The following information is provided for reference purposes only and should be used at your own risk S62 VANOS adjustment steps
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 units discussed here are BMW part # 11-36-7-831-486 and 11-36-7-831-487. They are a double Vanos, meaning both the intake and exhaust valve timing is varied. These Vanos units are identical with only the solenoid pack and solenoid cover installed upside-down. They are part of BMW 8-cylinder engine S62. This engine is incorporated into the E39 M5 98-03, E52 Z8 Roadster 99-03.
This Vanos piston seals and static seal O-rings are made of the correct materials and don’t experience premature failure. However over time and use the piston seal O-rings will experience notable compression set (flattening) and the Teflon rings will experience wear (loss of material). This can lead to degradation in performance. The static seal O-rings will also experience notable compression set and could eventually leak. Thus there is a need for a replacement seals solution for this Vanos.
You can acquire a VANOS seals/O-rings repair kit through Beisan Systems (www.beisansystems.com/products). This kit includes a VANOS replacement set with OEM-equivalent Teflon rings and Viton O-rings.
Symptoms
Loss of low end torque, uneven power delivery, and overall loss of power.
Diagnosis
The BMW DIS vanos diagnostic test can be run to assess speed and preciseness of adjustment.
Repair Procedure
The following procedure outlines the E39 M5 VANOS seals R&R (remove and replace). Specifically, it provides step-by-step instructions for removing and replacing the seals.
Repair time: 12 hours mechanic, 12+ hours DIY.
Parts, Tools, and Shop Supplies
Parts with part number pattern xx-xx-x-xxx-xxx are BMW parts and can be acquired from a BMW dealership.
Beisan Systems only provides the seals repair kit.
S62 vanos seals repair kit, MY 98 (BS061.1), MY 99+ (BS061.2) $120/each. Picture is BS061.2.
Note: Car model year 98 utilizes part BS061.1. Subsequent car model years 99+ utilize part BS061.2. The difference between the two products is the piston small seal size.
Perform this repair alongside the S54 VANOS seals and oil pump disk repair. Additionally, note that the seals repair kit covers both VANOS units, so therefore, only one seals kit is necessary.
Note: Seals kit incorporates 2 vanos oil pressure restrictor O-rings and 2 secondary air pipe end O-rings
First, you will need the following parts:
- Bank 1 valve cover gasket set (11-12-0-001-269) at $62.74 each.
- Bank 2 valve cover gasket set (11-12-0-001-278) at $62.74 each.
- 6 valve cover front bolt grommets (11-12-1-721-879) at $1.13 each.
- 20 valve cover side bolt grommets (11-12-1-437-395) at $1.17 each.
Next, gather these additional components:
- 2 coil cover gaskets (11-12-1-406-744) at $13.25 each.
- 1 intake manifold cover gasket (11-61-1-406-657) at $36.58.
- 4 intake manifold cover O-rings (11-61-1-406-747) at $2.12 each.
Additionally, you will require:
- 8 large VANOS solenoid O-rings (11-36-7-830-828) at $5.58 each.
- 8 small VANOS solenoid O-rings (11-36-7-830-829) at $5.10 each.
- 2 VANOS solenoid cover gaskets (11-36-1-406-838) at $15.22 each.
- 4 VANOS oil hose washers (07-11-9-963-072) at $0.51 each.
- 1 coolant drain bolt washer (07-11-9-963-225) at $0.09 each.
Note: The BMW VANOS solenoid O-rings have been redesigned with multiple facets to prevent high oil pressure from shredding them. These are specialized O-rings and are exclusively available from BMW.
4 x vanos supporting M6 long bolts (07-12-9-905-554) $1.50/each
Note: Any 6mm diameter, 1.0mm thread pitch, 50+mm long, bolt will do. Indicated BMW part is S54 vanos solenoid mounting bolt.
First, gather the following tools:
2 x putty knives (small, medium), a straight pick tool (small), and a 90-degree pick tool (small).
Pliers (medium), small needle-nose pliers, and a small razor knife.
Next, ensure you have a 27mm combo wrench, a short-handle adjustable wrench (27mm / 1+”), a 22mm combo wrench, a 10mm combo/ratcheting wrench, and a 7mm combo wrench.
Additionally, prepare flathead screwdrivers (small, medium, short), a Phillips screwdriver, a tack lifter, a T25 Torx bit driver, a magnet pickup, and a medium mirror.
First, prepare the following sockets:
- 32mm socket (1/2″), 19mm socket (1/2″), 19mm deep socket (3/8″), 14mm socket (3/8″), 13mm socket (3/8″), 10mm socket (3/8″), and 10mm deep socket (3/8″).
- Additionally, gather 10mm socket (1/4″), 6mm socket (1/4″), 5mm socket (1/4″), 6mm hex bit socket (3/8″), and 5mm hex bit socket (3/8″).
Next, ensure you have the following ratchets:
- 1/2″ ratchet, 1/2″ long-arm ratchet, 3/8″ ratchet, 3/8″ medium-arm ratchet, 3/8″ long-arm ratchet, 1/4″ medium-arm ratchet, and 1/4″ long-arm small-head ratchet.
Then, collect the necessary socket extensions:
- 1/2″ socket extension (short), 3/8″ socket extension (short), and 1/4″ socket extensions (short, medium wobble, and long wobble).
Finally, include a 3/8″ torque wrench capable of 8 Nm (6 ft-lb) and 14 Nm (10 ft-lb).
First, gather the necessary tools for V8 mechanical fan removal:
- A 32mm combo wrench, a BMW water pump pulley holder (11-5-050, approximately $20 each), and a handheld sledgehammer (3lb).
Alternatively, you can purchase a Baum Tools water pump pulley holder or a holder and 32mm wrench combo from the El Paso Tool store.
To find the tool, go to the El Paso Tool store website and perform a “Store search” for “115050.” Make sure to check the “in titles & descriptions” checkbox to locate the correct item.
El Paso Tool store
First, gather the following supplies:
- 3Bond Drei Sealant (BS0SS, $19.90, available at www.beisansystems.com), paper towels, a water-based cleaner (e.g., Simple Green diluted 1:10), brake cleaner, and spray lubricant.
Next, prepare a parts plate and assembly oil (lubricant oil) for organizing and lubricating components during the repair.
