REMOVAL & INSTALLATION
Except 524td Model
- Position the No. 1 piston at TDC on the beginning of its compression stroke.
- Remove the flywheel guard and lock the flywheel with a locking tool.
- Remove the drive belts and the fan.
- Remove the retaining nut and remove the vibration damper from the crankshaft.
The Woodruff key should be at the 12 o'clock position on the crankshaft.
- Remove the seal from the timing housing cover with a small pry bar.
- Using a special seal installer or equivalent, lubricate and install the seal in the cover. This tool is used to press the seal into the bore with even pressure around the entire perimeter.
If the balancer hub has serious scoring on the sealing surface, position the seal in the cover so that the sealing lip is in front of or behind the scored groove.
- Lubricate the balancer hub and install it on the crankshaft, being careful not to damage the seal.
- Complete the assembly, using the reverse of the removal procedure. Be sure to remove the flywheel locking tool before attempting to start the engine.
A number of special tools are necessary to complete this operation. They include: A wrench designed to hold the vibration damper hub BMW 11 2 150 or equivalent; a puller for the vibration damper hub; a pin to hold the vibration damper hub 11 2 040; a puller to remove the timing belt sprocket from the crankshaft such as BMW 00 7 501 and 11 2 131; seal installer 24 1 040 and 24 1 050; and special tools designed to protect the seals when the front engine cover is installed, 11 2 211 and 11 2 212. Equivalents may be available from other sources.
- Remove the timing belt cover and vibration damper as described above.
- Remove the radiator.
- Install the special wrench on the vibration damper hub. Then, unscrew the bolt at the center until it is about 3 turns out. Attach a puller such as 00 7 501 with bolts 11 2 132. The 2 outer bolts screw into holes in the outer rim of the damper hub. Then, turn the center bolt of the puller so it forces the hub off by pressing against the center bolt.
- Remove the timing belt. Then, use the special tool or another suitable means to hold the intermediate shaft stationary while removing the bolt at the center. Then, remove the intermediate shaft washer and sprocket.
- Screw the bolt into the center of the crankshaft until it is about 3 turns out. Screw the outer bolts for the puller into the outer edge of the crankshaft sprocket until they are secure. Then, screw in the center bolt of the puller to force the crankshaft sprocket off.
- Remove the arrow bolts, and oil pan bolts labeled 4, 5, and 6. Loosen the other pan bolts. Then carefully use a sharp knife to separate the oil pan gasket from the front cover. Remove the cover.
- From the rear of the cover, press the oil seals outward. Then use tools such as 24 1 040 and 24 1 050 to press in new seals. Replacement seals must be pressed in until 1.00-2.00mm indented. Apply clean engine oil to the sealing lips.
- Install tools such as 11 2 211 (crankshaft) and 11 2 212 (intermediate shaft) to the ends of these shafts to protect the seals. Then, install the front cover.
Installation is the reverse of removal. Keep the following points in mind:
- Install the crankshaft sprocket with the woodruff key in the proper position and the step forward.
- When installing the intermediate shaft sprocket, make sure the centering pin slides into its bore.