You are on page 1of 365

1.

REMOVING AND CLEANING A MKIV THROTTLE BODY (THROTTLE VALVE CONTROL MODULE) The following outlines the procedure for removing and cleaning the drive-by-wire (DBW) throttle body (officially known as the throttle valve control module) on a MKIV VW. The procedures were based on a 99.5 Jetta GLS VR6 and may be different on MKIV cars with different engines (1.8T, 2.0), body styles (Golf, GTI, New Beetle) and from different model years. Specifically, the procedures for removing and reinstalling the throttle body (herein referred to as TB) may differ due to slight differences in the design and orientation of the TB, however, the general removal/reinstallation procedures, as well as the cleaning procedures should be very similar. Please do these procedures at your own risk and be ready to make small adjustments while doing them. Also, please be observant while removing parts so that they go back together correctly. Before proceeding any further, I must make it clear that the DBW TBs used on the MKIV vehicles are high-precision, electromechanical devices. If you damage the servos and sensors which control the motion and position of the throttle valve (also known as the butterfly valve) while performing this procedure, there is a very great chance that your engine will not run correctly and the TB will need to be replaced. Since a new TB costs around $500, this is something that you will obviously want to prevent from happening. Therefore, be extremely careful when performing the procedure and heed the warnings and cautions that are given. I am not, nor will be held responsible if you mess up your TB while doing this procedure. This DIY is broken up into three parts... Part I deals with the removal of the TB from the intake circuit. Two methods for removing the TB are given. The first method is the "quick and dirty" method and requires that the least number of things be disconnected/removed in order to disconnect the TB. I did not perform this procedure, so I have no idea how long it takes. Nevertheless, I have supplied it for all the minimalist DIYers out there who like to keep things simple. (Note: If you follow this method, you may notice that the pictures posted for this method do not actually show anything disconnected. Please disregard these inconsistencies. Since I did not perform this procedure, I did not have the appropriate pictures and used those taken after everything was already reassembled. Just follow the written directions, using the photos only as a reference, and you should have no problems.) The second method is the "slow and thorough" method and requires that significantly more things be disconnected. The advantages of this method are that it (1) allows various other parts of the intake system, such as the main intake tube and PCV circuit to be examined and cleaned and (2) unclutters the "workspace", making it significantly easier to remove the coolant lines from the TB. This method is the one that I followed when cleaning my TB and I recommend that others use it as well. If you're familiar with this area of the engine bay, it will take approximately 30-60 mins to remove the TB using this method. Part II deals with the cleaning of the TB. The cleaning procedure should take 30-60 mins or more, depending greatly on how dirty your TB is and how careful and thorough you are when cleaning it. Part III deals with the adaptation of the TB to the engine control module (ECM) using a VAG-COM or other suitable scan tool. It is not absolutely necessary to perform this procedure, however doing so immediately following the reinstallation of the TB will help insure the smooth operation of the engine when it's first started. The tools/parts needed to perform the procedures are: 1) 10mm wrench or socket (to disconnect negative battery lead) 2) Appropriate tool for removing hose clamps. If you have the stock spring clamps, a pair of channel lock pliers works great for this purpose since the jaws are roughly perpendicular to each other (helps prevent clamps from slipping in plier jaws) and the jaw width can be adjusted for each particular clamp size. If you have screw-type clamps, you'll need the appropriate screwdriver. 3) 5mm hex/Allen wrench (to remove TB from intake manifold) 4) Phillips screwdriver (only needed in "slow and thorough" method if removing MAF housing from air filter housing) 5) Flat blade screwdriver (to help remove spark plug wire boots from coilpack - not needed for "quick and dirty" method) 6) T30 Torx driver (to remove engine cover pieces - not needed for "quick and dirty" method) 7) Can of intake/TB cleaner 8) Q-tips or something similar (to gently scrub away the TB deposits) 9) Sheet of plain white paper 10) Paper towels or rags optional ... 11) New TB-to-manifold gasket. The Bentley manual instructs that this gasket should be replaced when the TB is removed, but more than likely it can be reused. Mine was still in excellent shape so I reused it. If you are uncomfortable doing this, purchase a new gasket. 12) VAG-COM or other suitable scan tool (for performing adaptation of TB to ECM).

__________________________________________________ __________________ PART I - REMOVING THE THROTTLE BODY 1. The TB is located at the back of the engine bay between the air intake hose and the intake manifold and is indicated by the yellow arrow in picture below.

2. The TB is shaded blue in the picture below.

- To follow the "quick and dirty" removal method, follow steps 3 through 11. - To follow the "slow and thorough" removal method, follow steps 12 through 30.

QUICK AND DIRTY REMOVAL METHOD 3. Remove the battery box cover and disconnect the negative (-) battery lead from the battery using a 10mm wrench or socket. Secure the lead away from the (-) battery post so that it does not accidentally touch it while you're working on the car. 4. Disconnect the harness connector from the TB. The connector is indicated by the yellow arrow in the picture below.

5. Unclip the coolant hose (red arrow in picture below) and the PCV vacuum-assist hose (yellow arrow in picture below) from the top of the air intake tube.

6. Disconnect the upper coolant hose (yellow arrow in picture below) and lower coolant hose (blue arrow in picture below) from the TB. To do this, use the appropriate tool (pliers or screwdriver) to release the tension from the hose clamp, slide the clamp down the hose and out of the way (for spring clamps, make sure the clamp is moved past the end of the nipple inside the hose or the clamp will reapply pressure to the nipple when released), and then pull the hose off of it's nipple.

7. Release the tension from the clamp securing the main air intake tube to the TB (indicated by yellow arrow in picture below) and then slide the intake tube off of the TB.

8. Using a 5mm hex/Allen wrench, remove the 4 long bolts that secure the TB to the intake manifold. There is one bolt at each corner of the TB, two of which are indicated by the yellow arrows in the picture below. Support the weight of the TB as you remove the last bolt. You wouldn't want the TB to fall - it is a delicate, high-precision device. Note that one of the bolts also secures a ground wire to the TB (indicated by red arrow in picture below). In my case, the ground wire was secured by the lower, front bolt, but a different bolt may be used in your car. Remember which bolt the wire was attached with so that it can be reinstalled in the same position.

9. While holding the main intake tube and coolant/vacuum hoses out of the way, pull the TB up and off of the intake manifold.

CAUTION: Be careful not to let ANYTHING fall into the intake manifold while the TB is removed. You don't want any foreign objects being sucked into the engine when it's first started - this may cause severe damage!

10. The yellow arrow in the picture below indicates the gasket that seals the rear of the TB to the intake manifold. Prior to reinstalling the TB (new or existing), either replace the gasket with a new one or decide to reuse the existing one. If you decide to reuse the existing gasket, make sure to clean it by wiping it with a rag or paper towel to remove any debris or contaminants that may be on the mating surface. (The red arrow in the picture below shows a better view of the ground connection that is secured to the TB by one of its mounting bolts.)

If you want to remove the MAF housing from the air filter box. SLOW AND THOROUGH REMOVAL METHOD 12. . proceed to Part II. but you never know with these MAFs. If you're like me and are paranoid that anything you do under the hood can potentially harm the poorly-designed MKIV MAFs. If you are cleaning your existing TB. install the new unit by following steps 3 through 9 in reverse and then proceed to Part III (TB adaptation).11. so it may require some force to separate them. Secure the lead away from the (-) battery post so that it does not accidentally touch it while you're working on the car. It is not necessary to do this in order to remove the TB. 13. Remove the battery box cover and disconnect the negative (-) battery lead from the battery using a 10mm wrench or socket. remove the two Phillips screws that secure the MAF housing to the air filter box (one of the screws is indicated by the blue arrow) and GENTLY slide the housing out of the filter box. you may also want to remove the MAF and put it in a safe place. There is a large gasket sealing the two which snaps into the opening in the filter box. If you are replacing the TB. Release the tension from the clamp securing the main air intake tube to the MAF housing (indicated by yellow arrow in picture below) and then slide the intake tube off of the housing. disconnect the MAF harness connector (red arrow in picture below).

(Be careful not to rip the boots if you do this or the engine may misfire when moisture is present.) I recommend that you mark each wire so that it is reinstalled on the correct post later on. . as shown in the picture below.14. I used a flat blade screw driver to carefully slide the boots off of the posts. This may be difficult due to the suction created by the seal between the boots and posts. Carefully remove the spark plug wires from the ignition coilpack by pulling the rubber wire boots off of the posts on the coilpack.

Unclip the spark plug wires from the channels in the engine cover. .15. as shown below.

Remove the small engine cover piece with the VW logo on it by removing the single T30 Torx screw.16. Remove the long. 17. thin engine cover piece on the passenger's side of the engine by removing the two (2) T30 Torx screws indicated by the yellow arrows in the picture below. indicated by the yellow arrow in the picture below. .

you will need to thread the spark plug wires through their respective holes in the cover in order to fully remove it.18. Remove the main engine cover piece by removing the four (4) T30 Torx screws indicated by the yellow arrows in the picture below. As you lift up on the cover piece. .

The picture below shows how the top of the engine should look with the three engine cover pieces removed.19. .

unclip the TB harness connector lead from the top of the coolant hose which passes over top of the main air intake tube (white arrow in the picture below) and move the lead out of the way. Finally. Disconnect the electrical harness connectors for the TB (yellow arrow in picture below) and PCV valve heater (red arrow in picture below). . disconnect the vacuumassist hose (green arrow in picture below) from the PCV valve S-hose (between valve cover and main intake tube). Next. unclip the hose from the top of the main intake tube (blue arrow in picture below) and move the hose out of the way.20.

There is a depression on the underside of the hose at the bend to provide more clearance. Make sure to reinstall the hose in the same position later on so that abrasion does not occur. (Note the position of the bend in the S-hose relative to the bolt/nut just to the rear of the oil cap.) .21. release the tension from the clamp on the other end of the S-hose (red arrow in picture below). Disconnect the PCV S-hose from the PCV valve on the main intake tube by pushing the two serrated tabs together (yellow arrows in picture below) and carefully pulling the hose off. If you want to also clean the inside of the PCV S-hose (there WILL be oil in it). slide the clamp up the hose a bit and then pull the hose off of its nipple. There should be sufficient room between the hose and bolt so that the bolt does not cut into the hose.

.22. The picture below shows the inside of the PCV valve/heater on the main intake tube. you can see the abundance of condensed oil vapors. If you look closely.

. so the clamp has to be moved up the hose at least that much in order to remove the hose from the nipple.23. Disconnect the upper coolant hose (yellow arrow in picture below) from the TB. The nipple on the TB is approximately 1" long.

. so the clamp has to be moved down the hose at least that much in order to remove the hose from the nipple. Again the nipple on the TB is approximately 1" long. Disconnect the lower coolant hose (yellow arrow in picture below) from the TB.24.

Disconnect the vertical coolant hose (yellow arrow in picture below) from the T-junction in front of the TB/main air intake tube.25. Next. there should be no coolant hoses attached to the TB. unclip the horizontal portion of the coolant hose T-junction from the top of the main intake tube (red arrow in picture below) and then move the hose out of the way. . nor should there be any coolant hoses or electrical leads passing over the top of the main intake tube. At this point.

26. . Release the tension from the clamp securing the main intake tube to the TB (indicated by yellow arrow in picture below) and then slide the intake tube off of the TB.

(I can only imagine how much oil is in the intake manifold and elsewhere in the engine. Someday I'll clean it all out.) .27. The picture below shows the large amount of condensed oil vapor in the main intake tube due to the PCV circuit. I wiped this oil off the inside of the tube with a paper towel.

but a different bolt may be used in your car. Remember which bolt the wire was attached with so that it can be reinstalled in the same position. the ground wire was secured by the lower. as indicated by the yellow arrows in the picture below. Note that one of the bolts also secures a ground wire to the TB (indicated by red arrow in picture below). Support the weight of the TB as you remove the last bolt. . There is one bolt at each corner of the TB. front bolt.it is a delicate.28. high-precision device. remove the 4 long bolts that secure the TB to the intake manifold. Using a 5mm hex/Allen wrench. In my case. You wouldn't want the TB to fall .

) 30.0). As always. New Beetle) and from different model years. If you are cleaning your existing TB. proceed directly to Part II. If you decide to reuse the existing gasket. I had some free time and all the necessary pics. as well as the cleaning procedures should be very similar.this may cause severe damage! 29. body styles (Golf. If you are replacing the TB. do this procedure at your own risk. You don't want any foreign objects being sucked into the engine when it's first started . I am not responsible for any mistakes in the procedure or those that you make while performing it. No biggie. make sure to clean it by wiping it with a rag or paper towel to remove any debris or contaminants that may be on the mating surface. Prior to reinstalling the TB (new or existing). The yellow arrow in the picture below indicates the gasket that seals the rear of the TB to the intake manifold. (The red arrow in the picture below shows a better view of the ground connection that is secured to the TB by one of its mounting bolts. Let me know if you have any questions. Also.CAUTION: Be careful not to let ANYTHING fall into the intake manifold while the TB is removed. The procedures were based on a 99. install the new unit by following steps 12 through 28 in reverse and then proceed to Part III (TB adaptation). however. 2. so that's what I did. please be observant while removing parts so that they go back together correctly. either replace the gasket with a new one or decide to reuse the existing one. Specifically. REMOVING AND CLEANING A MKIV THROTTLE BODY (THROTTLE VALVE CONTROL MODULE) The following outlines the procedure for removing and cleaning the drive-by-wire (DBW) throttle body (officially known as the throttle valve control module) on a MKIV VW. the procedures for removing and reinstalling the throttle body (herein referred to as TB) may differ due to slight differences in the design and orientation of the TB. .5 Jetta GLS VR6 and may be different on MKIV cars with different engines (1. GTI. I determined that the gasket in my car was in good enough shape to be reused. so I put this little DIY together. Please do these procedures at your own risk and be ready to make small adjustments while doing them. the general removal/reinstallation procedures.8T. Hope it's useful to someone. 1.

you'll need the appropriate screwdriver. Part I deals with the removal of the TB from the intake circuit. using the photos only as a reference. Since I did not perform this procedure. such as the main intake tube and PCV circuit to be examined and cleaned and (2) unclutters the "workspace". The advantages of this method are that it (1) allows various other parts of the intake system. I did not perform this procedure. I did not have the appropriate pictures and used those taken after everything was already reassembled. you may notice that the pictures posted for this method do not actually show anything disconnected. nor will be held responsible if you mess up your TB while doing this procedure. so I have no idea how long it takes. It is not absolutely necessary to perform this procedure. If you're familiar with this area of the engine bay. Part II deals with the cleaning of the TB. it will take approximately 30-60 mins to remove the TB using this method. 12) VAG-COM or other suitable scan tool (for performing adaptation of TB to ECM). . purchase a new gasket. Mine was still in excellent shape so I reused it. Please disregard these inconsistencies. be extremely careful when performing the procedure and heed the warnings and cautions that are given. this is something that you will obviously want to prevent from happening. Just follow the written directions. The tools/parts needed to perform the procedures are: 1) 10mm wrench or socket (to disconnect negative battery lead) 2) Appropriate tool for removing hose clamps. I have supplied it for all the minimalist DIYers out there who like to keep things simple.. electromechanical devices. If you damage the servos and sensors which control the motion and position of the throttle valve (also known as the butterfly valve) while performing this procedure.not needed for "quick and dirty" method) 6) T30 Torx driver (to remove engine cover pieces . Part III deals with the adaptation of the TB to the engine control module (ECM) using a VAG-COM or other suitable scan tool.. Since a new TB costs around $500. __________________________________________________ __________________ PART I .Before proceeding any further.. there is a very great chance that your engine will not run correctly and the TB will need to be replaced. 3) 5mm hex/Allen wrench (to remove TB from intake manifold) 4) Phillips screwdriver (only needed in "slow and thorough" method if removing MAF housing from air filter housing) 5) Flat blade screwdriver (to help remove spark plug wire boots from coilpack . depending greatly on how dirty your TB is and how careful and thorough you are when cleaning it. This DIY is broken up into three parts. Two methods for removing the TB are given.REMOVING THE THROTTLE BODY 1.) The second method is the "slow and thorough" method and requires that significantly more things be disconnected. I am not. making it significantly easier to remove the coolant lines from the TB. but more than likely it can be reused. If you have screw-type clamps. The cleaning procedure should take 30-60 mins or more. Nevertheless. 11) New TB-to-manifold gasket. If you have the stock spring clamps.not needed for "quick and dirty" method) 7) Can of intake/TB cleaner 8) Q-tips or something similar (to gently scrub away the TB deposits) 9) Sheet of plain white paper 10) Paper towels or rags optional . The first method is the "quick and dirty" method and requires that the least number of things be disconnected/removed in order to disconnect the TB. I must make it clear that the DBW TBs used on the MKIV vehicles are high-precision. (Note: If you follow this method. The Bentley manual instructs that this gasket should be replaced when the TB is removed. This method is the one that I followed when cleaning my TB and I recommend that others use it as well.. The TB is located at the back of the engine bay between the air intake hose and the intake manifold and is indicated by the yellow arrow in picture below. a pair of channel lock pliers works great for this purpose since the jaws are roughly perpendicular to each other (helps prevent clamps from slipping in plier jaws) and the jaw width can be adjusted for each particular clamp size. however doing so immediately following the reinstallation of the TB will help insure the smooth operation of the engine when it's first started. Therefore. and you should have no problems. If you are uncomfortable doing this.

