We provide the following information for reference purposes only, and you should use it at your own risk: S54 Vanos Solenoid Procedure (E46 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

‘Vanos’ is BMW’s name for its variable valve timing units. Vanos units take on various shapes and design according to car year and model (engine model). The vanos discussed here is BMW part # 11-36-7-838-161. It’s a double vanos, meaning both the intake and exhaust valve timing is varied. This vanos unit is part of BMW 6-cylinder engine S54. The M3 E46 00-06, Z3 E36 M Roadster & M Coup 00-02, Z4 E85 M3.2 Roadster 05-08, and Z4 E86 M3.2 Coup 06-08 incorporate this engine.

Vanos Solenoid

This Vanos experiences three unit failures as well as two related failures. Primarily , the main Vanos failure is a Vanos solenoid coil pack malfunction. Secondly , and less commonly, another failure involves sticking solenoid valves. Finally , the third Vanos failure is the deterioration of the Vanos solenoid sealing plate rubber rings. Consequently , these failures are the focus of this procedure.

In addition , the other two Vanos-related failures include a rattle caused by loose intake sprocket mounting bolts, along with a Vanos malfunction caused by broken Vanos oil pump exhaust sprocket hub driver tab(s).

The vanos solenoid coil pack (black plastic housing) failure is due to cracked solder joints. The connector pins at the PCB (printed circuit board) have damaged solder joints.

S54 Vanos Solenoid Procedure

There are three main causes of damaged solder joints: cold solder joints, heat cycling, and mechanical movement. Although all the connector pin solder joints experience structural damage, the inner row of pins (intake side) almost always experiences significant damage and failure, while the outer row of pins (exhaust side) usually maintains the solder connection and doesn’t experience functional failure. This position-specific nature of the failure suggests that the cause is likely vibration. Furthermore, a cold solder joint might also contribute to the weak solder structure in the S54 Vanos Solenoid Procedure.

The solder damage could, in fact, be caused by external electrical cable/connector movement. However, the connector has a silicon gasket that maintains its good condition and firmly mounts the cable connector to the coil pack connector. Additionally, a cable tie straps the electrical cable just past the connector to the coil pack. Therefore, movement of the cable and cable connector is not likely the cause of the solder joint damage.

S54 Vanos Solenoid Fixing Steps

There is a cavity in the coil pack housing where the connector pins enter the housing (below picture). This leaves a long section of the pins not secured (potted). You mount the PCB last from the top onto the housing, a relatively long distance from the connector pin solder joints (see the picture below). Both of these design aspects potentially contribute to the vibration that damages the connector pin solder joints.

S54 Vanos Solenoid Procedure involves repairing the connector pin solder joints and incorporating design changes to address the problems that likely facilitate the failure.
You cut off the coil pack cover to open the unit and facilitate the repair. Afterward, you remount the cover with sealing adhesive.

Epoxy is inserted in the connector pins cavity to better secure the pins.

One introduce a new bolt to mount the PCB from the top, closer to the connector pins. You remove the board alignment stud and mount the bolt in its place.

You remove the pin solder joints and resolder them.

S54 Vanos Solenoid Procedure

The vanos solenoid valve sticking failure is due to sludge buildup in the valve piston cylinders. The solution is to clean the valve passages to remove the sludge.

The failure of the Vanos solenoid sealing plate rubber rings is due to the rubber material being Buna (NBR, Nitrile). The degradation and failure of the Vanos solenoid sealing plate rubber rings are attributed to the properties of the Buna (NBR, Nitrile) rubber material used in their construction. Buna’s temperature limitation of 100°C (212°F) is problematic because engine temperatures often exceed this level.

