Valve BMW 3 SERIES 1983 E30 User Guide

drag when the feeler gauge is moved back
and forth.
6If the gap is too large or too small, loosen
the locknut, insert a hook made from large-
diameter metal wire, and rotate the eccentric
to obtain the correct gap (see illustration).
7Once the gap has been set, hold the
eccentric in position with the hook, and
retighten the locknut securely. Recheck the
clearance - sometimes it’ll change slightly
when the locknut is tightened. If so, re-adjust
until it’s correct.
8On the M10 engine, the valves are adjusted
in the firing order, which is 1-3-4-2. After
adjusting No 1 cylinder valves, rotate the
crankshaft half a turn (180º), then check and
adjust the valves on No 3 cylinder. Repeat the
procedure on the remaining cylinders.
9On M20 and M30 engines, the valves are
adjusted following the firing order, which is
1-5-3-6-2-4. After adjusting No 1 cylinder
valves, rotate the crankshaft a third of a turn
(120º), then check and adjust the valves on No
5 cylinder. Repeat the procedure for the
remaining cylinders.
10Refit the valve cover (use a new gasket)
and tighten the mounting nuts evenly and
securely.
11Start the engine and check for oil leakage
between the valve cover and the cylinder
head.19 Throttle linkage -
check and lubrication
1
1The throttle linkage should be checked and
lubricated periodically to ensure its proper
operation.
2Check the linkage to make sure it isn’t
binding.
3Inspect the linkage joints for looseness, and
the connections for corrosion and damage,
renewing parts as necessary (see
illustration).
4Lubricate the connections with spray
lubricant or lithium-based grease.
20 Air filter renewal
1
Carburettor engines
1Release the spring clips, then unscrew the
centre nut and lift off the cover.
2Remove the air filter element, and wipe
clean the air cleaner body and cover
3Fit the new air filter element, then refit the
cover using a reversal of the removal
procedure.
Fuel injection engines
4Loosen the clamp on the air intake duct,
and detach the duct (see illustration).5Release the air cleaner cover retaining clips
(see illustration).
6Rotate the cover up, lift it off and lift the
element out, noting which way round it is
fitted (see illustrations).
7Wipe the inside of the air cleaner housing
with a clean cloth, then fit the new element. If
the element is marked TOP, be sure the
marked side faces up.
8Refit the cover and secure the clips.
9Connect the air duct and tighten the clamp
screw.
21 Fuel system check
1
Warning: Fuel is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don’t
smoke, or allow open flames or bare light
bulbs, near the work area. Don’t work in a
garage where a natural gas-type appliance
(such as a water heater or clothes dryer)
with a pilot light is present. Work in a well-
ventilated area. If you spill any fuel on your
skin, rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a fire extinguisher on hand. Mop
up spills immediately, but do not store
fuel-soaked rags where they could ignite.
1If you smell fuel while driving or after the
vehicle has been sitting in the sun, inspect the
fuel system immediately.
2Remove the fuel filler cap and inspect it for
damage and corrosion. The gasket should
have an unbroken sealing imprint. If the
gasket is damaged or corroded, fit a new cap.
3Inspect the fuel feed and return lines for
cracks. Make sure that the connections
between the fuel lines and the carburettor or
fuel injection system, and between the fuel
lines and the in-line fuel filter, are tight.
Warning: On fuel injection
models, the fuel system must be
depressurised before servicing
fuel system components, as
outlined in Chapter 4.
1•20
20.6b . . . and lift the air filter
element out20.6a Rotate the cover
upwards . . .