2. . The TB is shaded blue in the picture below.

QUICK AND DIRTY REMOVAL METHOD 3.To follow the "slow and thorough" removal method. 4. The connector is indicated by the yellow arrow in the picture below. .To follow the "quick and dirty" removal method. Secure the lead away from the (-) battery post so that it does not accidentally touch it while you're working on the car. Disconnect the harness connector from the TB. Remove the battery box cover and disconnect the negative (-) battery lead from the battery using a 10mm wrench or socket. follow steps 3 through 11. . follow steps 12 through 30..

. Unclip the coolant hose (red arrow in picture below) and the PCV vacuum-assist hose (yellow arrow in picture below) from the top of the air intake tube.5.

use the appropriate tool (pliers or screwdriver) to release the tension from the hose clamp. . Disconnect the upper coolant hose (yellow arrow in picture below) and lower coolant hose (blue arrow in picture below) from the TB.6. and then pull the hose off of it's nipple. make sure the clamp is moved past the end of the nipple inside the hose or the clamp will reapply pressure to the nipple when released). slide the clamp down the hose and out of the way (for spring clamps. To do this.

7. . Release the tension from the clamp securing the main air intake tube to the TB (indicated by yellow arrow in picture below) and then slide the intake tube off of the TB.

There is one bolt at each corner of the TB. high-precision device. remove the 4 long bolts that secure the TB to the intake manifold. two of which are indicated by the yellow arrows in the picture below. Using a 5mm hex/Allen wrench.it is a delicate. Note that one of the bolts also secures a ground wire to the TB (indicated by red arrow in picture below). You wouldn't want the TB to fall . Remember which bolt the wire was attached with so that it can be reinstalled in the same position. the ground wire was secured by the lower.8. but a different bolt may be used in your car. . front bolt. Support the weight of the TB as you remove the last bolt. In my case.

pull the TB up and off of the intake manifold. either replace the gasket with a new one or decide to reuse the existing one.this may cause severe damage! 10. (The red arrow in the picture below shows a better view of the ground connection that is secured to the TB by one of its mounting bolts. The yellow arrow in the picture below indicates the gasket that seals the rear of the TB to the intake manifold.) . If you decide to reuse the existing gasket. Prior to reinstalling the TB (new or existing). make sure to clean it by wiping it with a rag or paper towel to remove any debris or contaminants that may be on the mating surface.9. You don't want any foreign objects being sucked into the engine when it's first started . While holding the main intake tube and coolant/vacuum hoses out of the way. CAUTION: Be careful not to let ANYTHING fall into the intake manifold while the TB is removed.

.11. Remove the battery box cover and disconnect the negative (-) battery lead from the battery using a 10mm wrench or socket. remove the two Phillips screws that secure the MAF housing to the air filter box (one of the screws is indicated by the blue arrow) and GENTLY slide the housing out of the filter box. so it may require some force to separate them. If you want to remove the MAF housing from the air filter box. 13. you may also want to remove the MAF and put it in a safe place. install the new unit by following steps 3 through 9 in reverse and then proceed to Part III (TB adaptation). proceed to Part II. It is not necessary to do this in order to remove the TB. If you're like me and are paranoid that anything you do under the hood can potentially harm the poorly-designed MKIV MAFs. Secure the lead away from the (-) battery post so that it does not accidentally touch it while you're working on the car. SLOW AND THOROUGH REMOVAL METHOD 12. If you are cleaning your existing TB. If you are replacing the TB. disconnect the MAF harness connector (red arrow in picture below). There is a large gasket sealing the two which snaps into the opening in the filter box. but you never know with these MAFs. Release the tension from the clamp securing the main air intake tube to the MAF housing (indicated by yellow arrow in picture below) and then slide the intake tube off of the housing.

14.) I recommend that you mark each wire so that it is reinstalled on the correct post later on. as shown in the picture below. (Be careful not to rip the boots if you do this or the engine may misfire when moisture is present. This may be difficult due to the suction created by the seal between the boots and posts. Carefully remove the spark plug wires from the ignition coilpack by pulling the rubber wire boots off of the posts on the coilpack. . I used a flat blade screw driver to carefully slide the boots off of the posts.

.15. Unclip the spark plug wires from the channels in the engine cover. as shown below.

. indicated by the yellow arrow in the picture below. Remove the small engine cover piece with the VW logo on it by removing the single T30 Torx screw.16.

. Remove the long.17. thin engine cover piece on the passenger's side of the engine by removing the two (2) T30 Torx screws indicated by the yellow arrows in the picture below.

As you lift up on the cover piece. .18. Remove the main engine cover piece by removing the four (4) T30 Torx screws indicated by the yellow arrows in the picture below. you will need to thread the spark plug wires through their respective holes in the cover in order to fully remove it.

.19. The picture below shows how the top of the engine should look with the three engine cover pieces removed.

. unclip the TB harness connector lead from the top of the coolant hose which passes over top of the main air intake tube (white arrow in the picture below) and move the lead out of the way. Next. Disconnect the electrical harness connectors for the TB (yellow arrow in picture below) and PCV valve heater (red arrow in picture below).20. Finally. disconnect the vacuumassist hose (green arrow in picture below) from the PCV valve S-hose (between valve cover and main intake tube). unclip the hose from the top of the main intake tube (blue arrow in picture below) and move the hose out of the way.

There is a depression on the underside of the hose at the bend to provide more clearance.21. release the tension from the clamp on the other end of the S-hose (red arrow in picture below). If you want to also clean the inside of the PCV S-hose (there WILL be oil in it). There should be sufficient room between the hose and bolt so that the bolt does not cut into the hose.) . (Note the position of the bend in the S-hose relative to the bolt/nut just to the rear of the oil cap. Make sure to reinstall the hose in the same position later on so that abrasion does not occur. slide the clamp up the hose a bit and then pull the hose off of its nipple. Disconnect the PCV S-hose from the PCV valve on the main intake tube by pushing the two serrated tabs together (yellow arrows in picture below) and carefully pulling the hose off.

The picture below shows the inside of the PCV valve/heater on the main intake tube.22. If you look closely. . you can see the abundance of condensed oil vapors.

so the clamp has to be moved up the hose at least that much in order to remove the hose from the nipple. The nipple on the TB is approximately 1" long.23. Disconnect the upper coolant hose (yellow arrow in picture below) from the TB. .

24. so the clamp has to be moved down the hose at least that much in order to remove the hose from the nipple. . Again the nipple on the TB is approximately 1" long. Disconnect the lower coolant hose (yellow arrow in picture below) from the TB.

25. Disconnect the vertical coolant hose (yellow arrow in picture below) from the T-junction in front of the TB/main air intake tube. At this point. unclip the horizontal portion of the coolant hose T-junction from the top of the main intake tube (red arrow in picture below) and then move the hose out of the way. nor should there be any coolant hoses or electrical leads passing over the top of the main intake tube. there should be no coolant hoses attached to the TB. . Next.

26. Release the tension from the clamp securing the main intake tube to the TB (indicated by yellow arrow in picture below) and then slide the intake tube off of the TB. .

The picture below shows the large amount of condensed oil vapor in the main intake tube due to the PCV circuit. I wiped this oil off the inside of the tube with a paper towel.27.) . Someday I'll clean it all out. (I can only imagine how much oil is in the intake manifold and elsewhere in the engine.

the ground wire was secured by the lower. Note that one of the bolts also secures a ground wire to the TB (indicated by red arrow in picture below). There is one bolt at each corner of the TB. front bolt. .it is a delicate. Using a 5mm hex/Allen wrench. In my case. Remember which bolt the wire was attached with so that it can be reinstalled in the same position.28. as indicated by the yellow arrows in the picture below. remove the 4 long bolts that secure the TB to the intake manifold. but a different bolt may be used in your car. high-precision device. You wouldn't want the TB to fall . Support the weight of the TB as you remove the last bolt.

either replace the gasket with a new one or decide to reuse the existing one. make sure to clean it by wiping it with a rag or paper towel to remove any debris or contaminants that may be on the mating surface. I determined that the gasket in my car was in good enough shape to be reused. (The red arrow in the picture below shows a better view of the ground connection that is secured to the TB by one of its mounting bolts.this may cause severe damage! 29.CAUTION: Be careful not to let ANYTHING fall into the intake manifold while the TB is removed. so that's what I did.) . The yellow arrow in the picture below indicates the gasket that seals the rear of the TB to the intake manifold. You don't want any foreign objects being sucked into the engine when it's first started . If you decide to reuse the existing gasket. Prior to reinstalling the TB (new or existing). No biggie.

do this procedure at your own risk. install the new unit by following steps 12 through 28 in reverse and then proceed to Part III (TB adaptation). Modified by VgRt6 at 6:39 PM 5-13-2004 Reply With Quote 2. I am not responsible for any mistakes in the procedure or those that you make while performing it. 3. proceed directly to Part II. VgRt6 o o o o View Profile View Forum Posts Private Message View Blog Entries . As always. If you are cleaning your existing TB. Let me know if you have any questions. If you are replacing the TB.30.

CLEANING THE THROTTLE BODY 1. gum.CLEANING THE THROTTLE BODY 11-18-2003 09:56 PM #2 PART II . .156 PART II . 2002 Posts 16. The yellow arrows in these pictures point to the oil. The four pictures below show different views of the inside of the throttle body. varnish and other crap that deposits itself inside the TB over time. most of the deposits were located between the edge of the throttle valve and the TB wall (valve at idle position or fully closed) and on the roof of the TB wall behind the throttle valve. In my case.Moderator Join Date Mar 8th.

.

At idle. an increasing larger compensation must be made by the ECM. .Cleaning the TB often gets rid of the code. the amount of air that can pass through decreases and the ECM/DBW system must compensate by resetting the idle position of the valve from fully closed to open a few degrees or so. as the amount of deposits increases. the ECM cannot compensate by opening up the valve any further and the following OBDII code is commonly stored: 17990 . As deposits build up in this gap. IMO.make sure to choose something that is relatively gentle and will not harm DBW TBs . Normally there is a small 1-2mm gap between the edge of the valve and the wall. the valve remains fully closed and the air passing through this gap allows the engine to idle smoothly. Naturally..2. NOTE: The above description is MY understanding of how the TB operates at idle. it is imperative that the deposits in the above pictures be removed.e. no idle adaptation is needed. something to gently scrub off the deposits on the throttle valve and on the TB wall (I used Q-tips and paper towels) and a sheet of ordinary white paper.Idle Adaptation Limit Reached P1582 . since it allows the throttle valve to be fully closed at idle. the most critical of these deposits are those which lie between the edge of the throttle valve and the TB wall. To insure the proper operation of the TB. please inform me and I will change/remove the description. you will need a can of intake/TB cleaner (the stuff I used is shown in the picture below . i.35-00 . At some point. If this is incorrect. In order to safely clean the inside of the TB.some carb-type cleaners are not). 3.

triangular pieces approximately 1" x 4" (size is not critical). Cut the paper into thin.4. . as shown in the picture below. Also shown are some EXTREMELY dirty Q-tips that had already gone at the deposits in the TB by the time I took this picture.

Because . here are some VERY important warnings. the position of the throttle valve in a DBW TB is controlled electrically. why take the chance with a $500 piece of equipment. spray the TB cleaner onto the deposits inside the TB. most likely by a high-precision stepper motor. you should be able to remove all of the deposits EXCEPT for those between the edge of the throttle valve and TB wall. Unlike a drive-by-cable (DBC) TB in which the throttle valve is allowed to move freely and is held closed by a spring.5. First. Orienting the TB in this manner while cleaning it will help prevent the cleaner from leaking past the seals between the TB body and control module and possibly damaging it. To clean the TB. allow it to soak in for a few seconds and then gently scrub away the deposits with the Q-tips and/or paper towels. Using this method. We'll get to those deposits shortly. While the seals should be a sufficient barrier to this happening. WARNING: When spraying the TB cleaner inside the TB. WARNING: Be careful not to press too hard against the throttle valve while cleaning it. I HIGHLY recommend that you hold the TB with the electronic control module portion of the TB ABOVE the body of the TB.

Just be careful not to use too much pressure. you cannot simply move the throttle valve out of the way to remove the deposits that collect between the edge of the throttle valve and the TB wall. so there may be a very small amount of deposit left remaining in the gap near the axle. No big surprise that it looks much better than it did prior to the cleaning. Spray a little TB cleaner into the gap between the edge of the throttle valve and the TB wall and use the corner of one of the strips of paper to carefully scrape the deposits out of the gap. Most likely. 6. the throttle valve will not move freely and can be easily damaged if forced to move against the resistance of the stepper motor. I recommend that you use to the small strips of paper to clean this area. 7. . This is not a big deal. Since the throttle valve will not move freely due to stepper motor used by the DBW throttle valve controller. When in doubt.of this. slide the paper into the gap completely and move it back and forth to scrape the deposits out of the gap. Once the deposits have been removed from a small area of the gap. 8. similar to using dental floss to remove food from between your teeth. Using this method. Instead. The pictures below show various views of the TB following the cleaning procedure. Spray additional cleaner into the gap as needed during this procedure. use the least amount of pressure needed to remove the deposits and you should be OK. The picture below show how the gap between the edge of the throttle valve (in the fully closed position) and the TB wall should look once the deposits are removed from it. This does not mean that you cannot apply a small amount of pressure to the throttle valve with the Q-tip when cleaning it. it should be possible to remove virtually all of the deposits from the gap. the gap near the axle for the throttle valve will be too narrow to get the paper into it.

.

.

Following this. I recommend that you wait this long or more before reinstalling your TB. I allowed to the TB to sit for approximately 30 mins before reinstalling it. The picture below shows the cleaned TB ready to be reinstalled. To speed up the process. The pictures below of paper towels and Q-tips used during the cleaning procedure illustrate that while the TB did not look that dirty. WARNING: Prior to reinstalling the TB. .9. I inserted clean strips of paper into the gap between the edge of the throttle valve and TB wall to remove the cleaner held in there by capillary forces. 10. make sure to let it dry thoroughly or damage to the electronic control module or throttle position sensors may result. quite a bit of deposits were removed during the cleaning process.

IM LOCATED IN NEW YORK LONG ISLAND. PRICES DO NOT INCLUDE SHIPPING THANKS BRAND NEW POLISHED SCHIMMEL PERFORMANCE SHORT RUNNER INTAKE MANIFOLD W/FUEL LINE AND THROTTLE BODY .1 ADPATER ARM AND THROTTLE CABLE BRACKET WITH FUEL FITTING AND POLISHED INTAKE MANIFOLD ALLEN SCREWS AND WASHERS BOUGHT FROM SCHIMMEL PERFORMANCE INCLUDED $1100 . To reinstall the TB. follow the steps for the removal method in Part I that you used in reverse. and then proceed to Part III. SO THAT IS THE REASON FOR SELLING. I HATE TO SEE THESE PARTS SOLD BUT LOOKING TO BUY SOMETHING LIKE A MERCEDES SL 65 AMG REAR WHEEL DRIVE CAR. Let me know if you have any questions. As always.11. LL THESE PARTS ARE FROM A BIG VR6 12 VALVE TURBO PROJECT I NEVER GOT TO FINISH MOST OF THE PARTS ARE BRAND NEW OUT OF BOX. do this procedure at your own risk. I am not responsible for any mistakes in the procedure or those that you make while performing it.

2 .BRAND NEW SCHRICK CAMSHAFTS 12 VALVE VR6 260/264 DURATION $850 .

com/mm5/merchant.BRAND NEW VR6 12 VALVE WRD BIG VALVE HEAD STAGE 3 WITH HYDRAULIC LIFTERS INCLUDED ALSO THERES A CORE .mvc?S..3 CHARGE OF $250 AT WRD AND MJMAUTOHAUS $2200 http://wrdusa..a4gtivr6engine .

4 .BRAND NEW GARRET POLISHED COMPRESSOR GT4094R/42R HYBRID TURBO T4 FLANGE GOOD UP TO 850 HP $1700 .

BRAND NEW 50 MM TIAL POLISHED BLOW OFF VALVE $250 .5 .

BRAND NEW 44 MM TIAL POLISHED WASTEGATE WITH 38MM ADAPTER FLANGE TO ADAPT TO A TIAL 44 MM FLANGE TO .6 ATP TURBO MANIFOLD $440 .

