ECS Tuning BMW S54 Installation Instructions Manual
  1. Manuals
  2. Brands
  3. ECS Tuning Manuals
  4. Automobile Accessories
  5. BMW S54
  6. Installation instructions manual

ECS Tuning BMW S54 Installation Instructions Manual

Vanos rebuild kit
Hide thumbs
Table of Contents

Advertisement

Quick Links

BMW S54
Vanos Rebuild Kit
Installation Instructions
Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including
use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BMW S54 and is the answer not in the manual?

Questions and answers

Related Manuals for ECS Tuning BMW S54

Summary of Contents for ECS Tuning BMW S54

  • Page 1 BMW S54 Vanos Rebuild Kit Installation Instructions Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including...

  • Page 2: Step

    Pro - 4 • Valve adjustment 2 - Moderate Advanced - 3 Thank you for looking to ECS Tuning for all your performance and repair needs. We appreciate your business! ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 3: Step

    As you work your way through the repair, be sure and closely follow the links/directions next to any of the yellow street signs. These will direct you where to go depending on the step you are on or the components that you are replacing. ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 4: Return To Table Of Contents

    Specialty Tools • BMW Fan Clutch Tool Set ..............ES#2627584 • S54 Camshaft Alignment Tool Kit ..........ES#3145744 See Page 5 for additional information on specialty tools. Return to Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 5: Return To Table Of Contents

    SPECIALTY TOOLS The BMW fan clutch tools are very helpful for removing the The BMW S54 camshaft alignment tool set is required for fan/clutch. The wrench fits the large nut that holds the fan/ engine timing. During this repair, you will need to lock the...

  • Page 6: Shop Supplies And Materials

    Electrical tape - for wrapping wiring harnesses or temporary securing of small components medium high strength required Note that both thread locking compounds are for the S54 Dual Vanos repair. Return to Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 7 PREPARATION AND SAFETY INFORMATION ECS Tuning cares about your health and safety. Please read the following safety information. This information pertains to automotive service in general, and while it may not pertain to every job you do, please remember and share these important safety tips.

  • Page 8: Table Of Contents

    Vanos hub service ........................................ Page 71 Cam sprocket service ......................................Page 76 Upper timing chain guide replacement ................................ Page 79 Section 5: Reassembly Reassembly ..........................................Page 85 Return to Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 9: Step

    5. Engine Top Cover, Valve Cover, and Ignition Coils The Vanos system is located on the front of the engine at the top. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 10: 1A: Initial Component Removal And Vanos System Access

    (Intake) Vanos Transfer Gear Set and Vanos Hub (Exhaust) Vanos Piston Housing Vanos Valve Block w/Coil Pack - End of Section 1a - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 11: A: Removing The Valve Block

    Place shop rags underneath the valve block to protect the coolant hose and belts from oil that you’ll lose when you loosen the bolts. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 12: Valve Block Service 2A: Removing The Valve Block

    Remove the five mounting bolts, then pull the valve block out from underneath the piston housing and remove it along with the sealing plate. - End of Section 2a - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 13: Return To Vanos Repair Table Of Contents

    Remove the four coil pack mounting screws and lift the coil pack off of the valve block. Step 2: Unthread and remove the pressure limiter from the valve block (you should have loosened this on page 12). Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 14: 2B: Cleaning And Solenoid/Valve Operation

    “click” of the valve opening. With the valve open, spray brake cleaner into the corresponding hole underneath to flush out any debris. - End of Section 2b - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 15 Description....14mm OD x 2.0mm o-Ring Location ....Pressure Limiting Valve Small Quantity ....1 ES#3138146 Description....14.5mm ID x 3mm o-Ring Location ....Pressure Limiting Valve Large Quantity ....1 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 16: 2C: Seal And Filter Replacement

    The washer is split for the purpose of installation. o-ring o-ring Step 2: Install the new large and small o-rings, and the new screen onto the pressure limiter. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 17: Return To Vanos Repair Table Of Contents

    You’re all done with the valve block! You can set it aside for now until it’s time for reassembly. - End of Section 2c - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 18: A: Piston Housing Removal

    32mm socket, and if equipped with the four Torx bolts, you will need the special socket that is included in the S54 camshaft alignment tool kit. Requires 32mm Socket Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 19: Piston Housing Service 3A: Piston Housing Removal

    #1 are pointing together in an approximate 45 degree angle. When the cylinder #1 cam lobes are pointing at each other, this indicates that the engine is at (approximately) TDC. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 20: Return To Vanos Repair Table Of Contents