20.5 Use a screwdriver to detach the air
cleaner cover clips20.4 Detach the duct from the air cleaner
housing19.3 Check and lubricate the throttle
linkage at the points shown (arrowed) -
fuel injection engine shown
Every 12 000 miles

2A
General
Displacement
3-series, E30 body style
316i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1596 cc (M40/4-cylinder engine)
316 (1983 to 1988) and 318i (1983 to 1987) . . . . . . . . . . . . . . . . 1766 cc (M10/4-cylinder engine)
318i (1987 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1796 cc (M40/4-cylinder engine)
320i (1987 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990 cc (M20/6-cylinder engine)
325i (1987 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2494 cc (M20/6-cylinder engine)
5-series, E28 body style (“old-shape”)
518 (1981 to 1985) and 518i (1985 to 1988) . . . . . . . . . . . . . . . . 1766 cc (M10/4-cylinder engine)
525i (1981 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2494 cc (M30/6-cylinder engine)
528i (1981 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2788 cc (M30/6-cylinder engine)
535i (1985 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3430 cc (M30/6-cylinder engine)
M535i (1985 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3430 cc (M30/6-cylinder engine)
5-series, E34 body style (“new-shape”)
518i (1990 to 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1796 cc (M40/4-cylinder engine)
520i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990 cc (M20/6-cylinder engine)
525i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2494 cc (M20/6-cylinder engine)
530i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2986 cc (M30/6-cylinder engine)
535i (1988 to 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3430 cc (M30/6-cylinder engine)
Firing order
Four-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Six-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Lubrication system
Oil pressure (all engines)
At idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 2.0 bars
Running (for example, at 4000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 bars or above (typically)
Oil pump rotor clearance - M40 engine
(body-to-outer rotor/outer rotor-to-inner rotor) . . . . . . . . . . . . . . . . . . . 0.12 mm to 0.20 mm
Oil pump pressure relief valve spring length - M40 engine . . . . . . . . . . 84.1 mm
Chapter 2 Part A:
In-car engine repair procedures
Camshaft - removal, inspection and refitting . . . . . . See Chapter 2B
Compression check . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head - dismantling and inspection . . . . . . . See Chapter 2B
Drivebelt check, adjustment and renewal . . . . . . . . See Chapter 1
Engine - removal and refitting . . . . . . . . . . . . . . . . . See Chapter 2B
Engine mountings - check and renewal . . . . . . . . . . . . . . . . . . . . . . 17
Engine oil and filter change . . . . . . . . . . . . . . . . . . . See Chapter 1
Engine overhaul - general information . . . . . . . . . . . See Chapter 2B
Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Flywheel/driveplate - removal and refitting . . . . . . . . . . . . . . . . . . . 15
Front oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intake manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 5Oil pump - removal, inspection and refitting . . . . . . . . . . . . . . . . . . 14
Repair operations possible with the engine in the vehicle . . . . . . . . 2
Rocker arm and shaft assembly - dismantling, inspection
and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt and sprockets - removal, inspection and refitting . . . . . 10
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . 9
Timing chain and sprockets - removal, inspection and refitting . . . . 8
Timing chain covers - removal and refitting . . . . . . . . . . . . . . . . . . . 7
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearance check and adjustment . . . . . . . . . . . See Chapter 1
Valve cover - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves - servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
2A•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty
Specifications Contents

1 General information
This Part of Chapter 2 is devoted to in-
vehicle engine repair procedures. All
information concerning engine removal and
refitting and engine block and cylinder head
overhaul can be found in Chapter 2B.
The following repair procedures are based
on the assumption that the engine is still fitted
in the vehicle. If the engine has been removed
from the vehicle and mounted on a stand,
many of the steps outlined in this Part of
Chapter 2 will not apply.
The Specifications included in this Part of
Chapter 2 apply only to the procedures
contained in this Part. Chapter 2B contains
the Specifications necessary for cylinder head
and engine block rebuilding.
The single overhead camshaft four- and
six-cylinder engines covered in this manual
are very similar in design. Where there are
differences, they will be pointed out.
The means by which the overhead
camshaft is driven varies according to engine
type; M10 and M30 engines use a timing
chain, while M20 and M40 engines have a
timing belt.
2 Repair operations possible
with the engine in the vehicle
Many major repair operations can be
accomplished without removing the engine
from the vehicle.
Clean the engine compartment and the
exterior of the engine with some type of
degreaser before any work is done. It will
make the job easier, and help keep dirt out of
the internal areas of the engine.
Depending on the components involved, it
may be helpful to remove the bonnet to
improve access to the engine as repairs are
performed (see Chapter 11 if necessary).
Cover the wings to prevent damage to the
paint. Special pads are available, but an old
bedspread or blanket will also work.
If vacuum, exhaust, oil or coolant leaks
develop, indicating a need for gasket or seal
renewal, the repairs can generally be made
with the engine in the vehicle. The intake and
exhaust manifold gaskets, sump gasket,
crankshaft oil seals and cylinder head gasket
are all accessible with the engine in place.
Exterior components, such as the intake
and exhaust manifolds, the sump, the oil
pump, the water pump, the starter motor, the
alternator, the distributor and the fuel system
components, can be removed for repair with
the engine in place.
The cylinder head can be removed without
removing the engine, so this procedure is
covered in this Part of Chapter 2. Camshaft,
rocker arm and valve component servicing ismost easily accomplished with the cylinder
head removed; these procedures are covered
in Part B of this Chapter. Note, however, that
the camshaft on the M40 engine may be
removed with the engine in the vehicle since it
is retained by bearing caps.
In extreme cases caused by a lack of
necessary equipment, repair or renewal of
piston rings, pistons, connecting rods and
big-end bearings is possible with the engine in
the vehicle. However, this practice is not
recommended, because of the cleaning and
preparation work that must be done to the
components involved.
3 Top Dead Centre (TDC) for
No 1 piston- locating
2
Note 1:The following procedure is based on
the assumption that the distributor (if
applicable) is correctly fitted. If you are trying
to locate TDC to refit the distributor correctly,
piston position must be determined by feeling
for compression at the No 1 spark plug hole,
then aligning the ignition timing marks or
inserting the timing tool in the flywheel, as
applicable.
Note 2:The No 1 cylinder is the one closest to
the radiator.