7 .BRAND NEW ARP VR6 12 VALVE HEAD STUDS WITH WASHERS AND LUBRICANT $220 .

9 .8 TWO DOORS OR FOUR DOORS FOUR BRUSHED ALUMINUM DOOR PIECES FOR GOLD OR JETTA $250 FOR 2 DOOR GTIS $200 BRAND NEW SERPENTINE BELT TENSIONSER WITH PULLEY WITHOUT A/C SERPINTINE BELT INCLUDED $110 .BRAND NEW BRUSHED ALUMINUM OETTINGER DOORS SILLS WITH OETTINGER ENGRAVED IN IT FOR MK4 GTI/GOLF/JETTA .

MAIN STUDS AND IM SURE IF YOU CALL UP BILL HE HAS ME IN THE SYSTEM THAT HE BUILT THIS MOTOR FOR ME THE CROWER RODS ARE ONE OF THE VR6S BEST FORGED RODS THEY RETAIL LIKE OVER $1000 DOLLARS ALONE.CROWER RODS. NEW RINGS CLEARANCES CHECKED DECKED AND HOT TANKED CROWER FORGED CONNECTING RODS WITH HEAVY DUTY CROWER ROD BOLTS NEW THRUST BEARINGS INTERSHAFT BEARINGS 034 MOTORSPORTS MAIN AND ROD CERAMIC COATED BEARINGS WHICH WAS ANOTHER $360/ARP MAIN STUDS AROUND ANOTHER $100 AND NEW FREEZE PLUGS 0 MILES ON THIS PICKED UP FROM BILL SCHIMMEL MYSELF HAVE PAPERS FOR THE JE CUSTOM PISTONS. I TRIED NOT TO SKIMP ON ANYTHING.10 POLISHED CRANKSHAFT SPTURBO JE CUSTOM PISTONS 8. THIS MOTOR WAS BUILT FOR SERIOUS POWER IT CAN PROBABLY HOLD 1000HP TO THE CRANK ANY HIGHER THEN THAT YOUR GOING TO HAVE TO GO WITH A EUROSPEC FORGED CRANKSHAFT SERIOUS BUYERS ONLY $4000 .100 OVERBORE.0 LITER SHORT BLOCK STAGE 2 WITH .BRAND NEW FRESHLY BLACK PAINTED SCHIMMEL PERFORMANCE FULLY BUILT 3.5 TO 1 WHICH WERE AROUND $1000 ALONE .

11 BRAND NEW RECARO SPEED S TUNING BLACK AM VINYL SEATS BLACK INSERTS AND BOLSTERS WITH GRAY LOGO .BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE OIL TEMPERATURE GAUGE 52MM 140-320 DEGREES $60 .12 BASICALLY LOOKS LIKE FULL BLACK LEATHER $2000 .

13 IN MK4 CARS $225 EACH .TWO BRAND NEW WEDGE ENGINEERING CUSTOMS SLIDERS AND SEAT BRACKETS MADE TO FIT RECARO SPEED S SEATS .

BRAND NEW EUROGEAR CARBON FIBER BOSER HOOD FOR GTI/GOLF $700 .14 .

15 BEHR LOW TEMP THERMOSTAT $80 .BRAND NEW VW/OEM VR6 12 VALVE GENUINE THERMOSTATIC HOUSING AND COVER WITH O RINGS DOES NOT INCLUDE .

BRAND NEW OEM/VW R32/337/GLI/20TH BRUSHED ALUMINUM PASSENGER SIDE DOOR HANDLE $110 .16 .

17 .BRAND NEW VW/OEM GENUINE R32 REAR HATCH SPOILER ORDERED FROM MJMAUTOHAUS $350 .

18 DISC AND THROWOUT BEARING PURE DRAG HARSH ENGAGEMENT INCLUDES BOOKLET AND INSTALL INSTRUCTIONS $1700 .BRAND NEW CLUTCHMASTERS FX700 TWIN DISC CLUTCH FOR AN 02M INCLUDES ALUMINUM FLYWHEEL.PRESSURE PLATE. .

BRAND NEW 02M FWD DRIVESHAFT SHOP STAGE 5 AXLES HEAVY DUTY INCLUDES PAPERWORK $1500 .19 .

BRAND NEW FRONT STRUT MOUNTS WITH BEARINGS AND NUTS $50 .20 .

BRAND NEW SCHIMMEL PERFORMANCE POLISHED WATER TO AIR INTERCOOLER SYSTEM /INCLUDING WATER TO AIR .21 INTERCOOLER/INCLUDING 3 GALLON WATER TANK/ MEZEINER WATER PUMP/ LONG RUBBER BLACK HOSE AND BLACK LONG ROW HEAT EXCHANGER $1700 RETAILS FOR OVER $1700 .

BRAND NEW DTA S80 STANDALONE ENGINE MANAGEMENT ECU WITH CD AND BOOKLET AND PAPERWORK $2000 .22 .

23 .BRAND NEW OEM STYLE FENDERS $125 EACH .

.

26 BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE 52MM EGT/PYROMETER GAUGE ELECTRICAL 1-1..600 F .25 BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE OIL PRESSURE GAUGE 52MM 0-150 PSI $60 .28 EACH .BRAND NEW MK4 VR6 12 VALVE ALUMINUM OIL PAN $180 .27 DEGREES W/SENDING UNIT ELECTRICAL $190 BRAND NEW BLACK EUROPEAN SUNVISORS WITHOUT WARNING STICKERS ON THEM ORDERED FROM TMTUNING $125 .24 BRAND NEW OEM/VW G12 1 GALLON OF COOLANT $25 .

29 .BRAND NEW VR6 12 VALVE FULL TIMING CHAIN KIT $200 .

30 .BRAND NEW NEUSPEED POLISHED FRONT LOWER TIE BAR $170 .

31 .BRAND NEW ALUMINIUM VW/OEM AUDI TT MANUAL 3 PEDAL WITH DEAD PEDAL FOOTREST SET $130 .

32 .BRAND NEW ATP TURBO ALUMINUM HEAT SHIELD COVER $70 .

0 $900 .BARLEY USED CATBACK MILLTEK R32 EXHAUST STYLE STAINLESS STEEL 2.5 INCH EXHAUST WITH TWO 4" INCH POLISHED .8T OR 2.33 TIPS WITH MILLTEK SIGNATURES ON THEM MADE TO FIT MK4 GTI AND GIVE A R32 STYLE EXHAUST LOOK AND WITH ONE MUFFLER AND NO RESONATOR TOP OF THE LINE EXHAUST FOR A VR6 GTI 12 VALVE OR COULD FIT ANY MK4 CAR 1.

BRAND NEW OEM/VW GENUINE EARLY VIN PEARL GRAY W8 OVERHEAD CONSOLE WITH TWO AMBIENT RED .34 LIGHTS/INCLUDES SEPERATE SUNROOF SWITCH WHICH LIGHTS UP RED TO MATCH W8 PANEL AND W8 ADAPTER WIRING HARNESS ALL BRAND NEW $280 .

BRAND NEW MCCULLOCH TOP OF THE LINE 35 WATT H3 BULB SIZE 8000K BULBS HID CONVERSION KIT GERMAN MADE .35 ONE OF THE BETTER QUALITY HID KITS $250 .

BRAND NEW HEATER CORE $80 .36 .

BRAND NEW MISHIMOTO BLACK RADIATOR FAN 16 INCH $100 .37

BRAND NEW GRUVENPARTS VR6 12 VALVE BILLET STAINLESS STEEL POLISHED CRACKPIPE WITH CHROME DRAIN .38 COOLANT FITTING $100

USED BLACK SUNROOF SLIDER TRIM PIECE THAT COMES IN R32/337/20TH/GLI $40 .39

BRAND NEW GRUVENPARTS SHIFTER CABLE BLOCK IN BILLET FOR WEAK PLASTIC END LINKS ON FWD TRANSMISSIONS .40 $75

BRAND NEW OEM/VW GENUINE R32 SIDE SKIRTS ORDERED FROM ECS TUNING COMES IN PRIMER READY TO PAINT $800 .41

BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE SPEEDOMETER 0-160 $250 .42

BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE TACHOMETER 0-8000 rpm $250 .43

BRAND NEW 034 MOTORSTORTS VW PEDAL TO ACTUALLY CONVERT DRIVE BY WIRE SYSTEMS TO DRIVE BY CABLE .44 SYSTEMS FOR STANDALONE USE $125 .

BRAND NEW INNOVATE MOTORSPORTS XD-16 (16 IN 1) 52 MM DIGITAL AIR FUEL RATIO GAUGE COMES WITH 16 .45 DIFFERENT FACE GAUGE OPTIONS AND 2 TRIM RIMS CHROME AND BLACK WITH CD AND BOOKLET $230 .

USED CUP KIT INCLUDES 4 TOKICO SHOCKS AND 4 H&R SPRINGS LOWERS THE CAR ABOUT ONE INCH A DECENT STIFF .47 .46 RIDE $400 BRAND NEW PERFORMANCE POLISHED MISHIMOTO ALUMINIUM RADIATOR $260 .

48 .BRAND NEW BBM MUSTANG POLISHED 3 INCH THROTTLE BODY WITH GASKETS $270 .

BRAND NEW FK LED M3 LOOKALIKE TAILIGHTS $300 .49 .

TWO BRAND NEW 42 DRAFT DESIGNS ALUMINUM TRIPLE GAUGE INSERT PODS FOR MK4 CUBBY HOLES $50 EACH .50 .

51 .BRAND NEW BLACK SX FUEL PUMP SUPPORTS FUEL INJECTED ENGINES UP TO 1000HP AT 45 PSI $370 .

BRAND NEW 6 50 LB DELPHI INJECTORS $425 .52 .

Control Volkswagen windows and sunroof with your remote keyfob The KVW100 is a single use flash load device that will program your VW convenience control module with the necessary .55 The PowerGasket Plus™ is made from a purpose-built high performance composite material.air will stay 20-30° F cooler . Your intake manifold will stay 30-50° F cooler and your incoming .coding to control your windows via key fob remote BRAND NEW NEWSOUTH PERFORMANCE POWERGASKET PLUS INTAKE MANIFOLD PERFORMANCE SPACER GASKET $80 .BRAND NEW REAR CONSOLE CUPHOLDER DELETE IN BLACK $30 .53 BRAND NEW KVW100 WINDOW ROLL UP/ ROLL DOWN LOAD MODULE WITH INSTRUCTIONS $70 .54 . It conducts on average less than 1/500th of the heat of the steel gasket that it replaces.

56 .BRAND NEW MARSHALL FUEL PRESSURE GAUGE TO BE USED ON FUEL PRESSURE REGUALTOR $50 .

57 .BRAND NEW OEM/VW GENUINE R32 REAR BUMPER ORDERED FROM ECS TUNING COMES IN PRIMER READY TO PAINT $950 .

BRAND NEW EUROPEAN HEADLIGHT SWITCH WITH TWO FOGS AND CHROME ACCENTS TRIM $70 .58 .

BRAND NEW OEM/VW HEADLIGHT LEVELING RHEOTROSTAT FOR OEM HIDS OR PROJECTORS $60 .59 .

60 .BRAND NEW CHROME LICENSE PLATE FRAME WITH SCREW COVERS $20 .

BRAND NEW VR6 12 VALVE OIL PUMP $170 .61 .

62 .BRAND NEW POLISHED SPARCO HOOD PIN SET $60 .

BRAND NEW VR6 12 VALVE WATER PUMP $80 .63 .

BRAND NEW JOM CHROME AC/HEATING VENTS $40 .64 .

FOUR BLACK OVERHEAD HEADLINER GRAB HANDLES R32/20TH/337/GLI $60 .66 DEGREE TYPE XPR TYPE ENDS AND TWO XPR STRAIGHT ENDS FITTINGS AND MOCAL SANDWICH PLATE WITH FILTER STUD AND O RING $500 .65 BRAND NEW AUTOTECH THERMO 16 ROW SETRAB OIL COOLER SYSTEM WITH STAINLESS STEEL LINES AND TWO 90 .

67 BRAND NEW JOM POLISHED DOOR PINS $25 .68 .BRAND NEW VR6 12 VALVE OIL TEMP SWITCH $20 .

70 .69 BRAND NEW POLISHED ALUMINUM GRUVENPARTS AUXILLARY SECONDARY WATER PUMP BRACKET $80 .BRAND NEW VR6 BEHR LOW TEMP THERMOSTAT $30 .

BRAND NEW STAINLESS STEEL AEROQUIP 20 FT FUEL LINE -8 $130 .71 .

1 INCH CROSS DRILLED .74 AND SLOTTED ROTORS AND RED CALIPERS WITH HAWK HPS PERFORMANCE PADS $1200 .72 BRAND NEW COOLANT TEMP SWITCH $25 .73 BRAND NEW ECS TUNING REAR BIG BRAKE STAGE ONE VERSION TWO BIG BRAKE KIT WITH 12.TWO BLACK R32/337/20TH/GLI SIDE DOME LIGHTS ON HEADLINER $25 EACH .

.

76 .TWO BLACK R32/337/20TH/GLI VANITY LIGHTS FOR VANITY MIRRORS $20 EACH .75 BRAND NEW BLACK CLOTH SINGLE A PILLAR GAUGE POD FROM 42 DRAFT DESIGNS $60 .

BRAND NEW VW/OEM COOLANT RESIVIOR $40 .77 .

BRAND NEW FRONT MEYLE BALL JOINTS WITH HARDWARE $50 .78 .

79 .BRAND NEW MEYLE RIGHT TIE ROD END ASSEMBLY AND LEFT TIE ROD ASSEMBLY $50 EACH .

OEM FRONT WHEEL BEARING KIT $80 .80 .

81 .BRAND NEW MEYLE RIGHT AND LEFT CONTROL ARMS $90 EACH .

.

BRAND NEW VF ENGINEERING SWAY BAR END LINKS WITH URETHANE BUSHINGS $120 .82 .

83 .BRAND NEW WRD FRONT URETHANE CONTROL ARM BUSHING KIT $40 .

TWO PAIRS 6.84 INCLUDES 6.5 INCH COMPONENTS OF BRAND NEW JL AUDIO COMPONENT SPEAKERS ZR650-CSI TOP OF LINE SPEAKERS .5 SPEAKER WITH 1 INCH TWEETER AND CROSSOVER $500 A PAIR .

BRAND NEW MAGNETIC TRANSMISSION 17MM DRAIN PLUG TO REPLACE STOCK ONE $20 .85 .

86 .BRAND NEW ALUMINUM JAZ 15 GALLON FUEL CELL W/ GM SENDER UNIT $350 .

87 .BRAND NEW HEAVY DUTY MISHIMOTO TRANSMISSION COOLER KIT WITH 8 INCH ELECTRIC FAN $170 .

BRAND NEW JOM CHROME MANUAL SHIFTER TRIM $50 .88 .

89 .USED OEM/VW R32 BLACK LEATHER SHIFT BOOT WITH SILVER STICTHING $80 .

90 .BRAND NEW MAGNETIC OIL DRAIN PLUG WITH 10 COPPER WASHERS INCLUDED $20 .

91 .BRAND NEW VW/OEM POWER STEERING RESIVIOR $50 .

93 $80 .94 $60 .92 $80 .94 $60 .95 .BRAND NEW OEM/VW R32/337/GLI/20TH BRUSHED ALUMINUM CLIMATRONIC TRIM PIECE BRAND NEW OEM/VW R32/337/GLI/20TH BRUSHED ALUMINUM LEFT SIDE DASH INSERT BRAND NEW OEM/VW R32/337/GLI/20TH BRUSHED ALUMINUM RIGHT SIDE DASH INSERT BRAND NEW OEM/VW R32/337/GLI/20TH BRUSHED ALUMINUM LOWER DASH INSERT BRAND NEW OEM/VW R32/337/GLI/20TH BRUSHED ALUMINUM ASHTRAY COVER $80 .

.BRAND NEW REAR SHOCK MOUNTS SET OF TWO $50 .96 BRAND NEW OEM/VW R32/337GLI/20TH BRUSHED ALUMINUM CUSTOM CUPHOLDER DELETE PANEL WITH RADIO CAGE .97 INCLUDED $150 .

98 QUALITY BRUSHED ALUMINUM LOOK TRIM AROUND THEM $150 BRAND NEW TOP OF LINE MCCULLOCH D2S BULB SIZE 8000K REPLACEMENT HID BULBS GERMAN MADE $100 .CENTER VENT HOLDER LEFT VENT HOLDER AND RIGHT VENT HOLDER AC/HEATING SURROUNDING VENT HOLDERS WITH .99 .