    Insert the crankshaft locking pin into the hole in the pointer and into the crankshaft pulley. Make sure that the end of the pin is fully seated into the crank pulley. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 21 You may have to rock the cam back and forth at first to get it to rotate, and it does not have to rotate very far for the transfer gear to fully extend. NOTE Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 22: Return To Vanos Repair Table Of Contents

    90 degree angle to the cylinder head. Step 10: 5mm Allen (Hex Bit) Remove the two screws and lift off the cam chain guide. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 23: Return To Vanos Repair Table Of Contents

    Vanos bracket. Step 12: 14mm Socket, Ratchet Remove the banjo bolt holding the oil pipe to the top of the Vanos piston housing. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 24 Remove the five piston housing mounting bolts. There are two hex bolts in the upper corners, and three Allen bolts along the bottom edge. You can see them all in this picture. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 25: Return To Vanos Repair Table Of Contents

    This will support the piston housing as you disconnect the transfer gear sets in the next step. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 26 - End of Section 3a - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 27: Return To Vanos Repair Table Of Contents

    Description....20mm OD x 2.0mm o-Ring Location ....Oil Regulator Large End Quantity ....1 ES#3138143 Description....15mm OD x 2.0mm o-Ring Location ....Oil Regulator Small End Quantity ....1 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 28: Oil System Service

    Closely inspect the oil pump drive tabs on the Vanos exhaust hub. Make sure they are not worn or cracked. If these are visibly worn, you will have to order a replacement hub. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 29: Return To Vanos Repair Table Of Contents

    Once you have confirmed fit of the revised oil pump rotor, pull it back off and set it aside for the moment. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 30: Return To Vanos Repair Table Of Contents

    Step 6: Snap Ring Pliers Remove the oil pump snap ring. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 31: Return To Vanos Repair Table Of Contents

    Step 7: Small Angled Pick Remove the oil pump retaining washer. Step 8: Place the piston housing into a plastic bag as shown. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 32 Remove all parts from the bag. If the bearing ring is still inside the housing, remove it at this time as well. Bearing Ring Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 33: Return To Vanos Repair Table Of Contents

    Take stock of what you have to make sure nothing has been lost. The oil pump components should consist of: (1) Oil Pump Rotor (1) Bearing Ring (4) Spring Seats (4) Springs (4) Spring Caps Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 34 As demonstrated in the RH photo, the spring seat nipple must protrude into the spring. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 35: Return To Vanos Repair Table Of Contents

    Step 16: Pushing and holding the spring caps into the rotor, insert the rotor into the middle of the bearing ring as shown. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 36 Step 18: Snap Ring Pliers Install the oil pump retaining washer and snap ring. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 37 Check the operation of the oil flow regulator valve. The highlighted component should push into the regulator and spring back out. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 38 Be sure to locate the holes at the sides as shown. - End of Section 3b - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 39: C: Intake Piston Seal Replacement

    ES# on the label. Identical seal also used on exhaust piston - a total of two are included in the kit. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 40: Intake Piston Seal Replacement

    NOTE Step 2: Push/pull the intake piston out of its cylinder towards the direction of the cap. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 41 Carefully cut the sealing ring and o-ring using an exacto knife, then remove them from the piston ring groove. Use caution not to cut or damage the surface of the intake piston. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 42 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 43 Remove the Teflon sealing ring - and - the o-ring underneath. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 44 This might seem damaging at first, but the Teflon is very resilient and will return to shape after it is installed. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 45 Step 12: Lubricate both ends of the intake piston with clean engine oil. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 46 Allow it to remain installed for one minute, then remove it. This process will fully seat the Teflon ring onto the intake piston. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 47 Step 16: Angled Pick Remove the old seal from the piston cap and clean the groove thoroughly. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 48 Install the intake piston cap and torque the bolts to 10 Nm (7 Ft-lbs). 10 Nm (7 Ft-lbs) - End of Section 3c - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 49: D: Exhaust Piston Seal Replacement

    ES# on the label. Identical seal also used on intake piston - a total of two are included in the kit. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 50: Exhaust Piston Seal Replacement