Additionally, ensure you have a coolant receptacle on hand, though it is not shown in the list.
Preparation:
Important Notes:
- Before starting, ensure the car engine is cold to safely perform the repair procedure.
- Note that right and left designations are based on the car’s front hood orientation.
- Engine bank 1 head is on the left, and engine bank 2 head is on the right.
- Cylinders 1-4 are on bank 1 (front to rear), and cylinders 5-8 are on bank 2 (front to rear).
Repair Steps:
Finally, complete the removal of the intake manifold. Use the “Intake manifold removal” procedure as a reference.
Begin with the removal of the engine air intake. Refer to the “Engine air intake removal” procedure for detailed instructions.
Next, proceed with the removal of the fan and shroud. Follow the “Fan & shroud removal” guide for specifics.
After that, remove the cabin filter housing. Consult the “E39 cabin filter housing removal” instructions for details.
First, gather 1 gallon of BMW coolant, 1 gallon of distilled water, and 1 empty gallon container (e.g., an old BMW coolant container) for mixing the coolant.
Remove intake manifold top cover 15 mounting caps; 4 top and 11 perimeter (10mm socket 3/8″ / 3/8″ ratchet & extension).
Pull up and remove intake manifold cover from engine bay.
Begin by removing the air intake funnels located inside the intake manifold. For each funnel, use a 3/8″ drive ratchet with a 10mm socket and a medium-length extension to remove the two mounting nuts. After removing the nuts, carefully extract the funnel, using a magnetic pickup tool if needed. Note: The funnels for cylinders 1 and 5 are unique in design, while the funnels for cylinders 2-4 and 6-8 are identical. Be sure to keep track of their original locations for correct reinstallation.
Remove intake manifold 33 mounting bolts (10mm socket 3/8″ / 3/8″ ratchet & extension).
Note: Bolts are similar, but slightly longer, than coil ground bolts removed in coming steps. Maintain bolt separation to prevent misuse.
Remove bank 1 & 2 oil separator mounting bolts at front right and left of intake manifold (10mm ratcheting wrench).
To proceed, remove the intake manifold idle control valve hose located at the front center of the intake manifold.First, use a 1/4″ drive ratchet with a 6mm socket and extension to loosen the hose mounting clamp.Then, carefully pull the hose away from the intake manifold pipe.
Now, let’s move on to removing the intake manifold oil drain hose, which is also located at the front center of the intake manifold.Begin by using a 1/4″ drive ratchet with a 5mm socket and extension to loosen the hose mounting clamp.Following that, carefully pull the hose away from the intake manifold pipe.
Disconnect bank 1 & 2 oil separators from intake manifold front.
Lift manifold up and to rear and pull out each oil separator neck grommet from manifold.
Lift up and remove intake manifold from engine bay.
Note: Maintain intake manifold gaskets at throttles.
Removal of valve covers
To begin, open the trunk and lift the floor cover to gain access to the battery.Next, open the battery cover to expose the negative terminal.Then, using a 3/8″ drive ratchet with a 10mm socket and extension, carefully loosen the mounting nut on the battery’s negative cable.
Remove negative cable clamp from battery negative post and lift above battery cover.
Close negative terminal access cover.
Caution: Do not fully close trunk lid. It cannot be opened using electronic latch. If trunk lid closed, key is needed to mechanically open trunk lid.
Note: Battery negative cable removal is necessary for removal of battery positive cable at engine bank 2 valve cover in coming step.
Remove bank 1 & 2 ignition coil cover. For each cover perform following.
Take out 2 cover mounting bolts with washers & grommets (10mm socket 3/8″ / 3/8″ ratchet, tack lifter).Detach coil cover.Extract coil cover gasket from valve cover.
Disconnect bank 1 & 2 ignition coils electrical cable connectors. For each set of coils perform following.
For each coil, pull up on coil connector metal lock and pull off cable electrical connector.
Remove bank 1 & 2 coil harness rail. For each coil harness rail perform following.
Remove coil harness rail mounting nut at front mounting stud (10mm socket 3/8″ / 3/8″ ratchet).
Pull off coil harness rail from mounting studs and set to side.
Note: Rail rear mounting stud does not have mounting nut and is used to mount previously removed coil cover.
Disconnect bank 1 & 2 coil harness ground wires from valve cover. For each coil harness perform following.
Remove coil harness ground wire mounting bolt at top middle front and rear of valve cover (10mm socket 3/8″ / 3/8″ ratchet).
Note: Bolts are similar, but slightly shorter, than intake manifold mounting bolts removed in previous step. Maintain bolt separation to prevent misuse.
Remove bank 1 & 2 ignition coils. For each set of coils perform following.
Remove 2 mounting nuts at each coil (10mm socket 3/8″ / 3/8″ ratchet & extension).
Pull up and remove all coils.
Note: Maintain coil/cylinder association for reinstallation. This is not necessary, but is good practice.
Disconnect bank 1 & 2 coil harness ground wire at top rear of valve cover. For each coil harness perform following.
Remove coil harness ground wire mounting bolt at top rear of valve cover (10mm socket 3/8″ / 3/8″ ratchet).
Note: Bolts are similar, but slightly shorter, than intake manifold mounting bolts removed in previous step. Maintain bolt separation to prevent misuse.
Disconnect bank 1 & 2 valve cover ground strap. For each valve cover ground strap perform following.
Remove valve cover ground strap mounting bolt at valve cover coil well (10mm socket 3/8″ / 3/8″ ratchet & extension).
Note: Bolts are similar, but slightly shorter, than intake manifold mounting bolts removed in previous step. Maintain bolt separation to prevent misuse.
Caution:
- Before proceeding, disconnect the battery negative cable from the battery in the trunk. This step was also the first step in the valve cover removal section.
Steps:
Next, loosen the battery positive cable mounting nut at the bank 2 valve cover cable box using a 19mm socket (1/2″) and a 1/2″ ratchet.
Then, disconnect the battery positive cable from the cable box and valve cover, and carefully set it aside.
Eliminate bank 1 & 2 crankcase ventilation hose from valve cover. For each valve cover ventilation hose perform following.
S62 Vanos Procedure
Loosen vent hose mounting clamp at valve cover (6mm socket 1/4″ / 1/4″ ratchet & extension).
