BMW 7_aya the E38 series from 1994 to 2002
1. Introduction
2. Governing bodies and methods of operation
3. Settings and routine maintenance of the car
4. Engine
4.1. General information and preparatory operations
4.2. Check of compression pressure
4.3. Check of the engine by means of the vacuum gage
4.4. Petrol M60/1 and M60/2 engines
4.5. M62 engine
4.6. Diesel M57 engine
4.6.1. Removal and installation of a head of cylinders, camshafts and their asterisks
4.6.2. Removal and installation of the top section of the pallet of a case
4.6.3. Removal and installation of a cover of the GRM drive
4.6.4. Replacement of epiploons of a bent shaft
4.6.5. Removal and installation of a flywheel
4.6.6. Removal and installation of a damper of tortional fluctuations
4.6.7. Replacement of driving belts and their natyazhitel
4.6.8. Removal and installation of the oil pump
4.6.9. Removal and installation of the oil cooler
4.6.10. Removal and installation of the inlet pipeline
4.6.11. Removal and installation of a final collector
4.6.12. Removal and installation of the vacuum pump
4.6.13. Removal and installation of the engine
4.7. Diesel M67 engine
5. Cooling systems of the engine, heating, ventilation and air conditioning
6. A power supply system and production of the fulfilled gases
7. Systems of electric equipment of the engine
8. Manual box of gear shifting and coupling
9. Automatic transmission
10. Cardan and power shafts, reducer, differential and stupichny assemblies
11. Brake system
12. Suspension bracket and steering
13. Body
14. Onboard electric equipment
15. Schemes of electric equipment



4-6-dizelnyjj-dvigatel-m57.html

4.6. Diesel M57 engine

Removal and installation of a head of cylinders, camshafts and their asterisks

Removal

 PERFORMANCE ORDER

  1. Disconnect a negative wire from the rechargeable battery. Uncover a head of the block of cylinders.
  2. Take off driving belts (see the Section Replacement of Driving Belts and Their Natyazhitel).
  3. Empty the engine cooling system.
  4. Remove the vacuum pump (see the Section Removal and installation of the vacuum pump).
  1. Remove the lower protection covers of the engine and weaken turbocompressor arm bolts.
  1. By means of special adaptation No. 13 5 020 pick up the phone of high pressure (1).

At installation you monitor the correct provision of a rubber pillow (2). Turn out bolts (3) and remove the fuel distributive highway (4).


  1. Disconnect a turbocompressor from a final collector.

At installation new laying of a turbocompressor will be required; grease a carving with copper-bearing lubricant.


  1. Turn out screws 1 and 3 and remove an eye 2 and a returnable tube 4.
  1. Take out a cap from a back part of a case, below a starter, and turn the engine clockwise by means of adaptation No. 11 6 480 in front on a damper of tortional fluctuations. Fix the engine in position of the piston of the first cylinder in VMT of the end of a step of compression, having inserted the device No. 11 2 300 in the opening which opened under a cap.
  1. In the provision of VMT of top of cams of the camshaft, managing directors of valves of the first cylinder, have to be directed towards each other (shooters). Turn out screws (1) and remove a guide (2) chains of the GRM drive.
  1. Turn out a carving stopper.
  1. Lower pressure, having weakened a bolt of a natyazhitel of a chain.
  1. Install adaptation No. 11 6 322 (1) on a head of the block of cylinders, put on adaptation No. 11 6 321 the camshaft of inlet valves and record by means of adaptation No. 11 6 322.
  1. Slowly turn the camshaft of final valves for a bolt of fastening of an asterisk clockwise before full compression of a natyazhitel of a chain then install adaptation No. 11 3 340 in a natyazhitel of a chain (see an illustration).

At removal of one or both asterisks without preliminary blocking of a natyazhitel of a chain perhaps vyskalzyvany outside of the piston of a natyazhitel which installation into place is very labor-consuming operation.


  1. Weaken a bolt (1) on distributive to a shaft of inlet valves, and then completely turn out a bolt (2) on distributive to a shaft of final valves.
  1. Shift an asterisk of a cam-shaft of final valves forward, lift over it a chain (1) and remove an asterisk (2) in the direction of an arrow.
  1. Turn out a bolt of fastening of an asterisk of the camshaft of inlet valves and remove an asterisk.
  1. Twist a basic finger (1) of a level of a natyazhitel of a chain and a basic finger (2) guides of a chain.

At installation replace removal fingers. Extend a level of a natyazhitel and a guide of a chain of GRM up. Remove devices No. No. 11 6 321, 11 6 322.

In order to avoid damage of valves at the subsequent installation of camshafts any of pistons should not be in the provision of VMT.

  1. Remove the device for fixing of the engine in the provision of VMT (No. 11 2 300). Delay GRM chain up and hold it in the tense state so that it was possible to turn the engine. Turn the engine for a damper of tortional fluctuations by means of special adaptation No. 11 6 480 approximately on a corner 45 ° counterclockwise.
  2. Evenly, in stages on a half-turn, turn out bolts of fastening of covers of bearings of camshafts in the sequence from edges to the middle. Uncover bearings and put them aside, having in the order providing a possibility of the subsequent installation of covers of bearings on former places.
  3. Remove at first the camshaft of inlet valves, and then – a shaft of final valves.
  1. Remove all yokes (1) and hydrocompensators of valvate gaps and arrange them in the order providing a possibility of the subsequent installation on former places.
  1. Turn out bolts.
  1. Turn out bolts of fastening of a head of the block of cylinders in the return sequence.