BRAND NEW OEM/VW FRONT FENDER LINER HARDWARE KIT $25 EACH .100 BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE WATER TEMPERATURE 52MM 100-260 DEGREES F $60 .101 BRAND NEW GTI HEADLIGHTS CLEAR LAMIN-X WITH HARDWARE TO INSTALL TO PROTECT YOUR HEADLIGHTS $50 ..102 BRAND NEW EUROPEAN REAR FOG LIGHT KIT WITH BULB $20 .103 .

104 .BRAND NEW POLISHED MOMO E-BRAKE HANDLE COVER WITH BLACK LEATHER BOOT $140 .

105 .TWO BRAND NEW FRONT CHROME PLATED FLOOR MATS MADE ESPICALLY FOR A MK4 $120 .

106 $80 .TWO BRAND NEW ORDERED FROM TMTUNING CHROME POLISHED SEATBELT COVER CLASPS WITH SEATBELT RETAINERS .

108 BRAND NEW BOTH 12 VALVE STEEL EXHAUST MANIFOLD GASKETS $30 .107 BRAND NEW 12 VALVE VALVE COVER GASKET TO FIT METAL VALVE COVERS ONLY $20 .109 BARELY USED POLISHED ALUMINUM UNORTHODOX RACING PERFORMANCE PULLEY KIT INCLUDES CRANK PULLEY POWER .BARLEY USED LOWER ALUMINUM VF ENGINEERING ENGINE PENDULUM MOUNT W/HARDWARE $180 .110 STEERING PULLEY AND ALTERNATOR PULLEY $300 .

111 .BRAND NEW ALMOST MIRROR POLISHED GTI/JETTA HOOD PULL FROM GRUVEN PARTS $70 .

112 .BRAND NEW GRUVENPARTS LIGHT WEIGHT BILLET POLISHED ALUMINUM WATER PUMP PULLEY 12 VALVE VR6 $100 .

BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE ANALOG GAUGE SERIES 52 MM TRANSMISSION .113 TEMPERATURE 140-320 DEGREES F 214284 $60 .

BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE ANALOG GAUGE 52 MM FUEL LEVEL GAUGE 214224 $50 .114 .

BRAND NEW STEWART WARNER MAXIMUM PERFORMANCE ANALOG GAUGE 52 MM BOOST PRESSURE 0-60 PSI 214524 .115 $50 .

BRAND NEW MONO AMP ALPINE MRP-M2000 2000 RMS X 1 AT 2 OHMS $600 .116 .

117 .TWO BRAND NEW MRP-F300 4/3/2 CHANNEL AMP 75 X 4 RMS AT 2 OHMS $200 EACH .

BRAND NEW USP STAINLESS STEEL CLUTCH LINE FOR AN 02M TRANSMISSIONS $80 .118 .

BOOKLET AND REMOTE AND CD .BRAND NEW ALPINE TOP OF THE LINE FLIP SCREEN IVA-D106 INCLUDES ALL WIRING.119 AND INSTALL GUIDE $950 .

BRAND NEW VW TRANSVERSE ACTUAL THROTTLE CABLE CONVERTS DRIVE BY WIRE TO DRIVE CABLE $100 .121 $110 BRAND NEW SCHIMMEL PERFORMANCE STEEL STOCK COMPRESSION HEAD GASKET WORKS WELL WITH LOWER .121 COMPRESSION PISTONS IS MADE FOR A VR6 12 VALVE 83.5MM BORE PISTONS INCLUDES TWO MK4 GASKETS $200 .120 BRAND NEW POLISHED ARP VR6 12 VALVE EXHAUST MANIFOLD STAINLESS STEEL STUD SET WITH NUTS AND WASHERS .

122 .BRAND NEW ATP VR6 12 VALVE TURBO EXHAUST MANIFOLD $400 .

VW/OEM REAR BLACK LEATHER DOOR PANELS IN GOOD CONDITION $100 EACH .123 .

.

E38) .42 LIGHTS/REAR DOME LIGHTS/FRONT SUNVISOR LIGHTS/FRONT DOOR LIGHTS RED LED ONLY/TRUNK HATCH LIGHT $50 I HAVE WAY MORE STUFF BUT I WILL UPDATE IT LATER.DRAFT DESIGNS 10 PIECE MK4 LED INTERIOR LIGHTING KIT ALL WHITE LEDS/FRONT DOME LIGHTS/FRONT MAP 124.COM OR PM ME IM LOCATED IN NEW YORK LONG ISLAND M62TU Vanos Procedure (E39. CALL ME/TEXT ME IF INTERESTED 1 516 603 3850 NICK OR EMAIL IS MKIIIEURO98@YAHOO.

but is experiencing compression set (flattening) over time and use and is failing in its function. The Teflon ring has been found to lose significant material due to wear. “No further development will be done”. the correct material. This seating creates a functional oil seal that provides the oil chamber seal the O-ring was intended to achieve. New vanos units are being sold with the same pigment modified Teflon ring. BMW does not provide the vanos rod seal as a separate part. X5 E53 99-03. The rod seal Teflon ring can be replaced with a Teflon ring made from a very low friction Teflon compound but one that has significantly better resistance to wear and deformation. But it is still is very susceptible to wear and deformation. It’s a single vanos. It has been diagnosed that the failure is due to deterioration of the vanos seals. The vanos seals encompass an O-ring at the outer perimeter of the vanos plastic housing and a dynamic rod seal at the inner perimeter of the same plastic housing. Thus replacing the O-ring is appropriate when replacing the Teflon ring. The vanos plastic housing inner perimeter rod seal is made of a Teflon ring and backing O-ring. This vanos has been experiencing a failure. A special high grade Teflon carbon filler is available for such an application. consequential. The vanos discussed here is BMW part # 11-36-1-438-694. 7-series E38 99-01. The vanos plastic housing outer perimeter O-ring is made of Viton.The following information is provided for reference purposes only and should be used at your own risk In no event shall Beisan Systems. To achieve such low friction and low wear properties simultaneously requires special Teflon materials that are not readily available from seals companies. Due to the sealed nature of this vanos the plastic housing outer perimeter O-ring can’t be accessed and replaced. . It’s found in the 5-series E39 99-03. This compression set further reduces the seal material fill in the seal cavity and thus further compounds the Teflon ring material wear failure. Fortunately a method was found to slightly modify the vanos to circumvent the function for this O-ring and thus the need to replace it. or special loss or damages of any kind however caused. A low friction coefficient is necessary for this application due to the low engine oil pressure and the large rotary vanos movement. This engine was incorporated in multiple car models during years 1999-2005. Land Rover 03-05. Range Rover 03-05. The Teflon ring is not a standard part and needs to be semi-custom manufactured. LLC or its members be liable for incidental. BMW has been engaged regarding other vanos failures in the past but has elected to not address the issues. The Teflon ring is made from pigment modified (turquoise) Teflon. This special material is appropriate for this vanos application. This slight variation on virgin Teflon is slightly more resistant to wear and deformation than virgin Teflon. Vanos units take on various shapes and design according to car year and model (engine model). but is experiencing notable compression set (flattening). This filler is used on the i6 vanos OEM Teflon rings and has been used by Beisan for the replacement Teflon rings for the i6 vanos units for some time. the correct material for the application. meaning only the intake valve timing is varied. The vanos top lip is pressed down onto the plastic housing to press the plastic housing down and seat it on a vanos wall shelf. This vanos unit is part of BMW 8-cylinder engine M62TU. This loss of material is causing the Teflon ring to lose its functional characteristics and thus cause the vanos to fail. Introduction “Vanos” is BMW’s name for its variable valve timing units. The rod seal O-ring is made from Viton.

This section attempts to describe the system components and provide a breakdown of the vanos unit parts. Warm idle vanos clatter. www. The Beisan sourced Viton O-rings have been shown over time to have excellent compression set characteristics. The vanos front oil chamber is pressurized with oil and the vanos rear oil chamber is drained of oil. Vanos Components This vanos system (variable valve timing) is made of multiple components. and 4 O-rings for the two engine covers two mounting bolt shafts.com/products. The cold start rattle is the initial indication. The oil distribution piece also mounts over the camshaft and routs the oil paths through the camshaft. Thus the rod seal O-ring is replaced with this Viton material O-ring. The vanos center shaft mounts inside of the camshaft and completes routing the oil paths to their final destination vanos oil chambers. An oil distribution piece is mounted at the engine head front over the oil feed hole and provides oil distribution paths to the vanos front and rear oil chambers and oil drain. Loss of low end torque/power and uneven power delivery. similar to diesel engine. The following pictures show the vanos cut open and disassembled then piecemeal reassembled to show its parts. The kit also includes two O-rings for the secondary air pipe. Further. These extra O-rings are needed during the vanos seals repair and are provided as a value-add to the kit. and is then flowed by the warm idle clatter. The vanos center shaft rotates with the camshaft for timing adjustment while the vanos main body (sprockets) slides on the vanos center shaft during timing adjustment. This vanos has one rod seal comprised of a Teflon ring and O-ring. Symptoms Cold start vanos rattle.Viton material O-rings have variations in characteristics. A vanos press tool is also available from Beisan Systems to press the vanos lip to overcome the need to replace the inaccessible plastic housing outer perimeter O-ring. The solenoid is driven by a PMW (pulse width modulation) signal which modulates the solenoid and valves between the two positions. two O-rings for the two camshaft chain tensioners. A solenoid with valves mounts into the oil distribution piece and onto the oil feed check valve. A vanos seals/O-rings repair kit can be acquired through Beisan Systems (bee-saan). This keeps the vanos oil chambers from leaking when the engine is turned off. the main vanos unit is friction welded as one part with an insert shaft and thus cannot be easily assessed. A check valve is installed into this hole to prevent oil reverse leakage. It includes a vanos replacement set of high grade carbon Teflon rings and Viton O-rings.beisansystems. Oil feed to the system comes through a hole in the engine head front. one for each engine head. The solenoid with valves provides a two position system. or the reverse. Diagnosis The failure symptoms can be relied on for the diagnosis. There are two vanos units per engine. .

Internally it’s a cylinder with polished wall and a center cylinder shaft with helical gears on the outer diameter and polished wall on the inner diameter. Holes in the cylinder shaft provide an oil path to the vanos rear oil chamber. A shelf on the cylinder inner wall provides a stop/seating position for the plastic housing (three pictures below).The vanos incorporates the intake camshaft sprockets. .

The vanos body and piston create an oil chamber at the rear of the piston. A steel ring inserts into the piston outer perimeter groove and acts as a dynamic seal. .A piston with center cylinder shaft with helical gears on the inner and outer diameter inserts onto the vanos center cylinder shaft and mates the helical gears.

and plastic housing create an oil chamber at the front of the piston. . The washer also acts as the piston shaft inner diameter dynamic seal. The vanos body. piston. A washer installs at the piston inner diameter and acts as a bearing surface for the shaft (next pictures) to rotate on.A plastic housing with O-ring and Teflon ring in an inner perimeter groove and a small O-ring in an outer perimeter groove mounts at the front of the vanos.

The cup outer perimeter mates with the plastic housing O-ring and Teflon ring and seals the front oil chamber. .A shaft with cup with helical gears on the cup inner side mounts through the center of the vanos. The cup helical gears mate with the piston outer helical gears.

Tools. Oil passages flow through the camshaft to the vanos center shaft to the vanos two oil chambers. . and vanos press tool. extra Teflon ring. and Shop Supplies Parts with part number pattern xx-xx-x-xxx-xxx are BMW parts and can be acquired from a BMW dealership. Repair Procedure Parts. This is needed for the timing adjustment. The shaft mounts the vanos onto the intake camshaft while allowing the shaft and camshaft to rotate independently of the vanos. Beisan Systems only provides the vanos seals repair kit. pick tools.The shaft protrudes through the rear of the vanos and mounts inside of the camshaft.

com) If first time install. 2 x camshaft chain tensioner O-ring.M62TU vanos seals repair kit (BS051) $60/each (www.beisansystems.com). . Thus only one seals kit is needed.com) Note: Seals kit has seals for both vanos units. it is recommended to also acquire M62TU Vanos Extra Teflon Ring (BS052) $20/each (www. Note: If extra Teflon ring is not used it can be returned for a full refund within 60 days of purchase. M62TU pick tool kit (BS096) $5/each (www. 2 x secondary air pipe end O-ring.beisansystems.beisansystems. Note: Seals kit incorporates 4 x engine top cover bolt shaft O-ring.

.com) Note: This tool is included in Bimmer Tool Rental M62TU timing tool kit referenced below.beisansystems.M62TU vanos press tool (BS097) $40/each (www.

36/each 2 x solenoid gasket (11-14-1-435-023) $8.70/each Crankshaft chain tensioner (11-31-7-531-813) $79.98/each 2 x engine top cover gasket (11-12-1-733-969) $13.25/each Bank 1 upper timing cover gasket (11-14-1-741-532) $10.52/each.35/each.36/each. 2 x solenoid check valve (11-12-1-706-921) $16. bank 2 upper timing cover gasket (11-14-1-741533) $10.38/each (not shown) Crankshaft tensioner rubber grommet (11-14-1-736-758) $2.38/each 6 x valve cover front bolt grommet (11-12-1-721-879) $1. 16 x valve cover side bolt grommet (11-12-1-437395) $0.46/each. crankshaft chain tensioner washer (07-11-9963-355) $0.52/each 4 x camshaft chain tensioner guide (11-31-1-435-028) $5. bank 2 valve cover gasket set (11-12-0-034-105) $40.09/each . 6 x camshaft seal ring (11-31-1-705-512) $5.38/each.98/each Bank 1 vanos distribution piece gasket (11-36-1-705-578) $8. bank 2 vanos distribution piece gasket (11-361-705-579) $8.43/each.Bank 1 valve cover gasket set (11-12-0-034-104) $40.03/each. coolant drain bolt washer (07-11-9-963-225) $0.56/each.

This design change is found starting model year 00 cars (production 09/99). Note: Even if old design non-coated distribution pieces are found not scored they should still be replaced with new coated design.72/each Note: Initial production distribution piece can experience scoring from camshaft seal rings.Model year 99 Bank 1 vanos distribution piece (11-36-1-433-660) $57. bank 2 vanos distribution piece (11-36-1-433-664) $57.72/each. Model year 99 cars need to replace distribution pieces to incorporate new design distribution pieces. A design change was made to coat distribution piece with Teflon. .

magnet pickup 27mm socket 1/2”. An effective solution is to lengthen a 1. 125 Nm [92 ft-lb]). 90 degree pick tool. 13mm socket 3/8”. 3/8” long-arm ratchet. 19mm socket 1/2”. 10mm ratcheting wrench. E-10 torx socket 3/8”. 1/4” long-arm ratchet. putty-knife (medium). 3/8” breaker bar (2ft). 10mm socket 3/8”. 1/4” ratchet. Using 1/2" breaker bar with 3/8” to 1/2” socket adapter creates excess play and allows T55 torx bit to tilt. 1/2” long-arm ratchet. 1 small). 3/8” socket extension (short. medium). 1/2" breaker bar (2ft) 1/2” socket extension (short). tack lifter. razor knife. 5 flathead screwdrivers (1 wide head short. 1/2" torque wrench (25 Nm [18. 10mm deep socket 3/8”. 11mm socket 3/8”. 142 Nm [105 ft-lb]) Note: Torque wrenches must be capable of left hand thread Note: A minimum 2 ft 3/8” breaker bar is needed to remove vanos and exhaust sprocket bolts. pliers (medium). 1 stubby.5 ft 3/8” breaker bar. Insert pipe ~1/2 length onto breaker bar and tape onto breaker bar with duct tape (picture). 6mm hex bit socket 3/8” 10mm socket 1/4”. T55 torx bit socket 3/8”.Gasket scraper.005”) (not shown) Strait pick tool. T30 torx bit socket 1/4” 1/2” ratchet. thin feeler gauge (ex . 24mm socket 1/2”. 3/8” ratchet. mirror (small). 2 medium. 6mm socket 1/4”. hard hammer (plastic). 1/4” socket extension (medium) 3/8” torque wrench (8 Nm [6 ft-lb]. . 8mm socket 1/4”. diagonal cutters (medium) 27mm combo wrench. Philips screwdriver (medium) .5 ft-lb]. A 1 ft x 1" diameter gas pipe works well for this application. 3/8” to 1/2” socket adapter 19mm deep socket 3/8”.

. Return shipping/insurance is responsibility or renter ($16 USPS Priority medium flat rate). block and spindle (11-7-380. Rental is $75 for 30 days. 11-2-445) Bank 2 intake and exhaust camshaft locking blocks (11-2-442. $16 USPS Priority medium flat rate shipping/insurance. and refundable deposit of $350. This tool rental also includes the Beisan BS097 M62TU vanos press tool. 11-4-230) Solenoid socket (11-6-420 ) Vanos turning tool (11-6-440) The above M62TU timing tool kit can be rented in the US from Bimmer Tool Rental. www.com. strait and 90 degree (11-2-300.BMW M62TU timing tools: Bank 1 intake and exhaust camshaft locking blocks (11-2-441.bimmertoolrental. 11-5-180) 2 x Camshaft chain tensioner locking clip (11-3-310) Crankshaft chain tensioning tool. Late returns will receive an automatic rental renewal for an extra 30 days with $75 deduction from deposit. 11-2-446) Bank 1 & 2 timing wheel positioning tool (11-6-451. 11-6-452) Crankshaft locking pin.