Pull hose from valve cover vent pipe.
Remove engine oil filter canister 2 mounting nuts (10mm socket 3/8″ / 3/8″ ratchet & extension).
First, lift the engine oil filter canister and move it slightly to the side, placing it against the power steering reservoir canister.
Note: This slight repositioning of the oil filter canister will make it easier to remove the bank 2 valve cover in the next step.
Remove bank 1 & 2 valve cover mounting bolts. For each valve cover perform following.
Remove 11 valve cover mounting bolts w/ washers & grommets; 3 front and 4 at each side (10mm socket 3/8″ / 3/8″ ratchet & extension, tack lifter).
Note: Front 3 bolts are different from 8 side bolts.
Remove bank 1 & 2 valve cover. For each valve cover perform following.
Insert blade (medium putty-knife) between valve cover gasket and engine head at all front end accessible locations to break gasket bond.
Pull up and remove valve cover. If resistant, insert blade (medium putty-knife) between valve cover gasket and engine head at sticking locations.
Note: If valve cover cannot be removed, double check valve cover 11 mounting bolts have been removed. If valve cover is stuck, pull up on free front end of cover to break gasket bond on remainder of valve cover.
Take off valve cover perimeter gasket.Detach valve cover sparkplug well gasket.
Take out bank 1 & 2 camshaft oil rails. For each set of oil rails perform following.
Remove intake and exhaust oil rail 5 mounting nuts (10mm deep socket 3/8″ / 3/8″ ratchet, 10mm ratcheting wrench).
Remove oil rails.
Note: Bank 1 & 2 oil rails are different lengths.
Note: Oil rails are symmetrical front to rear and top to bottom. Thus maintaining oil rail orientation is not necessary.
Draining of coolant
Raise front of car and place on jack stands (follow appropriate procedure; chock both sides of both rear wheels).
First, remove the large engine compartment shield located underneath the front of the car.
Note: To remove the engine compartment shield, you must first remove the transmission shield located to the rear of it.
Next, remove the transmission shield:
Loosen the transmission shield perimeter mounting bolts by 1/2 turn to release the lock (using a Phillips screwdriver).
Once loosened, remove the transmission shield.
Then, loosen the engine compartment shield perimeter mounting bolts by 1/2 turn to release the lock (using a Phillips screwdriver).
Finally, pull the engine compartment shield out from the front bumper and remove it completely.
Drain coolant from engine block.
Remove engine left side (front orientation) coolant drain bolt (13mm socket 3/8″ / 3/8″ ratchet).
Note: Drain bolt is located on engine block between cyl 2 & 3.
Catch draining coolant in receptacle (coolant receptacle).
Lift up coolant expansion tank to drain coolant from it.
Remove and discard drain bolt crush washer.
Note: If washer not on bolt it is likely at hole or fallen in coolant receptacle.
Note: It is not necessary to drain coolant from engine right side. This does not affect repair and there is very little coolant to drain and thus is of no significance.
Drain coolant form radiator drain hole.
Turn radiator drain plug at bottom of radiator 1/4 turn and pull off from radiator (pliers).
Catch draining coolant in receptacle (coolant receptacle).
Place engine left side coolant drain bolt.Fit new crush washer on drain bolt.Tighten drain bolt (13mm socket 3/8″ / 3/8″ ratchet).
Fully tighten, 25 Nm (18.5 ft-lb) (by feel) (13mm socket 3/8″ / 3/8″ ratchet).
Install radiator drain plug.
Insert drain plug into radiator drain hole and turn 1/4 turn (pliers).
First, install the large engine compartment shield underneath the front of the car:
Insert the front of the shield inside the front bumper.
Align and insert the perimeter bolts into the bolt holes.
Turn the perimeter mounting bolts 1/2 turn clockwise to secure them (using a Phillips screwdriver).
Next, install the transmission shield:
Mount the shield in its proper position.
Align and insert the perimeter bolts into the bolt holes.
Turn the perimeter mounting bolts 1/2 turn clockwise to secure them (using a Phillips screwdriver).
After that, lower the car from the jack stands, following the appropriate procedure for safety.
Finally, proceed with the removal of the coolant hoses.
Remove radiator upper hose from radiator.
Pull out hose locking wire clip (small flathead).
Wiggle and pull hose connector off radiator.
Remove radiator lower hose from radiator.
Remove temperature sensor cable connector. Press in connector locking wire clip and pull off connector.
Pull out hose locking wire clip (small flathead).
Wiggle and pull hose connector off radiator.
Remove upper radiator hose from thermostat housing
Loosen hose mounting clamp (6mm socket 1/4″ / 1/4″ ratchet & extension).
Pull hose from thermostat and remove hose.
Remove lower radiator hose from thermostat housing
Loosen hose mounting clamp (6mm socket 1/4″ / 1/4″ ratchet & extension).
Pull hose from thermostat and remove hose.
Remove coolant expansion tank hose form thermostat housing.
Loosen hose mounting clamp (6mm socket 1/4″ / 1/4″ ratchet & extension).
Pull hose from thermostat housing pipe.
Remove coolant expansion tank cable electrical connector.
Press in connector clip and pull off connector.
Remove expansion tank with hose from engine bay.
Setting of engine timing to TDC
If manual transmission, place transmission in neutral. This allows turning of crankshaft.
Turn crankshaft pulley clockwise until cylinder 1 (bank 1) intake and exhaust cams point to each other at ~45 degree angle (32mm socket 1/2″ / 1/2″ long-arm ratchet & short extension).
Note: Turning crankshaft counter clockwise is acceptable.
Inspect TDC (top dead center) timing marks on engine timing cover and crankshaft harmonic balancer at ~11 o’clock position (mirror).
Adjust crankshaft pulley to align TDC timing marks (32mm socket 1/2″ / 1/2″ long-arm ratchet & short extension).
Note: Timing marks are far from each other and thus difficult to align. It is easier to align locking pin holes in harmonic balancer and locking bracket (picture).
Note: Turning crankshaft counter clockwise is acceptable.
Note: Precise alignment is not necessary.
Removal of Vanos solenoids
To position vanos engine timing, it is easiest to remove vanos solenoids to relieve hydraulic control and allow manual (by hand) vanos and camshaft positioning.
Place towels under bank 1 & 2 Vanos. For each Vanos perform following.