1Top Dead Centre (TDC) is the highest point
in the cylinder that each piston reaches as it
travels up and down when the crankshaft
turns. Each piston reaches TDC on the
compression stroke and again on the exhaust
stroke, but TDC generally refers to piston
position on the compression stroke.
2Positioning the piston at TDC is an essential
part of many procedures, such as timing belt
or chain removal and distributor removal.
3Before beginning this procedure, be sure to
place the transmission in Neutral, and apply
the handbrake or chock the rear wheels. Also,
disable the ignition system by detaching the
coil wire from the centre terminal of the
distributor cap, and earthing it on the engine
block with a jumper wire. Remove the spark
plugs (see Chapter 1).
4In order to bring any piston to TDC, the
crankshaft must be turned using one of the
methods outlined below. When looking at the
front of the engine, normal crankshaft rotation
is clockwise.
(a) The preferred method is to turn the
crankshaft with a socket and ratchet
attached to the bolt threaded into the
front of the crankshaft.
(b) A remote starter switch, which may save
some time, can also be used. Follow the
instructions included with the switch.
Once the piston is close to TDC, use a
socket and ratchet as described in the
previous paragraph.
(c) If an assistant is available to turn the
ignition switch to the Start position in
short bursts, you can get the piston close
to TDC without a remote starter switch.Make sure your assistant is out of the
vehicle, away from the ignition switch,
then use a socket and ratchet as
described in (a) to complete the
procedure.
5Note the position of the terminal for the
No 1 spark plug lead on the distributor cap. If
the terminal isn’t marked, follow the plug lead
from the No 1 cylinder spark plug to the cap
(No 1 cylinder is nearest the radiator).
6Use a felt-tip pen or chalk to make a mark
directly below the No 1 terminal on the
distributor body or timing cover.
7Detach the distributor cap, and set it aside
(see Chapter 1 if necessary).
8Turn the crankshaft (see paragraph 4
above) until the timing marks (located at the
front of the engine) are aligned (see
illustration). The M40 engine does not have
any timing marks at the front of the engine,
but instead has a timing hole in the flywheel
which must be aligned with a hole in the rear
flange of the cylinder block. On this engine,
turn the crankshaft until the distributor rotor is
approaching the No 1 TDC position, then
continue to turn the crankshaft until a suitable
close-fitting drill can be inserted through the
hole in the cylinder block and into the
flywheel.
9Look at the distributor rotor - it should be
pointing directly at the mark you made on the
distributor body or timing cover.
10If the rotor is 180 degrees out, the No 1
piston is at TDC on the exhaust stroke.
11To get the piston to TDC on the
compression stroke, turn the crankshaft one
complete turn (360°) clockwise. The rotor
should now be pointing at the mark on the
distributor or timing cover. When the rotor is
pointing at the No 1 spark plug lead terminal
in the distributor cap and the ignition timing
marks are aligned, the No 1 piston is at TDC
on the compression stroke. Note:If it’s
impossible to align the ignition timing marks
when the rotor is pointing at the mark, the
timing belt or chain may have jumped the
teeth on the sprockets, or may have been
fitted incorrectly.
In-car engine repair procedures 2A•3
3.8 Align the notch in the pulley with the
notch on the timing plate, then check to
see if the distributor rotor is pointing to the
No 1 cylinder (if not, the camshaft is 180
degrees out - the crankshaft will have to
be rotated 360 degrees)
2A

12After the No 1 piston has been positioned
at TDC on the compression stroke, TDC for
any of the remaining pistons can be located
by turning the crankshaft and following the
firing order. Mark the remaining spark plug
lead terminal locations just like you did for the
No 1 terminal, then number the marks to
correspond with the cylinder numbers. As you
turn the crankshaft, the rotor will also turn.
When it’s pointing directly at one of the marks
on the distributor, the piston for that particular
cylinder is at TDC on the compression stroke.
4 Valve cover-
removal and refitting
1
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal
1Disconnect the battery negative cable.
2Detach the breather hose from the valve
cover.
3On M20 engines, unbolt and remove the
intake manifold support bracket and, if
applicable, the bracket for the engine sensors
or idle air stabiliser (it will probably be
necessary to disconnect the electrical
connectors from the sensors and stabiliser).
4On M30 engines, disconnect the electrical
connector for the airflow sensor. Unclip the
electrical harness, moving it out of the way.
5Where necessary on M30 engines, remove
the hoses and fittings from the intake air hose,
then loosen the clamp and separate the hose
from the throttle body. Unscrew the mounting
nuts for the air cleaner housing, and remove
the housing together with the air hose and
airflow sensor.
6Remove the valve cover retaining nuts and
washers (see illustrations). Where necessary,
disconnect the spark plug lead clip or coverfrom the stud(s), and set it aside. It will usually
not be necessary to disconnect the leads from
the spark plugs.
7Remove the valve cover and gasket.