Reuse of bolts of fastening of a head of cylinders is not admissible.

Do not damage the glow plugs acting it is necessary the plane of a head of cylinders.

  1. If necessary remove glow plugs.
  1. Remove laying (1) of a head of cylinders, pay attention to quantity of openings (2) in laying. Clear all deaf carving openings (3) of oil, cooling liquid and dirt. Clear the interfaced surface (4).

Installation

 PERFORMANCE ORDER

  1. If on the block of cylinders the works causing change of a ledge of the bottom of pistons were not carried out, then it is necessary to use new laying of a head of the block with the same marking (1 cm an illustration) thickness, as on old laying. Otherwise it is necessary to determine anew the repair thickness of sealing laying, having measured for this purpose a ledge of the bottom of all pistons concerning the plane of the block of cylinders. At a ledge from 0.92 to 1.03 mm use laying with 2 openings, and at a ledge more than 1.03 mm - with 3 openings.
  2. Check the aligning plugs in the block of cylinders for absence of damage and correctness of installation; if necessary replace plugs.
  3. Establish new laying of a head of cylinders and fix a head on the block of cylinders by new bolts, having tightened them in the specified sequence (see an illustration).
  4. Tighten bolts (see an illustration).
  5. Oil motive beds and covers of bearings of camshafts. Establish all yokes and hydrocompensators on their former places.
  6. Install camshafts.

On inlet the tag of "E", and on final – "A" is put to a shaft; covers of bearings have the same alphabetic references, and also the digital designations indicating a cover arrangement, reading out from the party of release. Establish covers of bearings of camshafts and tighten their fixing bolts.


  1. Turn camshafts for hexagons so that tops of cams of inlet and final valves of the 1st cylinder specified at each other.
  1. Establish a level of a natyazhitel and the directing chain of GRM and fix them by new fingers.
  2. Center the camshaft of inlet valves and fix it by means of devices No. No. 11 6 321 and 11 6 322 at position of the piston of the first cylinder in VMT of the end of a step of compression.
  3. Establish the fuel distributive highway and fuel tubes of high pressure.
  4. Put on GRM chain an asterisk of the inlet camshaft, pull an asterisk over a shaft and fix it by a bolt, having tightened it to a dense prileganiye and then having weakened half way.

Any provision of an asterisk concerning the camshaft is allowed. Similarly establish an asterisk of the final camshaft.

  1. Establish GRM chain guide between asterisks with new laying and tighten a bolt of fastening of an asterisk of the final camshaft, holding a shaft from a provorachivaniye for a hexagon.
  2. Slowly turning the final camshaft clockwise, achieve full compression of a natyazhitel of a chain of GRM and remove a clamp of a natyazhitel.
  3. Again give half way a bolt of fastening of an asterisk of the final camshaft.
  4. Tighten a bolt of a natyazhitel of a chain and screw a stopper of a service opening of a natyazhitel with a new sealing ring.
  5. Turn the engine clockwise for a damper of tortional fluctuations from situation 45 ° before VMT in the provision of VMT.
  6. Block a bent shaft in VMT by means of special adaptation No. 11 2 300.
  7. Install adaptation No. 11 6 321 on the camshaft of inlet valves and record it. Tighten a bolt of fastening of an asterisk of a shaft by means of adaptation No. 00 9 120. Similarly tighten a bolt of fastening of an asterisk of the final camshaft.
  8. Remove adaptation No. 11 6 321 from the final camshaft.
  9. Delay adaptation No. 11 2 300 back so to release a flywheel (see an illustration).
  10. Turn the engine by means of adaptation No. 11 6 480 twice in the direction of rotation to position of the piston of the first cylinder just before VMT of the end of a step of compression.
  11. Turn the engine in the direction of rotation to the provision of VMT so that adaptation No. 11 2 300 (the fixing pin) was fixed with the heard click.

The engine provorachivaniye in the opposite direction is not allowed.

  1. Block a bent shaft in the situation corresponding to VMT of the piston of the first cylinder by means of adaptation No. 11 2 300 (see an illustration).
  2. Install adaptation No. 11 6 321 on the camshaft of inlet valves.

Adaptation No. 11 6 321 has to adjoin without gap to a head of the block of cylinders.

  1. Install adaptation No. 11 6 321 on the camshaft of final valves so that it without gap adjoined to a head of cylinders.
  2. Remove adaptation No. 11 6 321 from the camshaft of final valves. Remove devices No. 11 6 322 and No. 11 2 300.
  3. Insert into a service opening for blocking of a flywheel a cap.
  4. Establish new sealing laying.
  5. Establish a turbocompressor.

Grease a carving with copper-bearing paste.

  1. Establish a returnable tube and a lifting eye (see an illustration).
  2. Tighten bolts of fastening (1) of an arm of a turbocompressor.


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4.6.1. Removal and installation of a head of cylinders, camshafts and their asterisks