Fold towels and place under Vanos (towels).
Note: Towels will catch draining oil from Vanos solenoid housing in coming steps.
Remove bank 1 & 2 Vanos solenoid cover. For each Vanos perform following.
Remove Vanos solenoid cover 5 mounting bolts (6mm hex bit socket 3/8″ / 3/8″ ratchet).
Remove solenoid cover and cover gasket. Tear cover paper gasket as needed to remove.
Remove bank 1 & 2 Vanos solenoid electrical cable connector. For each Vanos perform following.
Slide solenoid cable connector off mounting clip on engine head.
Note: Solenoid cable mounting clip is brittle and easily breaks.
Press in cable connector side clips and wiggle connector off.
Dislodge bank 1 & 2 Vanos two lower solenoids from Vanos housing. For each Vanos perform following.
Pry out Vanos two lower solenoids by prying from middle groove and leveraging against upper solenoid to dislodge from solenoid housing (flathead).
Dislodge bank 1 & 2 Vanos two upper solenoids from Vanos housing. For each Vanos perform following.
Pry out Vanos two upper solenoids by prying from middle groove and leveraging against Vanos body to dislodge from solenoid housing (flathead).
Remove bank 1 & 2 solenoids from Vanos. For each Vanos perform following.
Remove solenoids with PC board and electrical cable from Vanos.
Fully retard banks 1 & 2 intake camshaft timing. For each intake camshaft perform following.
Place open wrench (27mm open 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.
Keep in mind: Camshaft rotation is most effective when standing at the side of the car.Be aware: The splined shaft can be seen protruding from the sprocket hub front when the camshaft is at the adjustment end position.It is important to remember: 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 banks 1 & 2 exhaust camshaft timing. For each exhaust camshaft perform following.
Place open wrench (27mm open wrench, short handle adjustable wrench) on exhaust camshaft hex at front of camshaft.
Note: Access is limited for standard 27mm open wrench. Use short handle adjustable wrench as needed.
Rotate exhaust camshaft counter clockwise to adjustment end position. If camshaft resistant to rotation rock camshaft back and forth to release seize.
Take note: Camshaft rotation is most effective when standing at the side of the car.Keep in mind: The splined shaft can be seen protruding from the sprocket hub front when the camshaft is at the adjustment end position.Remember: 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.
Install towel in bank 1 & 2 Vanos solenoid housing. For each Vanos perform following.
First, remove the towels placed under the VANOS unit.
Next, clean the VANOS solenoid housing using brake cleaner and towels.
Then, install a new towel in the VANOS solenoid housing, crumpling and pressing it into each solenoid housing cavity to ensure proper coverage.
After completing these steps, proceed with the removal of the VANOS hydraulic attachments.
Remove bank 1 & 2 Vanos oil accumulator hose. For each Vanos perform following.
Remove oil hose mounting banjo bolt at Vanos (14mm socket 3/8″ / 3/8″ ratchet).
Discard crush washer at each side of hose fitting.
First, remove the VANOS oil pressure restrictor from the oil distribution piece located at the front of the engine.
Next, place a towel under the distribution piece and restrictor to catch any draining oil.
Then, use a 22mm open wrench to remove the oil pressure restrictor.
After completing these steps, perform the rattle procedure as outlined in the repair instructions.
If performing rattle repair, follow rattle procedure at this time.
S62 Vanos Rattle Procedure
Removal of vanos units from engine heads
Remove bank 1 & 2 Vanos mounting bolts. Perform following for each Vanos.
Remove Vanos 9 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet & extension).
Pry bank 1 & 2 Vanos from engine head. Perform following for each Vanos.
Pry Vanos from engine head at intake and exhaust side designated slots (flathead, short flathead).
Pry Vanos evenly until Vanos releases from engine head (Vanos seal O-rings disconnect from upper timing cover).
Pull bank 1 & 2 vanos fully forward from engine head.
First, install the long supporting bolts on the right and left sides of the VANOS units for both bank 1 and bank 2.
Next, tighten the bolts with two full rotations to secure them in place.
Note: These supporting bolts provide stability to the VANOS units and allow you to disconnect the VANOS intake and exhaust pistons from the splined shafts.
After installing the bolts, proceed with disconnecting the VANOS pistons from the splined shafts.
Perform following procedure of disconnecting vanos intake and exhaust pistons from splined shafts for bank 1 & 2 vanos units.
Note: Bank 2 shown.
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).
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).
Repeat above procedure of disconnecting Vanos intake and exhaust pistons from splined shafts for second bank.
Remove bank 1 & 2 Vanos from engine head. Perform following for each Vanos.
Pull Vanos forward off engine head.
Unscrew Vanos right and left side supporting bolts and remove and take Vanos to work bench.
Remove bank 1 & 2 Vanos oil input regulator and oil return hole sealing O-rings stuck on upper timing cover.
Remove bank 1 & 2 oil input regulator from engine head by prying out regulator at rear (flathead) and pulling out from front.
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 piston seals
Following procedure shows installation of vanos intake piston seals. Same procedure applies to vanos exhaust piston seals.
Dislodge Vanos cylinder cover.
Unclamp cover 3 mounting bolts (5mm hex bit socket 3/8″ / 3/8″ ratchet).
Remove 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 piston from cylinder.
Press piston from Vanos inboard side to remove piston from Vanos outboard side (1/4″ socket extension).
Cut cross section of 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 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 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 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 piston (brake cleaner & towels).
Mount piston middle seal O-ring onto piston small end and roll O-ring along piston and drop into seal groove (fingers).
Center O-ring in seal groove (strait pick).
Mount piston middle seal Teflon ring onto piston small end.
Insert pick tool between Teflon ring and piston (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 slide over piston larger diameter.
Place 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 piston to seal groove rim (fingers/nails) (picture).
First, press down on the Teflon ring from the top end to seat it onto the piston seal groove rim, using your fingers or nails.
Then, carefully drop the Teflon ring into the seal groove.
Next, move the Teflon ring evenly along the piston, as shown in the accompanying picture.
After that continue here with the ring on the piston bottom.
First, insert one end of the piston end seal O-ring into the piston seal groove.
Then, stretch the other end of the O-ring over the piston and carefully drop it into the seal groove using your fingers.