Discard the old gasket. On the M40 engine,
also remove the camshaft cover (see
illustrations). If applicable, remove the semi-
circular rubber seal from the cut-out at the
front of the cylinder head.
Refitting
8Using a scraper, remove all traces of old
gasket material from the sealing surfaces of
the valve cover and cylinder head.
Caution: Be very careful not to
scratch or gouge the delicate
aluminium surfaces. Gasket
removal solvents are available at
motor factors, and may prove helpful.
After all gasket material has been
removed, the gasket surfaces can be
degreased by wiping them with a rag
dampened with a suitable solvent.
9If applicable, place a new semi-circular
rubber seal in the cut-out at the front of the
cylinder head, then apply RTV-type gasket
sealant to the joints between the seal and the
mating surface for the valve cover gasket.
Note:After the sealant is applied, you should
refit the valve cover and tighten the nuts within
ten minutes.
10Refit the camshaft cover (M40 engine), the
valve cover and a new gasket. Refit the
washers and nuts; tighten the nuts evenly and
securely. Don’t overtighten these nuts - theyshould be tight enough to prevent oil from
leaking past the gasket, but not so tight that
they warp the valve cover.
11The remainder of refitting is the reverse of
removal.
5 Intake manifold-
removal and refitting
2
Removal
1Allow the engine to cool completely, then
relieve the fuel pressure on fuel-injection
engines (see Chapter 4).
2Disconnect the battery negative cable.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
3Drain the engine coolant (see Chapter 1)
below the level of the intake manifold. If the
coolant is in good condition, it can be saved
and reused.
4On fuel injection engines, loosen the hose
clamp and disconnect the large air inlet hose
from the throttle body. It may also be
necessary to remove the entire air
cleaner/inlet hose assembly to provide
enough working room (see Chapter 4).
2A•4 In-car engine repair procedures
4.7b Removing the camshaft cover on the
M40 engine4.7a Removing the valve cover on the
M40 engine4.7c Removing the valve cover gasket on
the M40 engine
4.6b Valve cover bolt locations (arrowed)
on M20 six-cylinder engines4.6a Valve cover bolt locations (arrowed)
on M10 four-cylinder engines

5On carburettor engines, remove the
complete air cleaner assembly (see Chap-
ter 4).
6Disconnect the coolant hoses from the
throttle body/intake manifold as applicable.
7Disconnect the throttle cable and, if
applicable, cruise control cable (see Chap-
ter 4).
8Remove the EGR valve and line where
applicable (see Chapter 6).
9At this stage on the M40 engine, the upper
part of the intake manifold should be removed
by unscrewing the bolts and nuts. Remove
the gaskets (see illustrations).
10On fuel injection engines, disconnect the
vacuum hose from the fuel pressure regulator,
and disconnect the electrical connectors from
the fuel injectors (see Chapter 4).
11Disconnect the fuel lines from the fuel rail
or carburettor, as applicable (see Chapter 4).
12On the M40 engine, unbolt and remove
the support bracket from the bottom of the
intake manifold (see illustration).
13Disconnect all remaining hoses and wires
attached between the intake manifold/throttle
body assembly and the engine or chassis.
14Remove the bolts and/or nuts that attach
the manifold to the cylinder head (see
illustrations). Start at the ends and work
toward the middle, loosening each one a little
at a time until they can be removed by hand.
Support the manifold while removing the
fasteners so it doesn’t fall. Note: You can
remove the manifold without removing the
throttle body, injectors, vacuum/thermovalves, fuel pressure regulator or carburettor.
If you’re fitting a new manifold, transfer the
components (see Chapter 4) and lines to the
new manifold before it is fitted on the cylinder
head.
15Move the manifold up and down to break
the gasket seal, then lift it away from the head
and remove the gasket (see illustrations).
Refitting
16Remove the old gasket, then carefully
scrape all traces of sealant off the head and
the manifold mating surfaces. Be very careful
not to nick or scratch the delicate aluminium
mating surfaces. Gasket removal solvents are
available at motor factors, and may prove
helpful. Make sure the surfaces are perfectly
clean and free of dirt and oil.17Check the manifold for corrosion (at the
coolant passages), cracks, warping and other
damage. Cracks and warping normally show
up near the gasket surface, around the stud
holes. If defects are found, have the manifold
repaired (or renew it, as necessary).
18When refitting the manifold, always use a
new gasket. Where one side of the gasket has
a graphite surface, this must face the cylinder
head.
19Refit the nuts and bolts and tighten them
gradually, working from the centre out to the
ends, to the torque listed in this Chapter’s
Specifications.
20The remainder of refitting is the reverse of
removal. On the M40 engine, renew the
gaskets between the upper and lower parts of
the manifold.
In-car engine repair procedures 2A•5
5.9c . . . and gaskets5.9b . . . and remove the upper part of the
intake manifold . . .5.9a On the M40 engine, remove the nuts
and special bolts . . .