As a result, the rubber rings experience significant compression set (flattening), leading to oil seepage due to temperature overexposure. To address this issue, Beisan Systems offers a solution involving replacing the failed Buna rubber rings with Viton O-rings of the same thickness. Viton is rated to 204°C (400°F), making it a more suitable material for the high-temperature environment of the sealing plate application

Symptoms

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

P0013 (BMW xx, 0xxx): Vanos exhaust solenoid circuit
P0014 (BMW 22, 0x16): Vanos exhaust timing over advanced
P0015 (BMW 21, 015): Vanos exhaust timing over retarded
Pxxxx (BMW 185, 0xB9): Vanos exhaust position control
P1531 (BMW xx, 0xxx): Vanos exhaust solenoid open circuit

The failure of the vanos solenoid will cause the DME to not utilize the vanos. Unfortunately, the engine timing remains in the same position as when the failure occurred. As a result, the engine will likely behave better at low RPM and worse at high RPM, or conversely, worse at low RPM and better at high RPM. Moreover, engine misfire with fault codes can also occur.

Diagnosis

If a circuit code is present, first disconnect the Vanos solenoid electrical connector and clean both connectors with electronic contact cleaner. If this doesn’t resolve the code, the solenoid coil pack is likely faulty.

A less common failure that causes similar codes (excluding electrical codes) is sticking solenoid valves. You can clean the solenoid valves as outlined in the procedure to address this issue.

Moreover, the same codes (excluding electrical ones) can also occur if the Vanos oil pump driver tabs break. Therefore, it’s important to differentiate between a solenoid coil pack failure and a broken oil pump driver tab(s).

One simple, though not definitive, method of differentiation is to reset the fault codes, start the engine, and let it idle. If the oil pump driver tabs break, the fault codes and check engine light will appear within a few minutes. In contrast, a solenoid coil pack failure is often intermittent, requiring some driving before the fault codes and check engine light show up.

In some cases, a severely failed solenoid coil pack may trigger fault codes and the check engine light at idle. Additionally, if only one oil pump driver tab breaks, the codes and check engine light may not appear at idle, requiring some driving for them to appear.

The definitive method of identifying the failure is to remove the valve cover and inspect the oil pump driver tabs. If one or both are broken, they are the source of the problem. If they are intact, the issue is most likely with the solenoid coil pack.

Repair Procedure

The following is an E46 M3 vanos solenoid coil pack R&R (remove and replace) procedure.

At the end of the repair, it will be necessary to reset the engine fault codes in order to allow the DME (engine computer) to properly utilize the Vanos system.
In terms of time commitment, the repair is estimated to take approximately 1 hour.

Regarding parts, tools, and shop supplies, it’s important to note that parts with the part number pattern xx-xx-x-xxx-xxx are BMW parts, which means they can be acquired from a BMW dealership.
However , Beisan Systems only provides the Vanos solenoid coil pack, so additional components may need to be sourced separately if required.

S54 rebuilt vanos solenoid coil pack (BS023) $200 + $300 refundable core charge (www.beisansystems.com)
Note: Beisan vanos solenoid coil pack comes with vanos oil pressure restrictor O-rings.

Beisan Systems refunds the $300 core charge (deposit) upon the return of the original solenoid coil pack within 90 days of the purchase date, as outlined in the S54 Vanos Solenoid Procedure. However, if you have opened the solenoid valve or tampered with the electronics, Beisan Systems will assess whether you can still use the solenoid and whether we can refund the deposit. Additionally, if you have broken or torn the plug or other parts, we will not be able to use the control unit, and consequently, we will not refund the deposit.

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

S54 vanos sealing plate repair kit (BS024) $10/each (www.beisansystems.com)

Vanos oil filter (11-36-1-401-971) $9.66/each, cable strap (zip tie)

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

For this repair, you will need the following tools:
A torque wrench capable of 4 Nm (3 ft-lb) and 10 Nm (7 ft-lb). However , it’s worth noting that a 4 Nm torque is not strictly required, as this step can be performed by feel.

Additionally , you will need a 3/8″ ratchet and a 1/4″ ratchet, along with a short 3/8″ socket extension. A 22mm combo wrench will also be necessary.