Check the “in titles & description” check box. El Paso Tool store . BMW water pump pulley holder (11-5-050) $20/each Handheld sledge hammer (3lb) A Baum Tools water pump pulley holder or holder and 32mm wrench combo can be purchased from El Paso Tool store.V8 mechanical fan removal tools 32mm combo wrench. Go to El Paso Tool store and perform a “Store search” for “115050”.

flashlight. brake cleaner. 1 gallon distilled water. spray lubricant. coolant receptacle 1 gallon BMW coolant. assembly oil (lubricant oil) 2 x parts plate. small hose clamp Not shown: 3 small cloth towels. gasket sealant. Grease (synthetic graphite).Paper towels. 10mm thread diameter bolt. digital multimeter & alligator clip wires. water based cleaner (simple green 1:10). 3 ft bungee cord. water cup. 1 empty gallon container for mixing (old BMW coolant container) .

Removal of engine air intake Engine air intake removal Removal of fan & shroud Fan & shroud removal Removal of cabin filter housing E39 cabin filter housing removal Removal of valve covers Disconnect battery negative cable. Right and Left denotations are from car front at hood orientation.Repair Car engine must be cold to perform repair procedure. and cylinders 5-8 are on bank 2 front to rear. Cylinders 1-4 are on bank 1 front to rear. It cannot be opened using electronic latch. Open rear trunk lid. If trunk lid closed. Loosen battery negative cable mounting nut (10 mm socket 3/8” / 3/8" ratchet & extension). key is needed to . Caution: Do not fully close trunk lid. Remove negative cable clamp from battery negative post and set to side. Engine bank 1 head is on left and engine bank 2 head is on right. Open right fender cabin door (at trunk orientation).

mechanically open trunk lid. Note: Battery negative cable removal is necessary for removal of battery positive cable at engine bank 2 valve cover in subsequent step. . For each cover perform following. Remove bank 1 & 2 top cover. Pry off and remove 2 center caps (flathead).

magnet pickup).Remove 2 cover mounting bolts (10mm socket 3/8” / 3/8” ratchet & extension. Disconnect bank 1 & 2 ignition coils electrical cable connectors. For each set of coils perform following. . Note: Bolt shaft can remain in cover. Remove engine cover. For each coil. pull up on coil connector metal lock and pull off cable electrical connector.

. magnet pickup). Note: Maintain coil/cylinder association for reinstallation. Remove 2 mounting nuts at each coil (10mm socket 3/8” / 3/8” ratchet & extension. This is not necessary. Remove from coil studs. For each set of coils perform following.Remove bank 1 & 2 ignition coils. ground wires at coils 2 & 7 and ground straps at coils 3 & 6. but is good practice. Pull up and remove all coils.

For each O2 sensor perform following. For each camshaft position sensor perform following.Disconnect bank 1 & 2 O2 sensor cable connector. Disconnect secondary air control solenoid electrical connector at top left center of intake manifold. Disconnect bank 1 & 2 camshaft position sensor cable connector. Pull off O2 sensor electrical cable connector from top center of electrical housing (black box). Press in connector wire clip and pull off connector. Press in wire clip and pull off connector from top front of electrical housing (black box). .

Remove mounting nut from top front and rear electrical housing studs (10mm deep socket 3/8” / 3/8” ratchet & extension. magnet pickup). Remove secondary air solenoid mounting bracket from bank 1 electrical housing front stud. Remove vacuum accumulator mounting bracket from bank 2 electrical housing front stud. For each electrical housing perform following.Remove bank 1 & 2 electrical housing mounting nuts. .

Pull up on bank 1 & 2 electrical housings and tie together to keep up and off valve covers (bungee cord). For each set of fuel injectors perform following. From front to rear injector consecutively pry out injector connector wire clip (strait pick) and pull up on electrical housing to dislodge connector.Remove bank 1 & 2 fuel injector electrical connectors. .

Caution: Battery negative cable must first be disconnected from battery in trunk. . This was first step in procedure. Remove battery positive cable mounting nut at bank 2 valve cover cable box (19mm socket 1/2" / 1/2" ratchet). Remove battery positive cable from cable box and valve cover and set to side (see second picture below).

For each valve cover perform following. 3 at front and 4 at each side (10mm socket 3/8” / 3/8” ratchet & extension and 10mm socket 1/4” / 1/4” long-arm ratchet.Remove bank 1 & 2 valve cover mounting bolts. Loosen bolts evenly in multiple passes. flathead). . Note: Front 3 bolts are different from 8 side bolts. Remove 11 valve cover mounting bolts w/ washers & grommets.

Valve cover perimeter gasket will stick at rear half-moons due to gasket sealant. Note: If gasket is stuck to engine head. Pull up and remove valve cover. This facilitates gasket removal without breaking plasticized brittle gaskets into pieces. Pull up on gasket to release. . If resistant. Insert blade (putty-knife) between valve cover gasket and engine head at all front end accessible locations to break gasket bond. double check valve cover 11 mounting bolts have been removed. pull up on free front end of cover to break gasket bond on remainder of valve cover. Remove valve cover sparkplug well gasket from engine head. If valve cover is stuck. Note: Sparkplug well gasket could have maintained with valve cover.Remove bank 1 & 2 valve cover. Maintain valve cover perimeter gasket with cover. insert blade (putty-knife) between valve cover gasket and engine head at sticking locations. Note: If valve cover cannot be removed. For each valve cover perform following. attempt inserting blade between gasket and head from an edge (putty-knife).

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 bank 1 & 2 camshaft oil rails. Locking crankshaft . Note: Oil rails are symmetrical front to rear and top to bottom. Thus maintaining oil rail orientation is not necessary. Remove oil rails. magnet pickup).

If car has manual transmission. then place transmission in neutral. Note: Turning crankshaft counter clockwise is acceptable. If manual transmission. place transmission in neutral. . Turn crankshaft pulley clockwise until cylinder 1 (bank 1) intake and exhaust cams point to each other at ~45 degree angle (27mm socket 1/2” / 1/2” long-arm ratchet & short extension).

Thus reference exhaust cam for 45 degree positioning. chock both sides of both rear wheels). . Inspect TDC (top dead center) timing marks on engine timing cover and crankshaft harmonic balancer at ~11 o’clock position (mirror).Note: Intake camshaft will be rotated further clockwise due to vanos advancement. Note: Angle of view changes alignment position. A tilted view to ~11 o’clock position provides correct alignment view. Raise front of car and place on jack stands (follow appropriate procedure. but M62TU marks will be very similar. Note: Picture is not of M62TU engine. Adjust crankshaft pulley to align TDC timing marks (27mm socket 1/2” / 1/2” long-arm ratchet & short extension).

Remove large engine compartment shield underneath front of car. Turn 3 mounting bolts at each side 1/2 turn to release lock (Philips).

Locate crankshaft lock hole and inspection hole at bottom rear of engine.

Pull off inspection hole cap if present. Insert crankshaft lock pin into crankshaft lock hole. Pin will not likely fully insert.

Inspect position of lock pin and flywheel / drive plate lock hole through inspection hole (mirror & flashlight). Adjust crankshaft rotation position to perfectly align lock pin and lock hole (27mm socket 1/2” / 1/2” long-arm ratchet & short extension). Fully insert lock pin.

Draining coolant

Drain coolant from engine block.

Remove engine left side (front orientation) coolant drain bolt (13mm socket 3/8” / 3/8” ratchet). Note: Drain bolt located on engine block between cyl 2 & 3. Catch draining coolant in receptacle (coolant receptacle). Remove and discard 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.

If radiator drain plug is present at radiator bottom right, drain radiator coolant form drain hole. Turn radiator drain plug 1/4 turn and pull off from radiator. Catch draining coolant in receptacle (coolant receptacle).

If radiator drain plug is not present at radiator bottom right, drain radiator coolant form radiator lower hose connector. 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.

Rotate and lower coolant expansion tank down and let hang from hose. Place expansion tank overflow hose in receptacle to catch draining coolant.

Remove expansion tank cap to drain coolant form expansion tank. Catch coolant in receptacle. Reinstall expansion tank cap once expansion tank is emptied.

Install engine left side coolant drain bolt. Install new crush washer on drain bolt. Install 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).

Bring up expansion tank and overflow hose and lay expansion tank lower hose on AC compressor pulley. Maintain expansion tank overflow hose high to prevent loss of coolant.

Install large engine compartment shield underneath front of car. Removal of engine front components . Turn 3 mounting bolts at each side 1/2 turn clockwise to install (Philips). Lower car from jack stands (follow appropriate procedure). Align and insert side bolts into bolt holes. Insert shield front inside front bumper.

Remove radiator upper hose from thermostat.Remove radiator upper hose from radiator. Pull out hose locking wire clip (small flathead). . Wiggle and pull hose connector off radiator. Pull out hose locking wire clip (small flathead). Wiggle and pull hose connector off thermostat.

Pull out hose locking wire clip (small flathead). Remove radiator lower hose from thermostat. . Remove radiator upper hose from engine compartment. Wiggle and pull hose connector off alternator.Remove radiator upper hose from alternator.

Wiggle and pull hose connector off radiator. Wiggle and pull hose connector off thermostat.Pull out hose locking wire clip (small flathead). . remove radiator lower hose from radiator. If not previously performed. Pull out hose locking wire clip (small flathead). Remove radiator lower hose from engine compartment. Press in connector locking wire clip and pull off connector. Remove temperature sensor cable connector.

Pull off vacuum hose.Remove secondary air blower hose and secondary air vacuum control hose from secondary air exhaust valve. Press in blower hose circular locking clip at top and bottom and pull off hose. Note: Reposition expansion tank as necessary. . Place blower hose to side. Remove secondary air pipe left end mounting bolt (10mm socket 3/8” / 3/8” ratchet & medium extension).

Remove secondary air pipe right end mounting bolt (10mm socket 3/8” / 3/8” ratchet & medium extension). Remove secondary air pipe center mounting bolt (T30 torx bit socket 1/4” / 1/4” ratchet & extension). .

Allow purge valve to lower and suspend from hoses. 7 series .Pull secondary air pipe right and left ends out of engine and remove pipe from engine compartment. 5 series Remove fuel purge valve bracket mounting bolt (10mm socket 3/8” / 3/8” ratchet & extension).

.Remove hose/cable bracket mounting bolt just to left of bank 2 solenoid (10mm socket 3/8” / 3/8” ratchet & extension). Remove hose bracket mounting bolt at middle bank 2 upper timing cover (10mm socket 3/8” / 3/8” ratchet & extension).

Removal of crankshaft chain tensioner . Move fuel purge hose and alternator electrical cable down and away from bank 2 upper timing cover. Remove oil dip stick pipe clamp mounting bolt (10mm socket 3/8” / 3/8” ratchet & extension).Remove hose bracket mounting bolt at oil filter housing (10mm socket 3/8” / 3/8” ratchet & extension).

Place towel under tensioner to catch draining oil (towels).Remove crankshaft chain tensioner from engine lower left side (19mm deep socket 3/8” / 3/8” long-arm ratchet). Removal of vanos solenoids . Discard tensioner crush washer.

Remove bank 1 & 2 vanos solenoid electrical cable connector. For each solenoid perform following. Press in electrical cable connector wire clip and pull off connector. .

Remove bank 1 & 2 vanos solenoid gasket mounting bolts. . Remove gasket top and bottom mounting bolt (10mm socket 3/8” / 3/8” ratchet & extension). For each solenoid perform following.

Remove gasket by pulling out alternatingly at gasket top and bottom from bolt mount hole (90 degree pick tool). . For each solenoid perform following. Pry gasket at top sides to initially move gasket and break gasket seize (flathead).Remove bank 1 & 2 vanos solenoid gasket.

. Note: Do not remove solenoid.Loosen bank 1 & 2 vanos solenoid. For each solenoid perform following. Loosen (break seize) solenoid (32mm special deep socket 1/2” / 1/2” long-arm ratchet).

For each solenoid perform following. towels). Removal of upper timing covers .Remove bank 1 & 2 vanos solenoid. Place towel under solenoid to catch draining oil and unscrew and pull out solenoid (hands.

Remove cover 3 left and 3 right mounting bolts (10mm socket 3/8” / 3/8” ratchet & extension). . For each timing cover perform following. Bank 2 lower left mounting bolt requires a low profile tool for access (10mm ratcheting wrench). Loosen bolts evenly in multiple passes. Note: Bank 2 lower left mounting bolt cannot be removed due to access restriction and needs to be removed with cover.Remove bank 1 & 2 upper timing cover mounting bolts.

Pull forward on timing cover to break all cover gasket bond. . Note: If timing cover cannot be moved. Pull forward on timing cover while inserting blade to facilitate further insertion on blade. For each timing cover perform following. Insert blade (putty-knife) between timing cover gasket and engine head at cover top corner to break gasket bond.Break bond of bank 1 & 2 upper timing cover gasket. double check cover 6 mounting bolts have been removed.

Note: Camshaft position sensor remains mounted on timing cover and is removed with cover. Note: Sealant bond at top and bottom rear of cover will be broken.Remove bank 1 & 2 upper timing cover. . For each timing cover perform following. Pull forward and up on timing cover to remove. Remove gasket with cover.

Bank 1 & 2 with removed upper timing covers. Locking of camshafts .

.

Install bank 1 & 2 camshaft locking blocks. Note: If locking blocks are marked in German. . Place locking block set on intake and exhaust camshaft rear square ends. E is intake and A is exhaust. Loosen and retighten locking blocks matting bolt as needed to facilitate block mounting (6mm hex bit socket 3/8” / 3/8” ratchet). Adjust each camshaft position as needed to align for locking block insertion (27mm open wrench). Note: Each camshaft incorporates a hex to facilitate camshaft rotation. For each camshaft set perform following.

Removal of vanos units During following component removal. This is due to valve spring load and vanos timing advance. Rock each camshaft slightly back and forth while pressing down and forward on locking block to fully seat and align block on head surface. This is not necessary but is good practice. . Verify camshaft rear squares inserted into locking blocks rear narrow slot. maintain component to engine head association.Note: Bank 1 intake camshaft will need to be rotated counter clockwise opposing a valve spring to properly position for locking block. Thus camshaft rear squares will not fully seat to rear of blocks’ rear slot. Note: Camshafts ends extend to rear of camshaft rear squares.

For each timing wheel perform following. Note: Intake camshaft is counter held by locking block. thus unscrew by turning breaker bar from left to right (clockwise) (car front orientation). Counter hold intake camshaft and loosen timing wheel mounting nut. Remove timing wheel and mounting nut. left hand thread (24mm socket 1/2" / 1/2" breaker bar. Further counter hold camshaft at camshaft hex (27mm open wrench). Note: Nut is left hand thread. .Remove bank 1 & 2 intake camshaft timing wheel. 27mm open wrench). But do not rely on this alone as camshaft can be damaged.

Counter hold intake camshaft and loosen vanos mounting bolt. 27mm open wrench). left hand thread (T55 torx bit socket 3/8" / 3/8" breaker bar. Note: Intake camshaft is counter held by locking block. Note: Bolt is left hand thread. thus unscrew by turning breaker bar from left to right (clockwise) (car front orientation). But do not rely on this alone as camshaft can be damaged. Further counter hold camshaft at camshaft hex (27mm open wrench). .Loosen bank 1 & 2 vanos mounting bolt. For each vanos perform following.

Note: Verify tool inserts fully into vanos bolt head (T55 torx bit 3/8”). Loosen bank 1 & 2 exhaust sprocket mounting bolt. Do not remove vanos mounting bolt at this time. left hand thread (T55 torx bit socket 3/8" / 3/8" breaker bar. Note: Bolt is left hand thread. 27mm open wrench). For each exhaust sprocket perform following. thus unscrew by turning breaker bar from left to right (clockwise) (car front . Counter hold exhaust camshaft and loosen exhaust sprocket mounting bolt.

Do not remove exhaust sprocket mounting bolt at this time. But do not rely on this alone as camshaft can be damaged. For each camshaft chain tensioner perform following. Further counter hold camshaft at camshaft hex (27mm open wrench). Note: Verify tool inserts fully into sprocket bolt head (T55 torx bit 3/8”).orientation). . Lock bank 1 & 2 camshaft chain tensioner. Note: Exhaust camshaft is counter held by locking block.