Finally, center the O-ring in the seal groove using a straight pick tool.
First, insert one end of the piston end seal Teflon ring into the piston seal groove.
Then, stretch the other end of the Teflon ring over the piston and carefully drop it into the seal groove using your fingers.
Before finalizing the installation, stretch the Teflon ring at multiple locations along its length to ensure even distribution.
Finally, complete the final stretch over the piston and into the groove using your fingers.
First, insert the piston’s large end into the cylinder from the outboard side. Next, lightly lubricate the cylinder entry’s inner wall as well as the piston’s Teflon ring using assembly oil. Then, wiggle the piston gently and press it straight into the cylinder.
At this point, verify that the Teflon ring is inserting into the cylinder at all perimeter locations. If it isn’t, reposition the piston and try the insertion again to ensure the Teflon ring fully enters the cylinder around its entire perimeter. Once the Teflon ring has been successfully inserted at all points along the perimeter, continue wiggling the piston slightly while pressing it straight into the cylinder. This will help fully seat the Teflon ring inside the cylinder.
Note: The cylinder entry features a chamfer, which 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, place a small hose clamp around the piston’s middle seal Teflon ring.
Then, tighten the clamp using a Phillips screwdriver until it seats on the piston. However, be careful to tighten it only lightly.
Note: Mounting the clamp on the piston’s middle seal Teflon ring will compress the Teflon ring close to its original size, allowing for easier piston insertion in the next step.
Remove hose clamp from 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 piston middle seal Teflon ring (assembly oil).
Insert piston small end into exhaust cylinder outboard side.
Place flat object on 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 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 piston small end first into cylinder outboard side and press piston fully into cylinder.
Clean Vanos cylinder outboard side cover mating surfaces and cover mounting bolts (brake cleaner & towels).
Remove cylinder cover sealing O-ring.
Pry O-ring from cover groove and remove from cover (90 degree pick).
Clean cylinder cover (brake cleaner & towels).
First, install the new O-ring onto the cylinder cover.
Next, insert one end of the O-ring into the cover groove, then carefully stretch the other end over the cover and drop it into place using your fingers.
After that, lightly lubricate the O-ring with assembly oil to ease the cover installation.
First, install the cylinder cover onto the Vanos.
Next, orient the cover correctly to ensure its holes align with the Vanos holes. Since the cover is asymmetric, only one orientation will fit properly.
Then, install the three mounting bolts using a 5mm hex bit socket with a 3/8″ ratchet. Gradually tighten the bolts in multiple passes to draw the cover evenly onto the Vanos body.
After that, fully tighten the bolts to 10 Nm (7 ft-lb) using a 5mm hex bit socket with a 3/8″ torque wrench. Finally, verify with one additional pass to ensure all bolts are fully tightened.
Now, repeat the above piston seals installation procedure for the exhaust side.
Installation of Vanos Solenoid O-Rings
Begin by extracting the small solenoid O-ring using a 90-degree pick.
Remove same solenoid large O-ring (90 degree pick).
Remove remaining solenoid O-rings (90 degree pick).
Install all new small and large solenoid O-rings (using your fingers).Install each O-ring over the solenoid and roll it into the groove. Manipulate the O-ring within the groove to ensure it is correctly positioned. Note: The solenoid O-rings are special and have many facets. Inspection and repositioning of the O-ring is needed for correct installation. Repeat the above solenoid O-ring installation procedure for the second Vanos solenoid. Finally, proceed with the installation of the remaining Vanos O-rings.
Remove Vanos inboard intake head sealing O-ring.
Pry O-ring from housing groove and remove from Vanos (90 degree pick).
Clean O-ring housing groove (brake cleaner & towels).
First, install a new O-ring onto the Vanos inboard intake head sealing housing. To do this, insert one end of the O-ring into the housing groove, then stretch the other end over the housing and drop it into place using your fingers.
Next, lightly lubricate the O-ring with assembly oil to ensure smooth installation of the Vanos unit.
Remove Vanos inboard exhaust head sealing O-ring.
Pry O-ring from housing groove and remove from Vanos (90 degree pick).
Clean O-ring housing groove (brake cleaner & towels).
First, install a new O-ring onto the Vanos inboard exhaust head sealing housing. To do this, insert one end of the O-ring into the housing groove, then stretch the other end over the housing and drop it into place using your fingers.
Next, lightly lubricate the O-ring with assembly oil to ensure smooth installation of the Vanos unit.
Install new O-rings on Vanos inboard oil drain and oil regulator head sealing faces.
Clean O-ring face grooves (brake cleaner & towels).
Insert new O-ring in face groove (fingers).
Note: Strongly stretch oil regulator O-ring to increase diameter and allow mounting.
Note: Oil drain O-ring is same size as oil pressure regulator small O-ring.
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).
First, install a new small O-ring onto the regulator. To do this, insert one end of the O-ring into the regulator groove, then stretch the other end over the regulator and drop it into place using your fingers.
Next, lightly lubricate the O-ring with assembly oil to ensure smooth installation of the Vanos unit.
First, install a new large O-ring onto the regulator. To do this, insert one end of the O-ring into the regulator groove, then stretch the other end over the regulator and drop it into place using your fingers.
Next, lightly lubricate the O-ring with assembly oil to ease the regulator installation process.
After completing this step, repeat the same O-ring installation procedure for the second Vanos unit.
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.
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.
First, remove and discard the valve cover bolt grommets. Use diagonal cutters to cut off the three front bolt grommets on the valve cover.
Next, sanitize the battery positive cable mounting end using brake cleaner and towels.
Then, remove the valve cover gaskets and top cover gaskets from the valve covers. Afterward, sanitize the valve cover mating surfaces, including the inner gasket grooves, bolt access holes, coil mounting studs, ground strap/wire holes, vent pipe, and battery cable stud. Use brake cleaner and towels for this step.
After that, remove the intake manifold cover gasket and the four cover O-rings located at the manifold towers. Sanitize the intake manifold and intake manifold cover mating surfaces, mounting holes, studs, and hose pipes using brake cleaner and towels.
Moving on, degrease the throttle intake manifold mounting studs with brake cleaner and towels. Similarly, degrease all mounting bolts, nuts, and washers using the same method.