5.15b Removing the lower intake manifold
gasket (M40 engine)5.15a Removing the lower intake manifold
(M40 engine)
5.14a Remove the intake manifold nuts
with a socket, ratchet and long extension
(M20 engine)5.12 Removing the support bracket from
the bottom of the intake manifold
(M40 engine)
5.14b Removing the lower intake manifold
nuts (M40 engine)
2A

6 Exhaust manifold-
removal and refitting
1
Warning: Make sure the engine is
completely cool before beginning
work on the exhaust system.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
2On models where the air cleaner is on the
exhaust manifold side of the engine, remove
the air cleaner housing assembly and/or
airflow sensor to provide sufficient working
area (see Chapter 4, if necessary).
3Unplug the HT leads and set the spark plug
lead harness aside (see Chapter 1).
4Clearly label, then disconnect or remove, all
wires, hoses, fittings, etc. that are in the way.
Be sure to disconnect the oxygen sensor,
where fitted.
5Raise the vehicle, and support it securely
on axle stands. Working from under the
vehicle, separate the exhaust downpipe from
the manifold. Use penetrating oil on the
fasteners to ease removal (see illustrations).
6Remove the axle stands, and lower the
vehicle. Working from the ends of the
manifold toward the centre, loosen the
retaining nuts gradually until they can be
removed. Again, penetrating oil may prove
helpful.
7Pull the manifold off the head, then remove
the old gaskets (see illustrations). Note:Be
very careful not to damage the oxygen sensor,
where fitted.8Clean the gasket mating surfaces of the
head and manifold, and make sure the
threads on the exhaust manifold studs are in
good condition.
9Check for corrosion, warping, cracks, and
other damage. Repair or renew the manifold
as necessary.
10When refitting the manifold, use new
gaskets. Tighten the manifold-to-head
retaining nuts gradually, starting at the centre
and working out to the ends, to the torque
listed in this Chapter’s Specifications. Also
tighten the downpipe-to-manifold nuts.
11The remaining steps are simply a reversal
of the removal procedure.
7 Timing chain covers-
removal and refitting
5
Note 1:This procedure applies to M10 and
M30 engines.
Note 2:The upper timing chain cover can be
removed separately. If you need to remove
both the upper and lower covers, special tools
are required. Read paragraphs 8 and 9 before
beginning work.
Removal
1Disconnect the battery negative cable.Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code before
disconnecting the battery.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
2If you’re removing the lower timing chain
cover (the upper cover can be removed
separately), remove the cooling fan and fan
shroud, the radiator and the fan drivebelt
pulley (see Chapter 3).
3On the M10 engine only, remove the water
pump (see Chapter 3).
4On engines where the distributor cap is
mounted directly to the timing chain cover,
remove the cap, rotor and the black plastic
cover beneath the rotor (see Chapter 1).
5On the M30 engine fitted with the
L-Jetronic fuel system, remove the
distributor from the upper timing cover (see
Chapter 5).
6Remove the valve cover (see Section 4).
7If you’ll be removing the lower timing chain
cover on the M30 engine, remove the crankshaft
pulley from the vibration damper/hub. Hold the
pulley stationary with a socket on the centre
bolt, and remove the pulley bolts with another
socket (see illustration).
8If you’ll be removing the lower timing chain
2A•6 In-car engine repair procedures
6.7c Removing the exhaust manifold-to-
downpipe gasket (M40 engine)6.7b Removing the exhaust manifold
gasket (M40 engine)6.7a Removing the exhaust manifold
(M40 engine)
6.5b Exhaust manifold-to-downpipe flange
(M40 engine)6.5a Remove the exhaust manifold nuts
(arrowed) from the exhaust pipe (M20
engine) - soaking the nuts with penetrating
oil should make them easier to remove
Remove the windscreen
washer reservoir from the
right-hand side of the engine
compartment to give more
working room.

8 Timing chain and
sprockets- removal,
inspection and refitting
5
Note:This procedure applies to M10 and M30
engines.
Caution: Once the engine is set
at TDC, do not rotate the
camshaft or crankshaft until the
timing chain is reinstalled. If the
crankshaft or camshaft is rotated with the
timing chain removed, the valves could hit
the pistons, causing expensive internal
engine damage.
Removal
1Position the No 1 cylinder at Top Dead
Centre (TDC) on the compression stroke (see
Section 3).
2Remove the valve cover (see Section 4).
Double-check that the No 1 cylinder is at TDC
on the compression stroke by making sure the
No 1 cylinder rocker arms are loose (not
compressing their valve springs).
3Remove the upper timing chain cover (see
Section 7). Note the location of the camshaft
timing marks, which should now be aligned.