Compress chain tensioner and fully insert locking clip into locking holes. remove clip and press in locking clip pins to make parallel. then reattempt insertion. Note: Bank 1 chain tensioner is compressed from below tensioner and bank 2 chain tensioner is compressed from above tensioner. Remove bank 1 & 2 vanos and exhaust sprocket mounting bolts. For each vanos and exhaust sprocket perform . Note: If locking clip not fully inserting.

. Do not remove vanos and exhaust sprocket at this time.following. Unscrew and remove vanos and exhaust sprocket mounting bolts. left hand thread (hand).

.Remove bank 1 & 2 exhaust sprocket and camshaft chain. Reinstall vanos onto intake camshaft. For each exhaust sprocket and camshaft chain perform following. Pull vanos and exhaust sprocket forward and off camshafts. Remove exhaust sprocket and camshaft timing chain. Move exhaust sprocket closer to vanos to loosen camshaft chain and remove chain from vanos rear sprocket.

Remove crankshaft chain from vanos sprocket.Remove bank 1 & 2 vanos. Caution: Do not remove vanos center shaft from vanos body. Maneuver crankshaft chain past distribution piece and lay down to side of engine. . Shaft is balanced to vanos body and must be marked before removal. For each vanos perform following. Pull vanos forward and off intake camshaft. Remove vanos.

For each chain slot perform following.Cover up bank 1 & 2 crankshaft chain access slot. Lay towel over chain slot (towels). Note: Towel will prevent components from dropping in chain slot during following repair steps. Removal of vanos components .

is longer and has washer. . Loosen then remove distribution piece 5 mounting bolts (E-10 torx socket 3/8” / 3/8” ratchet & extension). Note: Lower mounting bolt. just below solenoid hole. For each vanos oil distribution piece perform following.Remove bank 1 & 2 vanos oil distribution piece mounting bolts.

. hard hammer). Note: Distribution piece can be stuck on camshaft due to camshaft seal ring scoring on distribution piece cylinder. For each vanos oil distribution piece perform following. If distribution piece resistant. Pull oil distribution piece from engine head. pry distribution piece off head while hitting distribution piece cylinder (wide flathead.Remove bank 1 & 2 vanos oil distribution piece. This can be seen once distribution piece is removed.

Remove bank 1 & 2 vanos oil distribution piece gasket. For each vanos oil distribution piece gasket perform following. . Pull off and remove oil distribution piece gasket. Discard distribution piece gasket.

Remove bank 1 & 2 intake camshaft seal rings. Press down one seal ring end and pull up other seal ring end and disconnect end locking hooks. Perform following for each seal ring. Pry off and remove 3 seal rings from camshaft from front to rear order. For each intake camshaft perform following. . Push in and up on seal ring from sides to push up seal ring ends out of camshaft seal grove. Pry apart seal ring ends and pull seal ring off camshaft moving each side forward in alternating increments. Rotate seal ring to position locking ends at top of camshaft. Remove and discard seal ring.

. but more standard 10mm 1. Pull off check valve from head (10mm thread diameter bolt). Unscrew installation tool from check valve and discard check valve. Screw removal tool into check valve (10mm thread diameter bolt). Note: Check valve is mounted in head by check valve O-ring. This is sufficient to mount and remove check valve. Note: Check valve thread pitch is 1. For each check valve perform following.Remove bank 1 & 2 vanos solenoid oil check valve.25 pitch bolt will thread some into check valve.0.

Remove 2 top mounting nuts (11mm socket 3/8” / 3/8” ratchet & extension).Removal of camshaft chain tensioners Remove bank 1 & 2 camshaft chain tensioner mounting nuts. For each chain tensioner perform following. .

.

. Pull up chain tensioner and insert pry tool under tensioner edge (putty knife). For each chain tensioner perform following. Prey up on tensioner to release tensioner mount (putty knife). Pull up and remove chain tensioner. Note: Tensioner mounted to engine head by O-ring.Remove bank 1 & 2 camshaft chain tensioner.

Bank 1 chain tensioner rebuild is very similar.Rebuilding of camshaft tensioners Perform following for each camshaft chain tensioner. . Compress chain tensioner and pull out locking clip. Following rebuild is of bank 2 camshaft chain tensioner.

Press guide on until it locks into place. .Pull off chain tensioner guide from tensioner base. Slide new chain tensioner guide on tensioner base.

If chain guide difficult to remove. . If necessary.Remove chain tensioner piston from tensioner. pry open guide bracket tabs (flathead). pull hard to remove piston.

Press guide on until it locks into place. . Slide new chain tensioner guide on tensioner piston.Pull off chain tensioner guide from tensioner piston.

Remove old O-ring from tensioner. . Note: Rocking of blade while pressing helps create cutting motion. Cut cross section of O-ring in groove (razor knife).Insert chain tensioner piston in tensioner.

Compress chain tensioner and fully insert locking clip into locking holes. Lightly lubricate O-ring to ease tensioner installation (assembly oil). Place O-ring in groove on one end and stretch and drop O-ring opposite end in groove. remove clip and press in locking clip pins to make parallel. Note: If locking clip not fully inserting. . then reattempt insertion.Install new O-ring on tensioner.

Thus vanos shaft must be marked to vanos body before removal to facilitate reinsertion in same position. Marking of vanos shaft to vanos body Vanos center shaft is balanced to vanos body. Note: Hold in vanos center shaft while cleaning to prevent from falling out of vanos.Replacement of vanos seals Perform following for each vanos. . Clean vanos surfaces (brake cleaner & towels).

Note: Vanos piston has to be in a fixed position that can be replicated for shaft reinsertion. Note: Do not use vanos plastic housing or plastic housing pins for reference as these can move. Mark vanos shaft and body to document rotational orientation of shaft to vanos body (magic marker). Note: It is helpful for reference to place marks along one of shaft top holes (picture).Rotate vanos center shaft fully clockwise to insert internal piston in vanos body. .

Note vanos piston is fully inserted in vanos. Shaft will need to rotate slightly clockwise to facilitate removal. Removal of vanos seals Following vanos seals removal and installation is best performed at table while sitting.Lift up and remove vanos center shaft from vanos body. . This was performed above by rotating vanos shaft clockwise.

If large washer in vanos piston center skip next step. pry washer and remove from shaft (combination pick). .If large washer is on vanos shaft.

press washer into vanos piston center (fingers).If washer was on shaft and removed. .

Note: Piston outer helical (slanted) gears end half way down piston and piston diameter decreases at piston lower half. Vanos can also be turned upside down and jerked to move piston out of vanos (hands).Pull up vanos piston by prying at washer inside bottom (combination pick). This decreased diameter facilitates space needed to access vanos seals in upper plastic housing. Thus pulling piston up allows positioning piston smaller diameter at plastic housing seals cavity and allowing for seals access and removal. During following seals removal. . hold piston in top most position by holding up at center washer (finger).

Fully remove Teflon ring from vanos (combination pick. release and attempt prying less of seal to only engage Teflon ring.Pry vanos seal Teflon ring from vanos plastic housing seal cavity (combination pick). . then fingers). Pull Teflon ring out and past piston and plastic housing (combination pick). Note: If O-ring is also engaged.

Fully remove O-ring from vanos (combination pick. then fingers). . Note: This will take some force.Pry vanos seal O-ring from vanos plastic housing seal cavity (combination pick). Pull O-ring out and past piston and plastic housing (combination pick).

Note O-ring flat side and flat inner diameter.Removed vanos seals. Note Teflon ring thin cross section. Note: Piston outer helical (slanted) gears end half way down piston and piston diameter decreases at piston lower . hold piston in top most position by holding up at center washer (finger). Installation of vanos seals During following seals installation.

In following step seal O-ring will be inserted into plastic housing seal cavity. Above two pictures show empty seal cavity and then seal O-ring installed in seal cavity.half. . Thus pulling piston up allows positioning piston smaller diameter at plastic housing seal cavity and allowing for access to seal cavity and seals installation. This decreased diameter facilitates space needed to insert new vanos seals into upper plastic housing.

Note: Above pictures are taken with vanos piston removed to allow for direct view. . Place vanos seal O-ring around vanos piston. Press down on O-ring incrementally along its circumference to press O-ring past piston helical gears and into vanos (90 degree pick) (picture). This cannot be performed without cutting vanos open. Insert O-ring into vanos.

Pull inserted O-ring up (combination pick) and press exposed O-ring into vanos to insert inserted O-ring into plastic housing seal cavity. Insert all inserted O-ring into seal cavity. Start O-ring insertion into seal cavity at center point of inserted O-ring. .Note: O-ring will drop below plastic housing seal cavity. Continue Inserting O-ring until it has been inserted ~3/4 along piston circumference (picture).

Insert exposed O-ring into vanos starting from one side (90 degree pick) while pressing on exposed O-ring to assure inserted O-ring enters seal cavity. .

< 70F (21C). soak Teflon ring in warm water for 2+ minutes.Insert last section of exposed O-ring into vanos and it will enter into seal cavity (90 degree pick). Remove and dry Teflon ring just before installation. Check no O-ring part is seen along piston and thus all O-ring is in seal cavity. . If seal Teflon ring in cold environment.

Place vanos seal Teflon ring around vanos piston. Insert Teflon ring into vanos at one end. .

Above pictures show two techniques needed to assure correct insertion. Teflon ring insertion and seating over O-ring in seal cavity can be verified by checking for space between Teflon ring . pull up on inserted section at center point and insert into seal cavity and seat over O-ring (combination pick). Note: Teflon ring will need to be bent some at transition point from exposed to inserted section to accomplish insertion into seal cavity.In following step seal Teflon ring will be inserted into plastic housing seal cavity. While inserting Teflon ring into vanos.

Note: Above pictures are taken with vanos piston removed to allow for direct view. This cannot be performed without cutting vanos open. Last picture above shows Teflon ring seated correctly over O-ring and no space found between Teflon ring top and seal cavity top. . Note: Second picture above shows Teflon ring not seated correctly over O-ring and space found between Teflon ring top and seal cavity top. There should be no space between Teflon ring top and seal cavity top.top and seal cavity top. (combination pick) (pictures).

There should be no space between Teflon ring top and seal cavity top. Note: Teflon ring will need to be bent some at transition point from exposed to inserted section to accomplish insertion into seal cavity. Insert all inserted Teflon ring into seal cavity while pressing incrementally on exposed Teflon ring. . pull up on inserted section at center point and insert into seal cavity and seat over O-ring (combination pick). Caution: Correct Teflon ring insertion and seating in seal cavity is critical to success of Teflon ring installation. Press in exposed Teflon ring until it notably bends at sides. Verify Teflon ring insertion and seating in seal cavity by checking for space between Teflon ring top and seal cavity top (combination pick). There should be no space between Teflon ring top and seal cavity top. If this step is performed incorrectly Teflon ring can be damaged in next step. This Teflon ring deformation is needed to keep Teflon ring from popping back out of vanos. Repeat Teflon ring insertion as needed to assure Teflon ring insertion and seating in seal cavity.While inserting Teflon ring into vanos. Verify Teflon ring insertion and seating in seal cavity by checking for space between Teflon ring top and seal cavity top (combination pick).

then inserted Teflon ring is not inserted and seated in seal cavity and procedure should be repeated. Note: If exposed Teflon ring cannot be easily inserted to inside of plastic housing. . Teflon ring will deform in process and multiple waves will develop in Teflon ring shape.Press in and down on exposed Teflon ring at different locations (90 degree pick) to insert exposed Teflon ring to inside of plastic housing (picture).

it can be mostly rectified by mounting it on vanos shaft sealing surface at cup rim (picture). Note: Damaged sides of Teflon ring are of no significance to Teflon ring function.If Teflon ring is damaged due to wrong insertion. . Heating Teflon ring (heat gun or hair dryer) and pressing in (90 degree pick) at center of damaged Teflon ring can further rectify damage.

This allows a progression of Teflon ring seating on O-ring in seal cavity. Last Inserted section of Teflon ring will have waves and wrinkled form.Press exposed Teflon ring in and down (90 degree pick). Last section of exposed Teflon ring will insert in one piece. Perform Teflon ring insertion from sides of unseated Teflon ring. This allows Teflon ring bottom edge to go past O-ring and for Teflon ring to seat on O-ring in seal cavity. .

begin to smooth Teflon ring by pressing along wrinkled section from end to end (90 degree pick). Preform pressing at multiple locations multiple times. Moderate force is needed at end of smoothing process for effective results. Continue to press along Teflon ring wrinkled section until much of wrinkles are smoothed. Once Teflon ring waves dampen. .Press protruding Teflon ring waves into seal cavity to stretch Teflon ring and return to original shape (90 degree pick).

Press vanos piston fully into vanos. Check that all Teflon ring is inserted in seal cavity (90 degree pick). Apply lubricant generously along top of Teflon ring (assembly oil). This will occur once Teflon ring is exposed to engine temperature and vanos is exercised. .Note: It is not necessary to fully smooth Teflon ring surface.

Turn vanos upside down on table. Adjust shaft as needed to facilitate helical gear matting.Insert vanos shaft into vanos. Insert shaft until resistance is met (picture). .

Resistance will be encountered. Note full insertion of vanos shaft into vanos (picture). then reattempt shaft insertion.Press strait down on vanos body to fully insert vanos shaft into vanos (hands/arms). Turn vanos right side up. . If shaft is resistant to insertion. remove shaft and repeat Teflon ring smoothing and oiling.

Rotate vanos shaft in vanos to check normal movement of vanos. Shaft will be difficult to rotate. Check Teflon ring is in seal cavity (90 degree pick). Pressing of vanos lip . Remove vanos shaft from vanos by pressing out from rear of vanos. This will ease as Teflon ring polishes and O-ring compresses during normal operation.

During following procedure vanos lip will be pressed down onto vanos plastic housing to fully seat plastic housing bottom onto vanos wall shelf below plastic housing. which is not practical. If present. Seating of plastic housing creates functional oil seal between plastic housing and shelf. Press vanos piston fully into vanos. washer should be fully pressed onto vanos and should not protrude past piston. This seal circumvents function of plastic housing failing outer O-ring and thus need to replace it. . clean oil sludge from vanos plastic housing (brake cleaner & towels). Vanos center washer can be present or removed from vanos during following procedure. As needed clean press tool and remove previous alignment marks from press bolt and press washer (brake cleaner & towels). If present.

A wall initial 2mm barrel chamfer allows initial alignment and seating of press cap on vanos. It is useful to understand press cap inner side design which facilitates this press function. Plastic housing will seat on vanos wall shelf below housing and ~.Press down plastic housing into vanos at multiple locations (medium flathead). In following steps press tool press cap will be pressed onto vanos lip to press lip down onto plastic housing. . A press cap wall functions to support vanos wall top to keep it from collapsing to outside when lip is pressed.9mm space will be present between vanos lip and plastic housing (picture).

Holes cannot be aligned further out as press shelf at pins would be removed. Three holes in press cap allow vanos test pins to insert into holes and avoid being pressed down. Only inner edge of vanos lip is pressed. An inner indentation prevents press cap from pressing against vanos center piston.Indentation of press cap along perimeter allows space for vanos wall to insert into indentation and not be pressed. Holes outer edge aligns with pins outer edge. Bend vanos three test pins to vanos inboard side by ~2mm at pin top to allow pin insertion into press cap holes and . This allows best leverage and thus easiest press.

Place press cap on top of vanos with a pin hole directly aligned with test pin and remainder of press cap aligned with vanos. .prevent being pressed down. Place vanos with a test pin directly facing you. Rest tool (press bolt head) on vanos lip and press against pin to bend. Orient press cap with flats to side and pin hole without flat facing you.

Tilt press cap as needed to align and insert. . Full insertion and alignment is not necessary. Check and align press cap on vanos so three test pins are inserted and roughly centered in pin holes. install press cap onto vanos. Press press cap down onto vanos wall.With press cap aligned with test pin and vanos.

Rest press cap flat on vise fixed jaw top and press cap against jaw. Install press cap and vanos upside down into vise.Open vise wide enough to insert vanos press cap. . Close vise to allow moving jaw to insert under press cap flat and lay press cap flat on top of jaw.

Center press cap in vise jaws and strongly tighten vise. . Insert press washer into vanos rear hole and rest on vanos.

. Insert press bolt into press washer center hole. Note: Applying grease to bolt is critical for proper function and longevity of press tool.Apply grease to press bolt lower 2/3 threads and head flange bottom (graphite grease).

As bolt fully tightens press cap will fully insert onto vanos and become aligned. Fully tighten bolt (27mm socket 1/2” / 1/2” ratchet).Press down and tighten press bolt to insert into press cap center threaded hole (27mm socket 1/2” / 1/2” ratchet). Marking will be used to reinstall press washer on vanos at same position if second. Mark press washer and vanos to document rotational position of press washer on vanos (magic marker). is necessary. further press. Note: Bolt can be difficult to thread as press cap can be misaligned. .