    NOTE Step 2: Push/pull the exhaust piston out of its cylinder towards the direction of the cap. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 51 Carefully cut the sealing rings and o-rings using an exacto knife, then remove them from the piston ring grooves. Use caution not to cut or damage the surface of the exhaust piston. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 52 Be sure and use the o-ring and Teflon sealing ring installation tips and procedures learned during intake piston seal replacement. Step 6: Lubricate the Teflon seals with clean engine oil. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 53 Leave it installed for a minute, then remove it. This process will fully seat the Teflon ring onto the small end of the exhaust piston. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 54 Step 10: Angled Pick Remove the old seal from the piston cap and clean the groove thoroughly. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 55 Install the exhaust piston cap and torque the bolts to 10 Nm (7 Ft-lbs). 10 Nm (7 Ft-lbs) - End of Section 3d - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 56: A: Vanos Transfer Gear Service

    Location ....Vanos Transfer Gear Quantity ....4 ES#3138151 Description....Transfer Gear Cap Socket Location ....N/A Quantity ....1 ES#3138153 Description....Transfer Gear Holding Tool Location ....N/A Quantity ....1 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 57: Vanos Transfer Gear Service

    If you are unable to easily pull out them out, you may need to loosen the hub bolts an additional turn. NOTE Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 58 Using brake cleaner, thoroughly clean the transfer gear and flush out the oil through the two holes in the cover plate. Flush Out Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 59 Roller Bearing Roller Bearing Bearing Ring Gear Cap End Washer End Washer Transfer Gear Bearing Race Shaft Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 60 Hold stationary as the shaft can be turned by hand using no Hold stationary more than light to medium force. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 61 Gear Cap Transfer Gear What is the difference between the original bearing The ECS Tuning bearing ring is narrower than the ring and the new ECS bearing ring, if an adjustment original, getting the adjustment very close, so fine may still need to be made after installation? tuning is a quick and easy procedure.
  • Page 62 Clearance Clearance Gear Cap Shaft Bearing Ring Transfer Gear Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 63 Bearing ring is too narrow, allowing the End washers to extend past the edges and get “crushed” into the bearings. Gear Cap Shaft Transfer Gear Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 64 Preload and axial play are set perfectly! and can be rotated by hand with Skip to Step 15 on Page 70 to continue. light or moderate effort. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 65 One side is beveled and should face “up” to make it easier to slide the transfer gear in place. NOTE Step 7: Slide the transfer gear into the holding tool. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 66 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 67 If the transfer gear shaft is too tight and you need to loosen the bearing by reducing the thickness of the end washers, skip to Step 14 on Page End Washer Gear Cap Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 68 Install the other bearing Install the other end washer Thread the gear cap into place Continue with Step 12 on the next page. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 69 This procedure will remove a very small amount of material, approximately .004 - .006mm from the total thickness of the ring. Thoroughly clean the bearing ring and continue with Step 11 on Page Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 70 Do not install the transfer gears back into the vanos hubs. Set them aside for now as you complete sections 4B and 4C. Installation will be covered in section 5. - End of Section 4a - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 71: B: Vanos Hub Service

    SECTION 4B: VANOS HUB SERVICE - REQUIRED PARTS ES#23235 Description....Vanos Diaphragm Spring Sets Location ....Vanos Hubs Quantity ....2 ES#15158 Description....M6 x 25 Hex Bolt Location ....Vanos Hubs Quantity ....12 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 72: Vanos Hub Service

    Occasionally, the springs and plates will remain in the back of the Vanos hubs. Make sure you remove them. Diaphragm Spring Pressure Plate Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 73 Thoroughly clean the Vanos hubs. Step 4: Install the new diaphragm spring into the back side of each Vanos hub with the cupped side down. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 74 Small Pick or Screwdriver Rotate the cam sprocket rear plates so that the bolt holes are centered in the slots of the cam sprockets. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 75 - End of Section 4b - You are now ready to completely reinstall the Vanos and finish the job. Continue with section 5A on Page Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 76: C: Cam Sprocket Service

    The original cam sprocket hub bolts commonly loosen up, and this service replaces the original bolts which addresses the problem and prevents it from reoccurring. NOTE Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 77: Cam Sprocket Service

    You will be replacing these bolts one at a time, working from top to bottom in order to prevent the cleaning solvent from getting onto the newly installed bolts. NOTE Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 78 Repeat the procedure for all of the remaining cam sprocket hub bolts and once you are complete, clean any debris/solvent out of the internal camshaft splines. - End of Section 4c - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 79: D: Upper Timing Chain Guide Replacement

    Description....Upper Timing Chain Guide bolt sealing washer. Location ....Engine Front RH Side Quantity ....1 ES#2603148 Description....Chain Tensioner Sealing Washer Location ....Chain Tensioner Large End Quantity ....1 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 80: Upper Timing Chain Guide Replacement

