston tool (medium nose pliers) from right to left (counter clockwise) (car front orientation).

Thread exhaust piston onto splined shaft stud; left hand thread (10mm open wrench / 7mm open wrench).
Note: Piston and shaft stud are left hand thread, thus screw by turning piston tool (10mm open wrench) from right to left (counter clockwise) (car front orientation).
Note: As needed, rotate piston tool (10mm open wrench) at every turn to facilitate tool access.
Tighten; left hand thread (10mm open wrench / 7mm open wrench).
Note: Due to left hand thread, it is not necessary to over tighten joint.

Remove covers (towels).

Press Vanos onto engine head until it stops or top corner alignment dowels are reached.

Caution: Do not attempt to forcibly fully mount Vanos to engine head. This can cause damage.

Inspect Vanos oil pump side hole and exhaust sprocket hub driver side tab for alignment.
Rotate Vanos oil pump as needed to achieve alignment (fingers).

Press Vanos onto engine head and verify driver tab insertion into oil pump hole.
Realign Vanos pump as need to facilitate tab insertion (fingers).

Remove solenoid long bolts at Vanos top corners.

Align Vanos dowels and mating holes and press on Vanos to mate.
Press on Vanos and wiggle and fully mate with engine head.

Install Vanos 5 mounting bolts; 2 top corner hex head and 3 lower hex bit head (10mm socket & 5mm hex bit socket 3/8″ / 3/8″ ratchet & extension).
Fully tighten, 10 Nm (7 ft-lb) (10mm socket & 5mm hex bit socket 3/8″ / 3/8″ torque wrench & extension).
Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

Reposition oil accumulator pipe to Vanos.
Align pipe lower bracket to mounting hole below radiator lower hose (mirror).

Install oil accumulator pipe bracket mounting bolt (10mm socket 3/8″ / 3/8″ ratchet & extension).
Note: Bolt is similar but shorter than Vanos bracket two mounting bolts.
Note: Initially install bolt by feel (hand).
Fully tighten by feel (10mm socket 3/8″ / 3/8″ ratchet & extension). Do not over tighten.

Install oil accumulator pipe at top of Vanos.
Install banjo bolt with new crush washer at both sides of pipe fitting (14mm socket 3/8″ / 3/8″ ratchet).
Note: Banjo bolt is smaller of two available banjo bolts and correspondingly crush washers are smaller of two sets of available crush washers.
Note: Lift pipe fitting up to allow bolt to align and thread.
Fully tighten, 13 Nm (9.5 ft-lb) (14mm socket 3/8″ / 3/8″ torque wrench).

Install Vanos bracket.
Cover cavities between Vanos and sprockets to keep bolts from falling down (towels) (not shown).
Position bracket in place. Note orientation of bracket.
Install 2 bracket bolts at Vanos (hand).
Do not tighten bolts.

Remove covers (towels).

Install chain rail guide.
Align Vanos bracket holes with camshaft bracket holes.
Align chain rail guide bolt holes and Vanos bracket bolt holes with camshaft bracket holes.
Install chain rail guide 2 mounting bolts (5mm hex bit socket 3/8″).
Fully tighten Vanos bracket and chain rail guide mounting bolts, 9 Nm (6.5 ft-lb) (5mm hex bit socket & 10mm socket 3/8″ / 3/8 torque wrench).
Tighten bolts evenly in multiple passes. Verify one pass with all bolts fully tightened.

Installation of Vanos solenoid

Clean Vanos solenoid matting surface (brake cleaner & towels).

Firstly, place the new sealing plate (silver part) on the Vanos solenoid valve body.
Next, align the sealing plate notch with the valve body notch.
Then, verify that the sealing plate bolt holes match up with the valve body bolt holes and that the sealing plate rubber rings align with the valve body’s oil holes.

Firstly, insert the solenoid along with its sealing plate under the Vanos.
Next, ensure that the oil pressure restrictor is oriented to the right.
Then, align the solenoid and sealing plate by matching the left front corner with the corresponding corner on the Vanos.
After that, align the bolt hole on the solenoid and sealing plate with the Vanos’s lower left bolt hole.
Finally, install the solenoid’s lower left mounting bolt by hand to secure the solenoid in place.

Firstly, install the solenoid’s five mounting bolts—three upper and two lower—using a 5mm hex bit socket with a 3/8″ ratchet and extension.
Next, align the solenoid and sealing plate with the Vanos to facilitate bolt insertion.
Then, fully tighten each bolt to 10 Nm (7 ft-lb) using a 5mm hex bit socket with a 3/8″ torque wrench and extension.
Finally, tighten the bolts evenly in multiple passes, verifying that each pass fully tightens all bolts.

If Vanos oil pressure restrictor previously loosened, fully tighten pressure restrictor (22mm open wrench)
Note: The pressure restrictor is sealed with a base O-ring, so only moderately tighten the restrictor.

Insert cable strap end into cable strap lock bracket.
Reduce cable strap formed circle to size larger than Vanos electrical cable connector.

First, orient the cable strap so that the excess strip points forward and upward, as illustrated in the accompanying diagram. Next, insert the cable strap over both the Vanos electrical cable and the solenoid electrical connector neck.

Install Vanos electrical cable connector. Press in connector until clips snap into place.

Tighten cable strap on electrical cable and solenoid electrical connector neck.
Cut cable strap excess strip (cutters).