. Caution: As bolt tightens turn bolt slowly to avoid overshooting torque value. Marking will be used to reinstall press cap on vanos at same position if second. further press. If vise begins to swivel.Mark press cap and vanos to document rotational position of press cap on vanos (magic marker). Tighten press bolt to 142 Nm (105 ft-lb) (27mm socket 1/2” / 1/2” torque wrench). loosen vise swivel and allow vise to rotate to swivel end position. Note: Counter hold vanos at socket (hand). is necessary.

Stop bolt tightening when bolt and washer alignment marks align again. Note: Counter hold vanos at socket (hand). If vise begins to swivel.Clean grease from press bolt base and press washer (brake cleaner & towels). Mark press bolt and press washer at a press bolt hex edge (magic marker). Tighten press bolt a further full turn (27mm socket 1/2” / 1/2” breaker bar). Note: Be sure to mark bolt head top as side mark can be scraped. loosen vise swivel and allow vise to rotate to swivel end position. Precise alignment is not necessary and slight .

Note: Great force is needed to accomplish press. Warning: Once press begins it must be completed. Loosen press bolt (27mm socket 1/2” / 1/2” breaker bar).under and over turning is acceptable. Otherwise if tool is removed it will be difficult to assess how much further press is needed. If vise begins to swivel. thus minimum 24” breaker bar is needed. Note: Counter hold vanos at socket (hand). . loosen vise swivel and allow vise to rotate to swivel end position.

go to next step of removing vanos from vise and hit washer through press cap hole to dislodge (3/8” medium extension).Unthread press bolt and remove press bolt and press washer from vanos (hand). . Loosen vise and remove vanos and press cap from vise. Note: If press washer difficult to remove.

Thread press bolt into press cap form vanos rear (hand). .

Unthread press bolt from press cap and remove press bolt and press cap from vanos. Note: Strong hitting will be needed to remove press cap from vanos. Vanos lip should be pressed against vanos plastic housing. .With vanos right side up. Inspect vanos lip in reference to vanos plastic housing. hold vanos from large sprocket at each side and repeatedly hit press bolt head onto vise anvil until press cap removes from vanos.

Second vanos press .Insert thinnest available feeler gauge to assess any remaining gap between vanos lip and plastic housing. There should be no movement. Turn vanos to its side and attempt to rotate plastic housing from test pin (hand & pliers). There should be none.

If gap is found between vanos lip and plastic housing. or if plastic housing rotates. Please contact Beisan Systems to report this situation and result. If not already present. Tighten press bolt until bolt and press washer marks align. a second further press is necessary. then further tighten bolt by ~10mm (1/3”). Alignment of vanos shaft to vanos body Remove vanos shaft from vanos body. Remove press tool as before and check vanos lip and plastic housing rotation as before. This should fully press vanos lip. Reinstall press tool on vanos as before but use marks to align press cap and press washer to vanos at same rotational position as before. Press vanos piston fully into vanos. install washer in vanos piston center. . Clean press tool and remove alignment marks (brake cleaner & towels).

Vanos shaft alignment mark should roughly align with vanos body alignment mark. remove vanos shaft and reattempt alignment and insertion.Insert vanos shaft in vanos body and orient alignment mark on shaft to left of vanos body alignment mark. Insert vanos shaft fully into vanos body. Turn over vanos and press on table as before to ease installation. . If marks do not align.

inner gasket grooves. Clean timing cover mating surfaces. Cut off valve cover front 3 bolt grommets (diagonal cutters). Clean all mounting bolts. Clean valve cover mating surfaces. 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. better positive cable mounting stud (brake cleaner & towels). Remove valve cover gaskets and top cover gaskets from valve covers. Remove upper timing cover gaskets from upper timing covers. camshaft bearing cap studs. washers (brake cleaner & towels). Clean heads matting surfaces. nuts. sparkplug well. timing cover perimeter. Clean coils ground straps and coil harness ground wire ends (brake cleaner & towels). This will ease as Teflon ring polishes and O-ring compresses during normal operation.Rotate vanos shaft in vanos to check normal movement of vanos. distribution piece (brake cleaner & towels). Remove and discard valve cover bolt grommets. . coil mounting studs. Shaft will be difficult to rotate. Clean battery positive cable mounting end and mounting post on bank 2 valve cover (brake cleaner & towels). bolt access holes. valve cover perimeter. Clean tensioners mating surfaces (brake cleaner & towels). bolt access holes (brake cleaner & towels). Cleaning of parts Note: When cleaning parts. Clean coils mounting hole surfaces. tensioner mount and studs. inner gasket grooves.

14 Nm (10.5 ft-lb) (11mm socket 3/8” / 3/8” torque wrench & extension). . For each chain tensioner perform following. Insert chain tensioner onto mounting studs and press down on tensioner to fully seat. Tighten nuts evenly in multiple passes. Install 2 mounting nuts (11mm socket 3/8” / 3/8” ratchet & extension). Verify one pass with both nuts fully tightened.Installation of camshaft chain tensioners Install bank 1 & 2 camshaft chain tensioner. Fully tighten.

For each head perform following.Installation of vanos components Install bank 1 & 2 vanos solenoid oil check valve. This is sufficient to mount and install check valve. Screw installation tool in new check valve (10mm thread diameter bolt). Fully press check valve into head at bottom of distribution piece gasket outline (10mm thread diameter bolt).0. . but more standard 10mm 1. Note: Check valve thread pitch is 1.25 pitch bolt will partially thread into check valve.

Pry apart new seal ring ends and push seal ring on camshaft moving each side in alternating increments until seal ring is positioned in seal groove. Install bank 1 & 2 intake camshaft seal rings. Perform following for each seal ring. Install 3 seal rings on camshaft from rear to front order.Note: Check valve is mounted in head by check valve O-ring. Unscrew installation tool from check valve. . For each intake camshaft perform following.

Rotate seal ring to position locking ends at top of camshaft and press down into seal groove.Push in and up on seal ring from sides to push up seal ring ends out of camshaft seal grove. For each distribution piece gasket perform following. Press one seal ring end down and under other seal ring end and engage seal ring end hooks. Lightly lubricate seal rings to ease distribution piece installation (assembly oil). Install bank 1 & 2 vanos oil distribution piece gasket. . Note: This is to prevent seal ring ends from protruding from seal groove and be disconnected when installing oil distribution piece.

For each vanos oil distribution piece perform following. Install bank 1 & 2 vanos oil distribution piece. Insert gasket onto vanos check valve and press onto head to fully install.Press new gasket top against head and up into camshaft housing groove. Note: gasket top tab printed number faces front (pictures). . Verify gasket bolt holes fully align with head bolt holes. Lightly lubricate distribution piece cylinder to ease installation.

Alternatingly tilt in top and bottom of distribution piece to insert over camshaft seals. Rotate distribution piece to align bolt holes with engine head bolt holes. Install bank 1 & 2 vanos oil distribution piece mounting bolts. Fully press distribution piece against engine head. For each vanos oil distribution piece perform . Rotate distribution piece to avoid obstacles.Press oil distribution piece onto camshaft and engine head.

just below solenoid hole. Remove towels from chain slot at bank 1 & 2.5 ft-lb) (E-10 torx socket 3/8” / 3/8” torque wrench & extension). Installation of vanos units . 10 Nm (7. Verify one pass with all bolts fully tightened.following. Fully tighten. Tighten bolts evenly in multiple passes. Install distribution piece 5 mounting bolts (E-10 torx socket 3/8” / 3/8” ratchet & extension). Note: Gasket will compress as bolts are tightened. is longer and has washer. Note: Lower mounting bolt.

Bring up crankshaft chain and maneuver past distribution piece. Install crankshaft chain onto vanos front sprocket. For each vanos perform following. . Mount vanos onto intake camshaft. Note: There is no relative orientation of vanos and crankshaft chain.Install bank 1 & 2 vanos.

Note: There is no relative orientation of vanos. and camshaft chain. Install camshaft chain onto vanos rear sprocket.Install bank 1 & 2 exhaust sprocket and camshaft chain. . exhaust sprocket. Pull vanos forward and off intake camshaft. For each exhaust sprocket and camshaft chain perform following. Mount vanos and exhaust sprocket onto intake and exhaust camshafts. Note: Exhaust sprocket rear has larger diameter oil mark circle than front. Mount camshaft chain onto exhaust sprocket.

left hand thread (T55 torx bit socket 3/8" / 3/8" ratchet). Note: Loosening bolts allows free rotation of vanos and exhaust sprocket which is needed for timing setup. . Install vanos and exhaust sprocket mounting bolts.Install bank 1 & 2 vanos and exhaust sprocket mounting bolts. Tighten then slightly loosen (1/8 turn) both bolts. For each vanos and exhaust sprocket perform following. left hand thread (hand). Note: Tightening bolts seats vanos and exhaust sprocket.

Compress chain tensioner and pull out locking clip from locking holes. Note: Bank 1 chain tensioner is compressed from below tensioner and bank 2 chain tensioner is compressed from above tensioner. . For each camshaft chain tensioner perform following.Unlock bank 1 & 2 camshaft chain tensioner.

Align block with head to facilitate bolt insertion. Position tool block on bank 1 head below exhaust sprocket (picture). Mount tool block with upper timing cover long bolt at top and short bolt at bottom. Lightly tighten bolts (10mm socket 3/8” / 3/8” extension).Install crankshaft chain tensioning tool. Tighten tensioner tool spindle to press against chain rail guide and tension crankshaft chain (8mm socket 1/4" / . Thread tool spindle nut fully into tool block.

fingers). Align tool spindle and rail guide as needed. Verify crankshaft chain is positioned on chain rail guides at bank 1 & 2. Tighten until difficult to further tighten (8mm socket 1/4" / fingers). Do not over tighten. Note: Amount of chain tightening and spindle protrusion from tool block will depend on chain age and stretch. Chain in picture is old and stretched. Verify crankshaft chain is tight at all segments. If chain is loose at a segment this is likely due to a tightly mounted vanos or exhaust sprocket. Slightly loosen vanos or exhaust sprocket mounting bolt to allow rotation and release of chain bind. Further tension chain as needed. Check and realign camshafts and camshaft locking blocks as necessary.

Fully retard bank 1 & 2 vanos timing. For each vanos perform following. Connect ohm meter positive lead to one of vanos test pins and negative lead to intake camshaft first bearing cap stud (digital multimeter & alligator clip wires). Turn on ohm meter (digital multimeter on ohm setting). Install vanos turning tool onto vanos center shaft. Insert tool pins into vanos shaft pin holes. Turn vanos shaft counter clockwise until end adjustment position (vanos turning tool & 24mm socket 1/2" / 1/2" ratchet). Ohm meter will display 0 ohm when vanos at fully retarded position. Note: Vanos internal piston will connect with vanos test pins when fully retarded and cause a short reading (0 ohm). Note: When ratchet pressure is released ohm reading can change to open circuit (infinite ohm). This is normal. Note: In some cases a short will not be achieved and a 0 ohm reading will not occur. This is normal. Remove ohm meter and wires.

Locking of engine timing
Perform following two steps in two passes. First pass lightly tighten vanos and exhaust sprocket mounting bolts to fix timing. Second pass fully tighten vanos and exhaust sprocket mounting bolts. Note: Mounting bolt tightening torque values are high and set timing can be disturbed in tightening process. Two pass tightening allows fixing set timing at first pass then fully tightening at second when timing can’t be disturbed.

Tighten bank 1 & 2 vanos mounting bolt. For each vanos perform following. Tighten bank 2 then bank 1. Note: This assures any chain looseness it drawn to chain tensioner. Counter hold intake camshaft and fully tighten vanos mounting bolt, first pass 20 Nm (15 ft-lb), second pass 110 Nm (81 ft-lb); left hand thread (T55 torx bit socket 3/8" w/ 1/2” to 3/8” socket adapter / 1/2" torque wrench, 27mm open wrench). Note: Verify tool inserts fully into vanos bolt head (T55 torx bit 3/8”).

Note: Intake camshaft is counter held by locking block. But do not rely on this alone as camshaft can be damaged. Further counter hold camshaft at camshaft hex. Check and realign camshafts and camshaft locking blocks as necessary.

Tighten bank 1 & 2 exhaust sprocket mounting bolt. For each exhaust sprocket perform following. Tighten bank 2 then bank 1. Note: This assures any chain looseness it drawn to chain tensioner.

Counter hold exhaust camshaft and fully tighten exhaust sprocket mounting bolt, first pass 20 Nm (15 ft-lb), second pass 125 Nm (92 ft-lb); left hand thread (T55 torx bit socket 3/8" w/ 1/2” to 3/8” socket adapter / 1/2" torque wrench, 27mm open wrench). Note: Verify tool inserts fully into sprocket bolt head (T55 torx bit 3/8”). Note: Exhaust camshaft is counter held by locking block. But do not rely on this alone as camshaft can be damaged. Further counter hold camshaft at camshaft hex. Check and realign camshafts and camshaft locking blocks as necessary.

Mount bank 1 & 2 intake camshaft timing wheel. For each timing wheel perform following. Mount timing wheel on vanos mounting bolt and install mounting nut; left hand thread (hand). Note: Timing wheel rear has center protruding neck which mounts into vanos. Do not tighten mounting nut at this time. Rotate timing wheel to position reference hole approximately as shown (picture).

Do not fully tighten bolts at this time. Precisely align positioning tool by aligning top bracket onto head top surface. Rotate timing wheel as needed for pin/hole alignment. .Install bank 1 & 2 timing wheel positioning tool. Lightly tighten mounting bolts (10mm socket 3/8” / 3/8” extension). Mount corresponding timing wheel positioning tool at timing cover head surface and insert tool pin in timing wheel hole. Rest positioning tool top bracket on head top to align positioning tool and facilitate bolt insertion. For each timing wheel perform following. Mount positioning tool with upper timing cover long bolt at top and short bolt at bottom.

40 Nm (29. Loosen chain tensioning tool spindle (8mm socket 1/4" / fingers). . Fully tighten timing wheel mounting nut.5 ft-lb).Tighten bank 1 & 2 timing wheel mounting nut. Remove bank 1 & 2 timing wheel positioning tool mounting bolts and remove positioning tools (10mm socket 3/8” / 3/8” extension). left hand thread (24mm socket 1/2" / 1/2" torque wrench). For each timing wheel perform following.

Unlocking of camshafts Remove bank 1 & 2 camshaft locking blocks. Remove tool spindle nut from tool block. For each camshaft set perform following.Remove tool block 2 mounting bolts and remove chain tensioning tool (10mm socket 3/8” / 3/8” extension). .

Dislodge and remove locking blocks. Installation of upper timing covers Remove bank 1 crankshaft chain tensioner rubber grommet. .Loosen locking blocks matting bolt (6mm hex bit socket 3/8” / 3/8” ratchet). Pry out grommet (90 degree pick tool).

Clean grommet mounting hole (brake cleaner & towels). .Install bank 1 crankshaft chain tensioner new rubber grommet. Fully press in new grommet into mounting hole (fingers).

Align and fully press in gasket into cover groove. Insert gasket. For each upper timing cover perform following. Note: Bank 1 & 2 gaskets are different. ridge side. Align gasket with timing cover perimeter groove. into cover groove. .Install bank 1 & 2 upper timing cover gasket.

Allow sealant to solidify for 2 minutes before mounting timing cover.Apply bank 1 & 2 upper timing cover lower rear gasket sealant. Place thin coat of gasket sealant at timing cover engine lower rear corners. . For each upper timing cover perform following.

For each upper timing cover perform following. Note: Bank 2 lower left mounting bolt must be installed in timing cover before installing cover on head. Mount upper timing cover on engine head. This is due to access restriction.Mount bank 1 & 2 upper timing cover. . Bolt is long with smooth neck.

For each upper timing cover perform following. 3 at each side of cover (10mm socket 3/8” / 3/8” extension). Screw in bolts until snug. Bank 2 right side upper bolt is short and fully threaded. Note: Upper and lower bolts are long with smooth neck and middle bolt is short and fully threaded. . Bank 2 lower left mounting bolt requires a low profile tool for access (10mm ratcheting wrench). Assemble 8 valve cover side bolts with 2 washers and new rubber grommet each.Install bank 1 & 2 upper timing cover bolts. Do not tighten at this time. Install 6 mounting bolts.

Note: Bolts are used in following step to mount valve cover without gasket and apply downward pressure on upper timing cover to position properly for mounting. . Note: Second bolt washer is needed to fill in space usually taken by valve cover gasket.

For each valve cover perform following. Do not over tighten bolts. Tighten bolts evenly in multiple passes. Position ground strap in sparkplug well. Install valve cover 4 side mounting bolts with 2 washers and new rubber grommet each at two front side bolt holes (10mm socket 3/8” / 3/8” ratchet & extension). Verify one pass with all bolts fully tightened.Install bank 1 & 2 valve cover without gasket. Mount valve cover on engine head. . Tight bolts until moderate resistance is reached.