Next, scrub the heads’ mating surfaces, including the spark plug well, valve cover perimeter, timing cover, and camshaft bearing cap studs, with brake cleaner and towels.
Then, wipe down the coils’ ground straps and coil harness ground wire ends using brake cleaner and towels. Additionally, clear the surface of the coils’ mounting holes to ensure proper installation.
Finally, proceed with the installation of the Vanos units onto the engine heads.
Verify bank 1 & 2 upper timing covers Vanos matting surfaces are clean (brake cleaner & towels).
Insert bank 1 & 2 Vanos oil input regulator into upper timing cover hole and orient with side oil relief holes to right and left.
Press bank 1 & 2 Vanos oil input regulator into head until flush with upper timing cover face (picture).
Clean bank 1 & 2 Vanos unit head matting surfaces (brake cleaner & towels) and pull pistons fully out of Vanos (medium nose pliers).
Mount bank 1 & 2 Vanos on engine head. Perform following for each Vanos.
Note: Vanos units are same and interchangeable, but it’s best practice to maintain Vanos to engine head association. Vanos is originally oriented with Vanos sticker to bottom.
Mount Vanos on engine head with Vanos long supporting bolt at right and left side of Vanos. Install supporting bolts with 2 turns.
Push bank 1 & 2 Vanos units towards engine heads until Vanos piston ends touch splined shaft studs.
Connecting of vanos pistons to splined shafts
Perform following procedure of mounting Vanos intake and exhaust pistons to splined shafts and inserting Vanos onto engine head for bank 1 & 2 Vanos units.
Note: Bank 1 shown.
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).
Moderately 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).
Lift up Vanos and 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).
Moderately tighten; left hand thread (10mm open wrench / 7mm open wrench).
Note: Due to left hand thread, it is not necessary to over tighten joint.
Press Vanos onto engine head until it stops.
Caution: Do not attempt to forcibly fully mount Vanos to engine head. This can cause damage.
Inspect Vanos oil pump side hole and intake sprocket hub side tab for alignment.
Rotate Vanos oil pump as needed to achieve alignment (fingers).
Press Vanos onto engine head and verify hub tab insertion into oil pump hole.
Realign Vanos pump as need to facilitate tab insertion (fingers).
Note: Vanos will not fully mate with head due to Vanos sealing O-rings.
Remove Vanos supporting bolts.
Repeat above procedure of mounting Vanos intake and exhaust pistons to splined shafts and inserting Vanos onto engine head for second bank.
Install bank 1 & 2 Vanos mounting bolts. Perform following for each Vanos.
First, install the VANOS 9 mounting bolts using a 5mm hex bit socket, 3/8″ ratchet, and extension. Next, tighten the bolts evenly in multiple passes to ensure the VANOS is drawn evenly to the engine head.
Then, fully tighten the bolts to 10 Nm (7 ft-lb) using a 5mm hex bit socket, 3/8″ torque wrench, and extension. After that, perform one final pass to verify all bolts are fully tightened.
Finally, proceed with the installation of the VANOS hydraulic attachments.
Install Vanos oil pressure restrictor in distribution piece (22mm open wrench).
Fully tighten (22mm open wrench).
Install bank 1 & 2 Vanos oil hose. For each Vanos perform following.
Mount Vanos oil hose on Vanos. Install new crush washer on banjo bolt at each side of hose pipe fitting (picture).
Tighten bank 1 & 2 Vanos oil hose. For each Vanos perform following.
Counter hold oil hose while tightening banjo bolt to keep hose form rotating (14mm socket 3/8″ / 3/8″ ratchet).
On bank 2, insert tool to interfere with hose pipe rotation (flathead).
Fully tighten, 13 Nm (9.5 ft-lb) (14mm socket 3/8″ / 3/8″ torque wrench).
Installation of vanos solenoids
Prepare bank 1 & 2 Vanos solenoid housing. For each Vanos perform following.
Remove towel from Vanos solenoid housing.
Inspect and clean Vanos solenoid housing (brake cleaner & towels).
Install bank 1 & 2 Vanos solenoids. For each Vanos perform following.
Orient solenoids with electrical cable at bottom and insert solenoids in solenoid cavities.
Fully insert bank 1 & 2 Vanos solenoids. For each Vanos perform following.
Press in on each solenoid until it inserts into solenoid cavity (thumb).
Solenoid PC board will insert into Vanos housing.
Install bank 1 & 2 Vanos solenoid cover gasket. For each Vanos perform following.
Insert cover gasket over solenoid electrical cable and mount gasket with middle protruding section at top (picture).
Adjust gasket middle protruding section to position under electrical wires.
Adjust electrical cable rubber boot flat end to sit against gasket (picture).
Install bank 1 & 2 Vanos solenoid cover. For each Vanos perform following.
Install solenoid cover on Vanos with cover notch down and over electrical cable rubber boot.
Adjust cover gasket as needed to conform to Vanos housing and solenoid cover.
Install cover 5 mounting bolts (hand).
Tighten cover 5 mounting bolts (6mm hex bit socket 3/8″ / 3/8″ ratchet & extension).
Fully tighten, 14 Nm (10 ft-lb) (6mm hex bit socket 3/8″ / 3/8″ torque wrench & extension).
Tighten bank 1 & 2 Vanos solenoid loading bolts. For each Vanos perform following.
Tighten solenoid cover 4 solenoid loading bolts (6mm hex bit socket 3/8″ / 3/8″ ratchet & extension).
Fully tighten, 12 Nm (9 ft-lb) (6mm hex bit socket 3/8″ / 3/8″ torque wrench & extension).
Install bank 1 & 2 solenoid electrical cable connector. Perform following for each Vanos.
Route Vanos solenoid electrical cable adjacent to Vanos.
Connect solenoid electrical cable connector to wiring harness connector.
Press in connectors until clips snap into place.
Installation of coolant hoses
First, install the coolant expansion tank onto the thermostat housing. To begin, orient the expansion tank into its mounting position, ensuring the hose is rotated to the correct position.
Next, press the hose firmly onto the thermostat pipe. Then, position the hose clamp over the pipe to secure it in place. Finally, use a 6mm socket with a 1/4″ ratchet and extension to tighten the hose clamp. This ensures a secure and leak-free connection.
Install coolant expansion tank cable electrical connector.
Press cable connector onto sensor until connector clip snaps into place.