Valve adjustment repair can be performed at this point in the procedure.

Installation of valve cover

Apply thin layer of 3Bond Drei Sealant (BS0SS) (www.beisansystems.com) at Vanos and head matting junctions at top right and left of Vanos (gasket sealant).
Allow sealant to solidify for 2 minutes before mounting valve cover gasket.

First, install the valve cover perimeter gasket and spark plug well gaskets on the engine head. Note: There is no specific orientation required for the spark plug well gaskets. Next, orient the valve cover gasket with the half-moons facing rearward and downward. Then, verify that the perimeter gasket alignment pins at cylinders 1 and 5 on each side of the head, and the two at the Vanos top, are fully aligned and inserted. Finally, verify that the gasket’s rear half-moons straddle and are fully inserted onto the head.
Note: If gasket perimeter pins do not fully insert into head and Vanos then gasket will not lay flat and will leak oil.
Note: Valve cover gasket and sparkplug well gaskets are Viton and can be reused.

First, install the valve cover on the engine head and Vanos. Then, lift up the rear connectors and cables and carefully insert the valve cover underneath them. Next, tilt the cover’s left side up and insert the cover’s right side under the fuel injector electrical rail. After that, align the valve cover with the engine head and gaskets and gently lay the valve cover onto the engine head. Following that, adjust the cover to align the head studs so they protrude at the center of the cover holes. Finally, check, by feel, that the gasket’s rear half-moons are aligned and seated correctly on the head and cover. In addition, check that the gasket dowels at cylinders 1 and 5 on each side of the head, and the two at the Vanos top, are fully inserted and that the gasket is laying fully flat at their location.

Do not install valve cover bolts at this time.

Install oil drain hose at exhaust side of valve cover.
Place O2 sensors connector bracket and coil harness rail at top of valve cover.
Install banjo bolt with new crush washer at both sides of pipe fitting (hand).
Note: Install one crush washer on banjo bolt. Place second crush washer on valve cover and slide down to bolt hole while inserting banjo bolt through hose fitting. Bolt will insert into crush washer once crush washer is lowered sufficiently on valve cover.
Fully tighten, 25 Nm (18.5 ft-lb) (17mm socket 3/8″ / 3/8″ torque wrench).
Place O2 sensors connector bracket and coil harness rail to exhaust side of valve cover.

Install valve cover 15 mounting bolts and studs w/ washers and rubber grommets; 2 front corner studs, 1 front center bolt, 6 bolts at each side (10mm socket & 10mm deep socket 3/8″ / 3/8″ ratchet & extension).
Install 2 new stud grommets. Note: Stud grommets are Buna and do fail. Remainder of valve cover bolt grommets are Viton and can be reused.
Tighten bolts/studs evenly working back and forth, assuring even pressure distribution on cover. Tighten until bolts/studs bottom out on head.
Fully tighten, 8Nm (6 ft-lb) (10mm socket & 10mm deep socket 3/8″ / 3/8″ torque wrench & extension).

Install each coil into original sparkplug well.
For each coil, orient coil tab to align with valve cover coil tab mating slot, insert coil boot into sparkplug well, and press coil onto sparkplug well until it snaps into place.

First, install the coil electrical harness. Next, place the coil harness rail on the valve cover. Following that, insert the cable boot into the valve cover slot at cylinder 4. Subsequently, for each coil, lift up on the connector pivot lock, press in the cable’s electrical connector, and lastly, push down on the connector pivot lock.

Install coil harness rail 2 mounting bolts (8mm socket 1/4″ / 1/4″ ratchet & extension).

First, install the O2 sensor connector bracket at the top of the valve cover. Then, insert the bracket’s left front and rear holes onto the cover studs at cylinders 2 and 5. Finally, orient the rear cables as shown in the picture.

Press right front and rear clips into coil harness bracket slots until clips snap into place.

Secure the coil harness ground strap using the mounting bolt at the valve cover exhaust side (13mm socket 3/8″ / 3/8″ ratchet).

First, attach the necessary components at the rear of the valve cover. Following that, connect the O2 sensor connectors. Afterward, fasten the O2 sensor cable mounting clips. Lastly, secure the rubber block along with the cable mounting clip.

First, install the engine top cover. Then, remove the oil fill cap. Next, lift up the cables and hose and carefully insert the top cover into position. After that, align the cover with the six mounting studs and gently lay the cover onto the studs and valve cover. Finally, adjust the cables at the valve cover’s left rear as needed to facilitate complete top cover installation.

Install oil fill cap.
Install ventilation hose onto crankcase vent valve at cover rear top. Press on hose connector until it snaps into place.

Install top cover 6 mounting caps (10mm socket 3/8″ / 3/8″ ratchet & extension).

Installation of suspension cross brace

If present, install suspension cross brace.

First, mount the suspension cross brace onto the studs at the right and left strut towers. Next, install the two mounting nuts at the left and right ends of the suspension cross brace using a 13mm socket with a 3/8″ drive and a 3/8″ medium-arm ratchet. Then, fully tighten the nuts to 40 Nm (29.5 ft-lb) using a 13mm socket with a 3/8″ drive and a 3/8″ torque wrench.

Moving on to the installation of the fan and shroud, specifically the E46 M3 fan and shroud installation. Following that, we’ll proceed with the installation of the cabin filter housing, again focusing on the E46 M3 cabin filter housing installation. Finally, we will cover the post-repair procedures.

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