. Fully tighten 6 mounting bolts. For each valve cover perform following. Tighten bolts evenly in multiple passes.5 ft-lb) (10mm socket 3/8” / 3/8” torque wrench & extension).Tighten bank 1 & 2 upper timing cover bolts. Bank 2 lower left mounting bolt requires a low profile tool for access (10mm ratcheting wrench). Remove bank 1 & 2 valve cover. For each upper timing cover perform following. 9 Nm (6. Verify one pass with all bolts fully tightened. Tighten 6 mounting bolts (10mm socket 3/8” / 3/8” ratchet & extension).

Remove valve cover from engine head. flathead).Remove valve cover 4 front side mounting bolts with 2 washers and grommet (10mm socket 3/8” / 3/8” ratchet & extension. Loosen bolts evenly in multiple passes. Installation of solenoids .

Apply bank 1 & 2 vanos solenoid gasket sealant. Apply thin layer of sealant at timing cover solenoid hole perimeter (gasket sealant). Sealant will allow longer functional life of gasket. For each solenoid perform following. Note: Solenoid gasket inner gasket is Buna and is susceptible to leaking. .

Install bank 1 & 2 vanos solenoid.5 ft-lb) (32mm special deep socket 1/2” w/ 3/8” to 1/2" socket adapter / 3/8” torque wrench). 25 Nm (18. Fully tighten solenoid. For each solenoid perform following. . Screw solenoid into engine head (hand).

Press gasket onto solenoid and wiggle and slide gasket until it reached timing cover.Install bank 1 & 2 solenoid gasket. Fully press gasket onto timing cover. Note: Timing cover gasket matting surface is slanted. For each solenoid perform following. Gasket will press in further at bottom and engine outer side. Note: Gasket flat side faces timing cover and gasket protruding side faces front (pictures). .

Install gasket 2 mounting bolts (10mm socket 3/8” / 3/8” ratchet & extension). Verify one pass with both bolts fully tightened.Install bank 1 & 2 solenoid gasket bolts. Fully tighten 2 mounting bolts. . Tilt first mounting bolt to side as needed to align gasket with bolt hole.5 ft-lb) (10mm socket 3/8” / 3/8” torque wrench & extension). Tighten bolts evenly. 9 Nm (6. For each solenoid perform following.

Press in and thread chain tensioner into engine (19mm deep socket 3/8” / hand). . For each solenoid perform following. Installation of engine front components Install new crankshaft chain tensioner.Install bank 1 & 2 solenoid electrical cable connector. Install new base crush washer on chain tensioner. Press solenoid electrical cable connector onto solenoid electrical connector until connector wire clip snaps into place.

5 series . 40 Nm (29.Note: Touch socket against AC compressor to properly align tensioner. Verify crankshaft chain is positioned on chain rail guides at bank 1 & 2. Install oil dip stick pipe clamp mounting bolt (10mm socket 3/8” / 3/8” ratchet & extension).5 ft-lb) (19mm deep socket 3/8” / 3/8” torque wrench). Fully tighten chain tensioner.

7 series Install hose/cable bracket mounting bolt just to left of bank 2 solenoid (10mm socket 3/8” / 3/8” ratchet & extension). .Install fuel purge valve bracket mounting bolt (10mm socket 3/8” / 3/8” ratchet & extension).

Install hose bracket mounting bolt at oil filter housing (10mm socket 3/8” / 3/8” ratchet & extension). .Install hose bracket mounting bolt at middle bank 2 upper timing cover (10mm socket 3/8” / 3/8” ratchet & extension).

Cut and remove O-rings (razor knife). . Lightly lubricate O-ring to ease pipe installation (assembly oil). Insert new O-ring in pipe groove at one end and stretch other end over pipe and drop into groove (hands/fingers). For each pipe end perform following.Remove secondary air pipe 2 pipe end O-rings. For each pipe end perform following. Install secondary air pipe 2 pipe end O-rings. Note: Rocking of blade while pressing helps create cutting motion.

Install secondary air pipe onto engine and insert right and left ends into engine mount holes (see next two pictures). . Pipe ends might not fully insert into holes. Align pipe left mounting bracket with bank 1 upper timing cover mount hole. Move pipe ends some while pressing in to align pipe and insert into mount hole. Install secondary air pipe left mounting bolt (10mm socket 3/8” / 3/8” ratchet & medium extension). Wiggle and press in pipe ends. Second pipe end insertion might need pipe bent in for hole alignment. This will be addressed in next step when mounting bolts are installed.

Install secondary air pipe center mounting bolt (T30 torx bit 1/4” / 1/4” ratchet & extension).Install secondary air pipe right mounting bolt (10mm socket 3/8” / 3/8” ratchet & medium extension). then retighten pipe end mounting bolts. . install center mounting bolt. loosen pipe end mounting bolts. If hole alignment is difficult.

Install radiator lower hose onto thermostat. Press hose connector onto thermostat until wire clip snaps into place. Press vacuum hose onto valve hose pipe. Press blower hose onto valve connector until hose clips snap into place.Install secondary air blower hose and secondary air vacuum control hose onto secondary air exhaust valve. . Press hose connector wire clip onto hose connector before mounting hose. Install hose connector onto thermostat and align hose notch with thermostat notch.

Install radiator lower hose onto radiator lower neck. Press cable connector onto sensor until connector wire clip snaps into place. 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. Install radiator upper hose onto alternator. . Press hose connector onto radiator neck until wire clip snaps into place. Install temperature sensor electrical cable connector.

Press hose connector onto thermostat until wire clip snaps into place. Install hose connector onto alternator and align hose notch with alternator notch. Install radiator upper hose onto thermostat.Press hose connector wire clip onto hose connector before mounting hose. Press hose connector onto alternator until wire clip snaps into place. Install hose connector onto thermostat and align hose notch with thermostat notch. Press hose connector wire clip onto hose connector before mounting hose. .

Press hose connector wire clip onto hose connector before mounting hose.Install radiator upper hose onto radiator upper neck. . Press hose connector onto radiator neck until wire clip snaps into place. Unlocking crankshaft Raise front of car and place on jack stands (follow appropriate procedure. Install hose connector onto radiator upper neck and align hose notch with radiator neck notch. chock both sides of both rear wheels).

Install inspection hole cap. then cap lower tab into hole. Insert cap side tabs into inspection hole. Note: Picture cap orientation wrong. .Pull out crankshaft lock pin from crankshaft lock hole. Lower car from jack stands (follow appropriate procedure). Orient cap with handle ridge vertical.

and oil rail top and bottom are same and can be installed either ways.Installation of valve covers Install bank 1 & 2 camshaft oil rails. Note: Intake and exhaust oil rails are same and can be switched. For each set of camshafts perform following. Note: Bank 1 & 2 camshaft oil rails are different. . Note: Oil rail front is denoted by dimple between first and second hole.

Install bank 1 & 2 valve cover gaskets. Tighten nuts evenly. . Install 5 mounting nuts at each oil rail (10mm deep socket 3/8” / 3/8” ratchet. Note: Bank 1 & 2 gaskets are different. Verify one pass with all nuts fully tightened. 10mm ratcheting wrench). 10mm ratcheting wrench). For each valve cover perform following.Install intake and exhaust camshaft oil rails in position over bearing cap studs. Fully tighten. 8 Nm (6 ft-lb) (10mm deep socket 3/8” / 3/8” torque wrench.

Note side flaps on rear half-moon gasket section. Align perimeter gasket with valve cover perimeter groove and sparkplug well gasket with valve cover sparkplug well groove. Insert gaskets. ridge side. into cover grooves. These flaps must straddle head rear when valve cover is installed. Align and fully press in gaskets into cover grooves.Note: Orientation of sparkplug well gasket tab is of no significance. .

.Apply bank 1 & 2 head rear half-moon gasket sealant. Place thin coat of gasket sealant at head rear half-moon corners. For each head perform following. Allow sealant to solidify for 2 minutes before mounting valve cover.

Place thin coat of gasket sealant at each side of timing cover gasket joint with head. .Apply bank 1 & 2 head front timing cover gasket sealant. For each head perform following. Allow sealant to solidify for 2 minutes before mounting valve cover.

Place valve cover with gaskets on engine head. Note: On 540.Install bank 1 & 2 valve cover. . Adjust cover position to center cover holes with studs and screw on bolts to position cover on head (hands). Reinstall gasket in cover once cover is in position above head. Install 2 side bolts w/ washer and grommet at front top and rear bottom of valve cover. bank 2 valve cover is difficult to install due to fuel hose. Position ground strap in sparkplug well. For each valve cover perform following. Install bolts with only one turn to allow valve cover to stay loose. Cover perimeter gasket will come off due to being hit by intake camshaft bearing cap stud.

Verify bank 1 & 2 valve cover seating. Verify gasket 2 rear half-moons are properly inserted in head half-moons (mirror & flashlight). Half-moon rear flaps should be seated to rear of head (pictures). . Reposition cover and gaskets as needed to correctly align gaskets. For each valve cover perform following. Inspect valve cover gasket seating along valve cover perimeter and sparkplug well (mirror & flashlight).

3 at front and 4 at each side (10mm socket 3/8” / 3/8” ratchet & extension).Install bank 1 & 2 valve cover mounting bolts. 8Nm (6 ft-lb) (10mm socket 3/8” / 3/8” torque wrench & extension). For each valve cover perform following. Tighten bolts evenly working back and forth. Install 11 valve cover mounting bolts w/ washers & grommets. Note: Front 3 bolts are different than remaining 8 bolts. Tighten until bolts bottom out (stop turning). . assuring even pressure distribution on cover. Fully tighten.

Install battery positive cable on stud and mount with nut (19mm socket 1/2" / 1/2" ratchet). .Install battery positive cable on bank 2 valve cover and insert into cable box.

.Install bank 1 & 2 top cover gasket. For each valve cover perform following. Install top cover gasket on valve cover.

Note: Electrical housing mounting studs will be inserted into mounting brackets. Position bank 1 & 2 electrical housings with fuel injector electrical connectors on fuel injectors. Press bank 1 & 2 electrical housings fuel injector electrical connector wire clips onto connectors. Release bank 1 & 2 electrical housings tie (bungee cord). .Install bank 1 & 2 electrical housings. Press down on bank 1 & 2 electrical housings to press on each fuel injector electrical connector until connector wire clip snaps into place.

Install vacuum accumulator mounting bracket onto bank 2 electrical housing front stud. Install bank 1 & 2 2 electrical housing mounting nuts (10mm deep socket 3/8” / 3/8” ratchet & extension). For each O2 sensor perform following. Press down on housing while mounting nut to keep housing stud from slipping out of mounting bracket.Install secondary air solenoid mounting bracket onto bank 1 electrical housing front stud. Install bank 1 & 2 O2 sensor cable connector. Press O2 sensor electrical cable connector onto electrical housing top middle connector until connector tabs snaps .

Press cable connector onto secondary air solenoid connector at top left middle intake manifold until connector wire clip snaps into place. For each camshaft position sensor perform following.into place. Install bank 1 & 2 camshaft position sensor cable connector. . Install secondary air control solenoid cable connector. Press camshaft position sensor cable connector onto electrical housing top front connector until connector wire clip snaps into place.

Note: Coil boot will not fully insert onto sparkplug during initial mount. 9Nm (6. coil harness ground wires at coils 2 & 7 and coil ground straps at coils 3 & 6. and push down on connector metal lock. Install on coil studs. Tighten coil mounting nuts evenly to mount coil evenly.5 ft-lb) (10mm socket 3/8” / 3/8” torque wrench & extension). Fully tighten. press in cable electrical connector. This is normal.Install bank 1 & 2 ignition coils. lift up on connector metal lock. 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). Seat each coil connector cable rubber bracket onto top cover gasket. For each coil. .

Note: Bolt shafts will be in top cover holes if not previously removed with bolts. Install 4 top cover mounting bolt shaft new O-rings.Remove 4 top cover mounting bolt shaft O-rings (90 degree pick tool). .

Bank 2 top cover has 5th slot for batter positive cable. Note: Bank 1 & 2 top covers are different. . Align silver lines on cap with cover.Install bank 1 & 2 top cover. Install top cover on valve cover. Verify banks 2 battery positive cable inserts into cover slot. For each bank perform following. Verify 4 coil cable rubber brackets insert into cover slots. Install 2 cover mounting bolts with shafts (10mm socket 3/8” / 3/8” ratchet & extension). Insert clip at an angle and gently press down on other end (picture). Install 2 bolt cover caps.

Open rear trunk lid. Tighten battery negative cable mounting nut (10mm socket 3/8" / 3/8" ratchet & extension). . Install negative cable clamp on battery negative post. Installation of cabin filter housing E39 cabin filter housing installation Installation of fan & shroud Fan & shroud installation Installation of engine air intake Engine air intake installation Post repair procedures Mix 2 gallons of coolant.Install battery negative cable at battery. Open right fender cabin door (at trunk orientation). BMW coolant is mixed 50/50% coolant/distilled water.

. Pour coolant into expansion tank until coolant level stick reaches tank rim. Drive car until coolant and engine fully warm up. Pour coolant into expansion tank until coolant level stick reaches tank rim. Start engine.Remove coolant expansion tank cap. Place towel around coolant expansion tank cap (towels).

LLC or its members be liable for incidental.com/forum M62TU Engine Air Intake Procedure The following information is provided for reference purposes only and should be used at your own risk In no event shall Beisan Systems. Close expansion tank cap when only coolant and no air is escaping.beisansystems. www.Slowly unscrew expansion tank cap until air/coolant leak out. consequential. . or special loss or damages of any kind however caused. Check coolant level and fill as needed when engine is fully cold (morning). Please provide feedback on vanos forum after seals break-in period. Engine air intake removal Press in on engine acoustic cover 4 mounting latches to release cover.

Remove intake duct upper vacuum hose. .Lift up and remove engine acoustic cover. Press in on retaining clip and pull off hose.

Press in on connector side clips and pull off connector. . Remove MAF sensor electrical cable connector. Pull off hose.Remove intake duct lower vacuum hose.

Disconnect MAF electrical cable from clip under intake boot. Remove air filter box mounting bolt at rear of air filter box (10mm socket 3/8” / 3/8” ratchet & medium extension). .

Remove intake resonator mounting bolt just to rear of MAF sensor (10mm socket 3/8” / 3/8” ratchet & medium extension). Note: Leave bolt in bracket after unscrewing.

Loosen intake duct hose clamp at throttle (6mm socket 1/4" / 1/4" ratchet & medium extension).

Pull intake duct from throttle. 7 series

Loosen air filter box plastic knob mounting clamp at fender side of air filter box (6mm socket 1/4" / 1/4" ratchet & extension).

Remove secondary air hose from air filter box at front of air filter box. Loosen secondary air hose clamp (6mm socket 1/4" / 1/4" ratchet & extension). Pull off secondary air hose form air filter box.

Lift up on air filter box and intake duct and remove from engine compartment. Wiggle air filter box to pull out mounts from fender.

Engine air intake installation

Inset air filter box and intake duct into engine compartment. Note: Insert intake resonator rear mounting bolt in resonator bracket hole for ease of installation. Resonator mounting bolt is longer than air filter box mounting bolt.

Insert air filter box 3 mounts into location. Insert Lower large air boot into duct. Insert upper plastic knob into rubber boot. Insert rear lower rubber knob into bracket. Wiggle air filter box and push down to fully mount. 7 series

Install air filter box plastic knob mounting clamp at fender side of air filter box (6mm socket 1/4" / 1/4" ratchet & extension).

Install secondary air hose onto air filter box at front of air filter box. Insert secondary air hose onto air filter box hose neck. Install and tighten secondary air hose clamp (6mm socket 1/4" / 1/4" ratchet & extension).

Install air filter box mounting bolt at rear of box (10mm socket 3/8” / 3/8” ratchet & medium extension). Reposition box to align mounting bracket hole. Fully tighten, 10 Nm (7 Ft-lb) (10mm socket 3/8” / 3/8” torque wrench & medium extension).

Install intake resonator mounting bolt at rear of MAF sensor (10mm socket 3/8” / 3/8” ratchet & medium extension). Reposition intake duct to align mounting bracket hole. Fully tighten, 10 Nm (7 Ft-lb) (10mm socket 3/8” / 3/8” torque wrench & medium extension).

. Position and tighten air duct hose clamp at throttle (6mm socket 1/4" / 1/4" long-arm ratchet & medium extension).Install air duct end onto throttle. Verify duct is fully inserted onto throttle.

Install MAF electrical cable in clip under intake boot. . Install MAF sensor electrical cable connector. Press connector onto MAF until it snaps into place.

Press hose onto fitting. © Copyright 2011 Beisan Systems. Install intake duct upper vacuum hose. LLC . Press hose onto fitting until clip snaps into place.Install intake duct lower vacuum hose.