On four-cylinder (M10) engines, there’s
usually a stamped line on the camshaft flange
that aligns with a cast mark on the top of the
cylinder head; also, the camshaft sprocket
dowel pin hole will be at its lowest point. On
six-cylinder (M30) engines, a line drawn
through two of the camshaft sprocket bolts
opposite each other would be exactly vertical,
while a line drawn through the other two bolts
would be horizontal. Additionally, the locating
pin should be in the lower left corner (between
the 7 and 8 o’clock positions). Be sure you’ve
identified the correct camshaft TDC position
before dismantling, because correct valve
timing depends on you aligning them exactly
on reassembly. Note:As the engine is
mounted in the engine compartment at anangle, all references to horizontal and vertical
whilst timing the camshafts are in relation to
the crankshaft, and not the ground.
4Hold the crankshaft stationary with a socket
and ratchet on the vibration damper centre bolt,
then loosen (but don’t unscrew completely) the
four bolts attaching the camshaft sprocket to
the camshaft. Be very careful not to rotate the
camshaft or crankshaft. Note:Some earlier
models may have locking tabs for the camshaft
sprocket bolts. Bend the tabs down before
loosening the bolts. The tabs are no longer
available from the manufacturer, and do not
have to be used on refitting.
5Remove the lower timing chain cover (see
Section 7).
6Unscrew and remove the four camshaft
sprocket bolts, then disengage the chain from
the crankshaft sprocket and carefully remove
the chain and camshaft sprocket from the
engine. It may be necessary to gently prise
the camshaft sprocket loose from the
camshaft with a screwdriver.
Inspection
Timing sprockets
7Examine the teeth on both the crankshaft
sprocket and the camshaft sprocket for wear.
Each tooth forms an inverted V. If worn, the
side of each tooth under tension will be
slightly concave in shape when compared
with the other side of the tooth (i.e. one side of
the inverted V will be concave when
compared with the other, giving the teeth a
hooked appearance). If the teeth appear to be
worn, the sprockets must be renewed. Note:
The crankshaft sprocket is a press fit on the
crankshaft, and can be removed with a jaw-
type puller after the Woodruff key and oil
pump are removed (see Section 14). However,
BMW recommends the new sprocket be
pressed onto the crankshaft after being
heated to 80°C (175°F) on the M10 engine, or
to 200°C(390°F) on the M30 engine. For this
reason, if the crankshaft sprocket requires
renewal, we recommend removing the
crankshaft (see Part B of this Chapter) and
taking it to an engineering works to have the
old sprocket pressed off and a new one
pressed on.
Timing chain
8The chain should be renewed if the
sprockets are worn or if the chain is loose
(indicated by excessive noise in operation).
It’s a good idea to renew the chain anyway if
the engine is stripped down for overhaul. The
rollers on a very badly worn chain may be
slightly grooved. To avoid future problems, if
there’s any doubt at all about the chain’s
condition, renew it.
Chain rail and tensioner
9Inspect the chain guide rail and tensioner
rail for deep grooves caused by chain contact.
Renew them if they are excessively worn. The
rails can be renewed after removing the
circlips with a pointed tool or needle-nose
pliers (see illustration).10Shake the tensioner plunger, and listen for
a rattling sound from the check ball. If you
can’t hear the ball rattling, renew the plunger.
11To further check the tensioner plunger,
blow through it first from the closed end, then
from the slotted (guide) end. No air should
flow through the plunger when you blow
through the closed end, and air should flow
through it freely when you blow through the
slotted end. If the tensioner fails either test,
renew it.
Refitting
12Refit the tensioner rail and chain guide
rail, if removed.
13Temporarily refit the lower timing chain
cover and vibration damper, so you can check
the crankshaft timing marks. Once you’ve
verified the TDC marks are aligned, remove
the damper and cover.
14Loop the timing chain over the crankshaft
sprocket, then loop it over the camshaft
sprocket and, guiding the chain between the
chain guide and tensioner rail, refit the
camshaft sprocket on the camshaft. Make
sure the camshaft timing marks are aligned.
15The remainder of refitting is the reverse of
removal. Be sure to tighten the fasteners to
the correct torques (see this Chapter’s Speci-
fications).
9 Timing belt covers-
removal and refitting
2
Note:This procedure applies to M20 and M40
engines.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
2Remove the fan clutch and fan shroud (see
Chapter 3).
3On the M20 engine, remove the radiator
(see Chapter 3).
4Remove the fan drivebelt pulley.
2A•8 In-car engine repair procedures
9.6a Unbolt the distributor cap
(M40 engine) . . .
8.9 To remove the tensioner or chain guide
rail, remove the circlips with a pointed tool
or needle-nose pliers - the circlips tend to
fly off when they’re released, so make sure
you catch them or they’ll get lost (or,
worse, wind up in the engine!)

5If applicable, disconnect the reference
sensor wiring harness which runs across the
front of the timing belt cover, and set it aside.
6If the distributor cap is mounted directly to
the upper timing belt cover, remove the cap,
rotor and the black plastic cover beneath the
rotor (see illustrations).
7Remove the lower fan drivebelt pulley and
vibration damper. Secure the crankshaft
pulley centre bolt while you loosen the outer
pulley/damper bolts (see illustration 7.7).