Install radiator upper hose onto radiator upper neck.
Press hose connector wire clip onto hose connector before mounting hose.
Install hose connector onto radiator upper neck and align hose notch with radiator neck notch.
Press hose connector onto radiator neck until wire clip snaps into place.
Install radiator lower hose onto radiator lower neck.
Press hose connector wire clip onto hose connector before mounting hose.
Install hose connector onto radiator lower neck and align hose notch with radiator neck notch.
Press hose connector onto radiator neck until wire clip snaps into place.
Install temperature sensor electrical cable connector. Press cable connector onto sensor until connector wire clip snaps into place.
Install upper radiator hose on thermostat housing.
Press hose onto thermostat pipe.
Position hose clamp over pipe and tighten hose clamp (6mm socket 1/4″ / 1/4″ ratchet & extension).
First, install the lower radiator hose onto the thermostat housing by pressing the hose firmly onto the thermostat pipe. Next, position the hose clamp over the pipe to secure it in place. Then, use a 6mm socket with a 1/4″ ratchet and extension to tighten the hose clamp. This ensures a secure and leak-free connection.
After completing the hose installation, proceed with the installation of the valve covers.
Install bank 1 & 2 camshaft oil rails. For each set of camshafts perform following.
Keep in mind: Bank 1 & 2 camshaft oil rails are different.Be aware: The oil rail front is denoted by a dimple between the first and second hole.Remember: Intake and exhaust oil rails are the same and can be switched, and the oil rail top and bottom are the same and can be installed either way.
First, position the intake and exhaust camshaft oil rails over the bearing cap studs. Next, install the five mounting nuts for each oil rail. Use a 10mm deep socket with a 3/8″ ratchet or a 10mm ratcheting wrench for this step.
Then, fully tighten the nuts to the specified torque of 8 Nm (6 ft-lb). For this, use a 10mm deep socket with a 3/8″ torque wrench or a 10mm ratcheting wrench. As you tighten the nuts, do so evenly to ensure proper alignment and pressure distribution.
Finally, verify that all nuts are fully tightened by completing one final pass. This ensures the oil rails are securely mounted and ready for operation.
Install bank 1 & 2 valve cover gaskets. For each valve cover perform following.
Note: The gaskets for Bank 1 and Bank 2 are different, so ensure you use the correct one for each bank. Additionally, the orientation of the spark plug well gasket tab is not significant, so you don’t need to worry about its alignment.
First, align the perimeter gasket with the groove around the valve cover perimeter. At the same time, align the spark plug well gasket with the groove in the valve cover’s spark plug well.
Next, insert the gaskets—ridge side down—into the cover grooves. Finally, ensure the gaskets are fully aligned and press them firmly into the grooves to achieve a proper fit.
Note side flaps on rear half-moon gasket section. These flaps must straddle head rear when valve cover is installed.
First, apply 3Bond Drei (BS0SS) gasket sealant to the timing covers for both Bank 1 and Bank 2. For each timing cover, follow these steps:
Begin by placing a thin coat of 3Bond Drei (BS0SS) gasket sealant at the top right and left side gasket joints where the timing cover meets the cylinder head. Ensure the application is even and precise to create a proper seal.
Next, allow the sealant to solidify for approximately 2 minutes before proceeding to mount the valve cover. This waiting period is essential to ensure the sealant adheres properly and provides an effective seal.
Install bank 1 & 2 valve cover. For each valve cover perform following.
Position sparkplug well ground strap in sparkplug well.
Place valve cover with gaskets on engine head.
Keep valve cover high off engine head until fully positioned at rear before lowering onto engine head. This will prevent valve cover gasket from hitting bearing cap studs and dislodging.
Adjust cover position to center cover holes with studs.
Verify bank 1 & 2 valve cover seating. For each valve cover perform following.
First, inspect the valve cover gasket seating along the perimeter of the valve cover and around the spark plug well. Use a mirror, flashlight, and your sense of touch to carefully check for proper alignment.
Next, verify that the two rear half-moon sections of the gasket are properly inserted into the corresponding half-moon grooves on the cylinder head. Again, use a mirror, flashlight, and your fingers to confirm their correct positioning. Additionally, ensure that the half-moon rear flaps are seated toward the rear of the cylinder head, as shown in the provided pictures.
If any issues are found during inspection, reposition the cover and gaskets as needed to correctly align and seat the gaskets. This step is crucial to prevent leaks and ensure a proper seal.
Install bank 1 & 2 valve cover mounting bolts. For each valve cover perform following.
Install 11 valve cover mounting bolts w/ washers & grommets, 3 at front and 4 at each side (10mm socket 3/8″ / 3/8″ ratchet & extension).
Note: Front 3 bolts are different than remaining 8 bolts.
Tighten bolts evenly working back and forth, assuring even pressure distribution on cover. Tighten until bolts bottom out (stop turning).
Fully tighten, 8Nm (6 ft-lb) (10mm socket 3/8″ / 3/8″ torque wrench & extension).
Set up engine oil filter canister in its mounting position.
Install oil filter canister 2 mounting nuts (10mm socket 3/8″ / 3/8″ ratchet & extension).
Install bank 1 & 2 crankcase ventilation hose on valve covers. For each valve cover ventilation hose perform following.
Press hose onto valve cover vent pipe.
Position hose clamp over pipe and tighten hose clamp (6mm socket 1/4″ / 1/4″ ratchet & extension).
Mount battery positive cable on bank 2 valve cover and insert into cable box.
Install battery positive cable on stud and mount with nut (19mm socket 1/2″ / 1/2″ ratchet).
Install bank 1 & 2 valve cover ground strap. For each valve cover ground strap perform following.
Install valve cover sparkplug well ground strap with mounting bolt (10mm socket 3/8″ / 3/8″ ratchet & extension).
Note: Mounting bolt is short and should not be confuse with many intake manifold slightly longer bolts.
Install bank 1 & 2 coil harness ground wire at top rear of valve cover. For each coil harness perform following.
Install coil harness ground wire with mounting bolt at top rear of valve cover (10mm socket 3/8″ / 3/8″ ratchet).
Note: Mounting bolt is short and should not be confuse with many intake manifold slightly longer bolts.
Install bank 1 & 2 ignition coils. For each bank perform following.