To handle various tasks during the repair , medium-sized cutters and pliers are recommended. Furthermore , a large flathead screwdriver, a tack lifter, a hook pick tool, and a razor knife will come in handy for specific steps.

Finally , for working with specialty fasteners, you’ll need an E-5 Torx or 4mm socket (1/4″), a 3/8″ to 1/4″ socket adapter, as well as a 5mm hex bit socket (3/8″).

For this step, you will need strong magnet(s). A recommended option is the Harbor Freight Craft Magnet Blocks (2 pc), part #98406, available for $1.50. However , if the magnet is not strong enough on its own, you can combine multiple magnets to increase their strength.

Importantly , a strong magnet—or a combination of magnets—is essential for opening the Vanos solenoid valves during the cleaning process. This ensures that the valves can be accessed and cleaned effectively.

Paper towels, water based cleaner (simple green 1:10), brake cleaner

Engine fault code reader (needed to reset fault codes at end of repair)

Repair

Car engine must be cold to perform repair procedure.

Right and Left designations are from car front at hood orientation.

Removal of fan shroud left air guide

Remove the shroud air guide rivet at the top of the shroud. First, pry out the rivet center pin (tack lifter), and then fully pry out the rivet from the base (tack lifter).

Next, remove the left air guide rivet at the rear face of the air guide. Again, pry out the rivet center pin (tack lifter), and then fully pry out the rivet from the base (tack lifter).

Push left air guide to rear to release from mounting bracket.
Pull up and remove air guide from engine compartment.

Removal of vanos solenoid

Remove vanos electrical cable connector.
Press in connector side clips and pull off connector. If resistant, pry connector from end (large flathead).
If present, pull off and discard cable strap.

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

Slightly loosen vanos oil pressure restrictor (22mm open wrench).
Note: You will perform the pressure restrictor work at the bench. You will find it easier to loosen it while the 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 compartment.

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

Remove sealing plate and clean oil from solenoid valve body (silver part) (water based cleaner & towels).

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.

After cleaning the valves, you should hear each valve’s internal piston move and click easily when you apply and remove the magnet on the 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 (hook pick tool).

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.

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 solenoid

Clean vanos solenoid matting surface and solenoid vanos mating surface (brake cleaner & towels).
Insert solenoid under vanos. Orient oil pressure restrictor to right.

Insert new sealing plate on solenoid. Orient sealing plate notch to left rear.
Align solenoid and sealing plate left front corner to vanos edge.
Install solenoid lower left mounting bolt to hold solenoid (hand).

Install solenoid 5 mounting bolts, 3 upper and 2 lower (5mm hex bit socket 3/8′ / 3/8“ ratchet & extension).
Align solenoid and sealing plate to vanos to facilitate bolt insertion.
Tighten bolts evenly in multiple passes.
Fully tighten, 10 Nm (7 ft-lb) (5mm hex bit socket 3/8′ / 3/8′ torque wrench & extension).

Fully tighten vanos oil pressure restrictor (22mm open wrench)
Note: You should lightly tighten the pressure restrictor, as it is sealed with the base O-ring.

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

Orient cable strap with excess strip pointing front and up (picture).
Insert cable strap over vanos electrical cable and solenoid electrical connector neck.

Install vanos electrical cable connector. Press connector until clips snap into place.

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

Installation of fan shroud left air guide

Insert shroud left air guide into place.
Insert guide right lower hook into shroud slot.
Press guide forward and insert guide square hole onto shroud bracket.

Install rivet at rear face of left air guide. Pry rivet center pin out, fully insert rivet base into air guide, then press in rivet center pin.

Align left and right shroud air guides at shroud top center.
Install rivet at shroud top center. Pry rivet center pin out, fully insert rivet base into shroud and right and left guides, then press in rivet center pin.

Reset engine fault codes to allow DME (engine computer) to utilize vanos.

Return original solenoid coil pack to Beisan Systems within 60 days of purchase date for a $150 core charge (deposit) refund.
Coil pack should be wrapped to protect from damage.
Include name and date on purchase transaction in return package.