8Remove the bolts/nuts attaching the timing
belt covers to the engine (see illustration).
9Remove the upper cover first, then the
lower cover (see illustrations). Note: The
upper cover has two alignment sleeves in the
top bolt positions. Be sure these are in place
upon reassembly.
10Refitting is the reverse of the removal
procedure. Tighten the cover bolts securely.
10 Timing belt and sprockets-
removal, inspection and
refitting
5
Note 1:This procedure applies to M20 and
M40 engines.
Note 2:Before removing the camshaft
sprocket on the M40 engine, it is necessary to
obtain a tool to hold the camshaft for the
refitting procedure (see paragraph 10).Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you
have the correct activation code
before disconnecting the battery.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal1Disconnect the negative cable from the
battery.
2Remove the timing belt covers (see Sec-
tion 9).
3On the M40 engine, drain the cooling
system (see Chapter 1), then disconnect thehose, unbolt the thermostat housing and
remove the thermostat (see Chapter 3).
4Set the No 1 piston at TDC (see Section 3).
Caution: Once the engine is set at
TDC, do not rotate the camshaft
or crankshaft until the timing belt
is refitted. If the crankshaft or
camshaft is rotated with the timing belt
removed, the valves could hit the pistons,
causing expensive internal engine damage.
5On the M20 engine, the crankshaft mark
should be aligned with the mark on the inner
cover(see illustration). The mark on the
camshaft sprocket should be aligned with the
stamped line on the cylinder head (see
illustration). On the M40 engine, make an
In-car engine repair procedures 2A•9
9.8 Remove all the nuts/ bolts (arrowed)
that attach the upper and lower covers
(M20 engine - removed for clarity)9.6c . . . and remove the black plastic
cover9.6b . . . then unbolt the rotor . . .
9.9c Removing the lower timing belt cover
on the M40 engine9.9b Removing the upper timing belt cover
on the M40 engine
10.5b Align the mark on the camshaft
sprocket with the mark on the cylinder
head (arrowed)10.5a Align the groove in the hub on the
end of the crankshaft with the notch in the
front inner cover (arrowed) and mark them
for assembly reference later on
9.9a Remove the upper timing belt cover
first, then the lower cover (M20 engine)
1 Upper timing belt cover
2 Lower timing belt cover
2A

alignment mark on the camshaft sprocket and
rear timing cover to ensure correct refitting.
6On the M20 engine, loosen the two
tensioner roller retaining bolts a little, and
push the tensioner towards the water pump
(see illustration). With the timing belt tension
relieved, re-tighten the retaining bolt.
7On the M40 engine, loosen the tensioner
retaining nut, and use an Allen key to rotate
the tensioner clockwise. This will relieve the
tension of the timing belt. Tighten the
retaining nut to hold the tensioner in its free
position.
8If the same belt is to be refitted, mark it with
an arrow indicating direction of rotation.
Caution: It is not advisable to
refit a timing belt which has been
removed unless it is virtually
new. On the M40 engine, BMW
recommend that the timing belt is
renewed every time the tensioner roller is
released.
9Remove the timing belt by slipping it off the
roller(s) and the other sprockets (see
illustrations).
10If it’s necessary to remove the camshaft
or the intermediate shaft sprocket, remove the
sprocket bolt while holding the sprocket to
prevent it from moving. To hold the sprocket,
wrap it with a piece of an old timing belt
(toothed side engaging the sprocket teeth) ora piece of leather, then hold the sprocket
using a strap spanner. If a strap spanner is not
available, clamp the ends of the piece of belt
or leather tightly together with a pair of grips.
Before loosening the bolt, make sure you have
the necessary tool for positioning the
camshaft as described in the following
paragraph (see illustration).
Caution: Do not use the timing
belt you’re planning to refit to
hold the sprocket. Also, be sure
to hold the camshaft sprocket
very steady, because if it moves more than
a few degrees, the valves could hit the
pistons.
Note: On the M40 engine, the sprocket is not
directly located on the camshaft with a key, as
the groove in the end of the camshaft allows
the sprocket to move several degrees in either
direction. The retaining bolt locks the sprocket
onto a taper after positioning the camshaft
with a special tool.
11The BMW tool for positioning the camshaft
on the M40 engine consists of a metal plate
which locates over the square lug near the No
1 cylinder lobes on the camshaft - the valve
cover must be removed first (see
illustrations). If the BMW tool cannot be
obtained, a home-made tool should be
fabricated out of metal plate. The tool must be
made to hold the square lug on the camshaft
at right-angles to the upper face of the cylinder
head (ie the contact face of the valve cover).
12If it’s necessary to remove the crankshaft
sprocket, remove the crankshaft hub centre
bolt while holding the crankshaft steady.