Install each coil into original sparkplug well and onto mounting studs and mount with 2 nuts (10mm socket 3/8″ / 3/8″ ratchet & extension).
Tighten coil mounting nuts evenly to mount coil evenly.
Note: Coil boot will not fully insert onto sparkplug during initial mount. This is normal.
Fully tighten, 9Nm (6.5 ft-lb) (10mm socket 3/8″ / 3/8″ torque wrench & extension).
Install bank 1 & 2 coil harness ground wires on valve covers. For each coil harness perform following.
Install coil harness ground wire with mounting bolt at top middle front and rear of valve cover (10mm socket 3/8″ / 3/8″ ratchet).
Note: Mounting bolt is short and should not be confuse with many intake manifold slightly longer bolts.
Install bank 1 & 2 coil harness rails. For each coil harness rail perform following.
Mount coil harness rail onto valve cover 2 mounting studs and install 2 mounting nuts (10mm socket 3/8″ / 3/8″ ratchet).
Install bank 1 & 2 ignition coils electrical cable connectors. For each set of coils perform following.
For each coil, pull up on coil connector metal lock, insert cable connector onto coil connector, and press down on coil connector metal lock.
Install bank 1 & 2 coil cover gasket on valve cover. Perform following for each valve cover.
Install coil cover gasket on valve cover. Position gasket open end at rear.
Note: Bank 1 & 2 coil cover gaskets are same part.
First, install the Bank 1 and Bank 2 coil covers onto the valve covers. For each valve cover, follow these steps:
Begin by orienting the cover so that the end hole is positioned at the front. Next, align the rear ridge of the cover with the coil harness boot groove, and carefully install the cover onto the boot and valve cover.
Then, install the two mounting bolts with washers and grommets. Use a 10mm socket with a 3/8″ ratchet for this step. As you tighten the bolts, work back and forth to ensure even pressure distribution across the cover. Finally, tighten the bolts until they bottom out (stop turning), which ensures the cover is securely in place.
Install battery negative cable at battery in trunk.
Mount negative battery cable clamp on battery negative post and tighten mounting nut (10 mm socket 3/8″ / 3/8″ ratchet & extension).
Installation of intake manifold
First, position all components in preparation for mounting the intake manifold onto the engine. Next, route the MAF sensor’s long electrical cables to the front of the engine and secure them in the cable clips located at each cylinder head.
Afterward, position the idle control valve and ensure the drain hose clamps on the intake manifold are correctly placed at the end of each hose. Make sure the clamp bolt heads are facing the front and oriented upward, as shown in the picture.
Finally, position the oil separators on the sides of the engine heads, ensuring that their mounting necks are facing the rear of the engine, as illustrated in the picture.
First, install the intake manifold cover gasket onto the intake manifold. To do this, align the gasket with the perimeter groove of the manifold. Then, insert the gasket—ridge side down—into the manifold’s perimeter groove. Afterward, fully press the gasket into the groove to ensure a secure fit.
Next, proceed to install the four O-rings onto the four towers of the intake manifold. Carefully insert each O-ring into the corresponding O-ring grooves on the towers, ensuring they are properly seated.
Place intake manifold on top of engine (picture).
Insert bank 1 & 2 oil separator neck grommets into intake manifold at manifold front right and left.
Install bank 1 & 2 oil separator mounting bolt (10mm ratcheting wrench).
First, install the intake manifold front lower drain hose by pressing the hose firmly onto the manifold pipe. Next, position the hose clamp over the pipe to secure it in place. Then, use a 5mm socket with a 1/4″ ratchet and extension to tighten the hose clamp. This ensures a secure and leak-free connection.
First, install the intake manifold front idle control valve hose.
Next, press the hose firmly onto the manifold pipe to ensure a secure fit.
Then, position the hose clamp over the pipe and tighten it using a 6mm socket with a 1/4″ ratchet and extension.
First, carefully position the intake manifold to align the bolt mounting holes with those on the engine. Once everything is properly aligned, you can proceed to the next step. Then, begin installing the intake manifold by securing its 33 mounting bolts. For this task, use a 10mm socket with a 3/8″ ratchet and extension.
Next, gradually tighten the bolts in multiple passes. This ensures proper seating and even pressure distribution across the manifold. After completing all the passes, take a moment to double-check that all bolts are fully tightened during the final pass.
First, install the air intake funnels inside the intake manifold. To do this, mount each funnel onto its two mounting studs and ensure that it is fully seated. Note: The funnels for cylinders 1 and 5 are unique, while the funnels for cylinders 2–4 and 6–8 are identical.
Next, secure each funnel by installing its two mounting nuts. Use a 10mm socket with a 3/8″ ratchet and extension for this task. Then, tighten the nuts evenly in multiple passes to ensure proper alignment and avoid any potential damage.
Install intake manifold cover on intake manifold.
First, install the intake manifold cover by securing its 15 mounting caps: 4 on the top and 11 around the perimeter. Use a 10mm socket with a 3/8″ ratchet and extension for this task. Then, tighten the caps evenly in multiple passes to ensure proper alignment and pressure distribution. After completing all passes, verify that all caps are fully tightened.
Next, proceed with the installation of the cabin filter housing. For E39 models, follow the specific steps for cabin filter housing installation. Once that is complete, move on to installing the fan and shroud. Carefully follow the guidelines for fan and shroud installation to ensure proper fitment.
Afterward, install the engine air intake system. Refer to the detailed steps for engine air intake installation to avoid any misalignment or damage.
Finally, as part of the post-repair procedures, mix 2 gallons of coolant. BMW coolant should be mixed at a 50/50 ratio of coolant to distilled water. This ensures optimal performance and protection for the cooling system.
First, remove the coolant expansion tank cap. Then, pour coolant into the expansion tank until the coolant level reaches the “max” line on the side of the tank. After that, start the engine. While the engine is running, continue pouring coolant into the expansion tank until the level once again reaches the “max” line.
Once the engine is running and the coolant level is stable, install the expansion tank cap. Next, drive the car until both the coolant and the engine are fully warmed up. Afterwards, unscrew the expansion tank cap slightly until you hear air escaping. Once the air has been released, close the expansion tank cap securely.
Finally, check the coolant level and refill it as needed when the engine is fully cold, such as in the morning.
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