    Remove the old sealing ring, clean up the tensioner, and install the new sealing ring. Set the tensioner aside for now. New Sealing Ring Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 81 Allow the chain to hang over the intake sprocket so it is out of the way of the timing chain guide. Timing Chain Guide Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 82 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 83 10mm Hex Bit (Allen) Socket, Torque Wrench Lower the new Upper timing chain guide into place and install the guide bolt. Torque the bolt to 24 Nm (18 Ft-lbs). Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 84 Reinstall the timing chain tensioner and once it is snug, tighten it approximately an additional 1/2 turn to “crush” the sealing washer. Proceed with step 6 on Page - End of Section 4d - Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 85 Description....Vanos Valve Block Sealing Plate Location ....Between Coil Pack and Valve Block Quantity ....1 ES#2702388 Description....Piston Housing Gasket Location ....Between Piston Housing and Cyl Head Quantity ....1 Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 86: 5A: Reassembly

    Once the intake camshaft is aligned as described above, pull out the dowel pin. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 87 Once the exhaust camshaft is aligned as described above, pull out the dowel pin and remove the camshaft bridge. Step 4: Thoroughly clean the Vanos gasket surface on the front of the cylinder head. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 88 3) Tighten them by hand and be careful not to over tighten them. Due to the left hand thread, they do no need to be excessively tightened. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 89 It works either way. If you have a preference, you can move the dowels from one component to the other - your call. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 90 2) Once engaged, only push them in a short way, the oil pump rotor still need to be aligned. 3) The Vanos hubs will rotate counter-clockwise as the transfer gears are pushed in. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 91 Do not tighten them. Confirm that the Vanos pistons are pushed all the way back into the housing. Push them back in if necessary. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 92 You will have to remove the Vanos piston housing w/transfer gears, reset the cam position, then reinstall it, making sure the bolts are loose enough. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 93 (highlighted). Note the following: 1) For clarity, the photo is shown without the piston housing installed. 2) Tighten the bolts only until they are snug. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 94 1) For clarity, the photo is shown without the piston housing installed. 2) There is not enough room for a torque wrench, so you will have to estimate the torque by feel. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 95 1) For clarity, the photo is shown without the piston housing installed. 2) There is not enough room for a torque wrench, so you will have to estimate the torque by feel. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 96 Fully retard the intake and exhaust camshafts. Reference page 21 for additional information. Step 22: Holes Install the alignment bridge between cylinders 2 and 3 as you did before. Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 97 (a small gap - approximately .5mm - between the head and the feet of the bridge is acceptable). Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 98 5mm Allen Socket, Torque Wrench Reinstall the oil pipe banjo bolt, the oil pipe securing bolt, and the Vanos bracket. Bracket Banjo Bolt Oil line bolt Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 99 Reinstall the valve block using the new sealing plate and torque the bolts to 10 Nm (7 Ft-lbs). Step 28: Tighten the pressure limiting valve and connect the electrical connector. Pressure Limiting Valve Electrical Connector Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...
  • Page 100 SECTION 5A: REASSEMBLY Step 29: Install the cam chain guide. Step 30: Reinstall the spark plugs and torque them to 25 Nm (18 Ft-lbs). Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 101: Engine Top Cover, Valve Cover, And Ignition Coils 5

    1. Air Box 2. Radiator Fan and Shroud 3. Cabin Filter Housing 4. Suspension Cross Brace 5. Engine Top Cover, Valve Cover, and Ignition Coils Return to Vanos Repair Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 102: Torquing Tips

    A non-ribbed bolt is identified by torque specification. the smooth contact surface Return to Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 103: Torque Specifications

    Vanos Hub Mounting Bolts .......................... 14 Nm (10.5 Ft-lbs) Vanos Oil Line Banjo Bolt ..........................13 Nm (9.5 Ft-lbs) Vanos Piston Housing Mounting Bolts ..................... 10 Nm (7 Ft-lbs) Return to Table of Contents ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM...

  • Page 104: Schwaben Tools

    SCHWABEN - BUILD THE ULTIMATE TOOL COLLECTION At ECS Tuning, we carry a line of high quality Schwaben tools and equipment to help you build your ultimate tool collection. Never before has affordability and quality been so closely related. Our entire Schwaben line is subjected to strict in house testing for strength and durability.
  • Page 105 FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH vehicle or compromise its safety. RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.

Table of Contents