Note:The removal of the crankshaft hub
mounting bolt requires a heavy-duty holding
device because of the high torque used to
tighten the bolt. BMW has a special tool,
numbered 112150 (M20 engines) or 112170
(M40 engines), for this purpose. If this tool
cannot be bought or borrowed, check with a
tool dealer or motor factors for a tool capable
of doing the job. Note that the tool number
112170 bolts on the rear of the cylinder head
and engages with the flywheel ring gear, so it
will only be possible to use this tool if the
gearbox has been removed, or if the engine is
out of the vehicle (see illustrations). On
2A•10 In-car engine repair procedures
10.12a Home-made tool for holding the
crankshaft stationary while the crankshaft
pulley bolt is being loosened (engine
removed for clarity)
10.11b The BMW camshaft-holding tool in
position on the M40 engine10.11a The BMW tool for holding the
camshaft in the TDC position on
M40 engines
10.10 Removing the camshaft sprocket on
the M40 engine
10.9b Removing the timing belt from the
camshaft sprocket on the M40 engine
10.9a When removing the timing belt on
models with a two-piece crankshaft hub,
it’s a tight fit to remove it around the hub,
but it’s a lot easier than removing the
crankshaft hub assembly, which is secured
by a very tight bolt10.6 Loosen the idler pulley bolts
(arrowed) to relieve the tension on the
timing belt so it can be removed

models with a two-piece hub, after removing
the outer hub piece, you’ll then need to
remove the sprocket with a bolt-type puller
(available at most motor factors). When using
the puller, thread the crankshaft centre bolt in
approximately three turns, and use this as a
bearing point for the puller’s centre bolt.
Inspection
13Check for a cracked, worn or damaged
belt. Renew it if any of these conditions are
found (see illustrations). Also look at the
sprockets for any signs of irregular wear or
damage, indicating the need for renewal.
Note:If any parts are to be renewed, check
with your local BMW dealer parts department
to be sure compatible parts are used. On M20
engines, later sprockets, tensioner rollers and
timing belts are marked “Z 127”. Renewal of
the timing belt on M20 engines will mean that
the later belt tensioner should also be fitted, if
not already done.
14Inspect the idler roller and, on M20
engines, the tension spring. Rotate the
tensioner roller to be sure it rotates freely, with
no noise or play. Note:When fitting a new
timing belt, it is recommended that a new
tensioner be fitted also.
Refitting
15On the M20 engine, refit the idler/
tensioner/spring so that the timing belt can be
fitted loosely.
16Refit the sprockets using a reversal of the
removal procedure; tighten the retaining bolts
to the specified torque. On the M40 engine,
turn the camshaft sprocket clockwise as far
as possible within the location groove, then
tighten the retaining bolt to an initial torque of
1 to 3 Nm at this stage.
17If you are refitting the old belt, make sure
the mark made to indicate belt direction of
rotation is pointing the right way (the belt
should rotate in a clockwise direction as you
face the front of the engine).
18Refit the timing belt, placing the belt
under the crankshaft sprocket first to get bythe housing. Guide the belt around the other
sprocket(s).
19Finally, place the belt over the
idler/tensioner rollers.
20On the M20 engine, loosen the tensioner
bolts and allow the spring tension to be
applied to the belt.
21On the M20 engine, lightly apply pressure
behind the tensioner to be sure spring
pressure is being applied to the belt (see
illustration). Don’t tighten the bolts while
applying pressure; lightly tighten the bolts
only after releasing the tensioner.
22On the M40 engine, unbolt and remove
the valve cover, then use the special tool to
hold the camshaft in the TDC position (see
paragraph 11).
23On the M40 engine, loosen the tensioner
roller retaining nut, and use an Allen key to
rotate the roller anti-clockwise until the timing
belt is tensioned correctly. The 90°-twist
method of checking the tension of the timing
belt is not accurate enough for this engine,
and it is strongly recommended that the
special BMW tensioning tool is obtained if at
all possible (apply 32 ±2 graduations on the
tool) (see illustration). A reasonably accurate
alternative can be made using an Allen key
and a spring balance (see illustration).Make
sure that the spring balance is positioned as
shown, since the tensioner roller is on an
eccentric, and different readings will be
obtained otherwise. The spring balance
should be connected 85 mm along the Allen
key, and a force of 2.0 kg (4.4 lb) should be
In-car engine repair procedures 2A•11
10.13a Inspect the timing belt carefully for
cracking, as shown here. . .
10.13b . . . and any other damage
10.12c Removing the crankshaft sprocket
from the front of the crankshaft10.12b Removing the crankshaft pulley
bolt (M40 engine)
10.23b Using a spring balance and Allen
key to adjust the tension of the timing belt
on the M40 engine
Dimension A = 85 mm
10.23a Using the special BMW tool to
check the tension of the timing belt on the
M40 engine
10.21 On the M20 engine, after the belt
has been installed correctly around all
sprockets and the tensioner pulley, lightly
apply pressure to the tensioner, to be sure
the tensioner isn’t stuck and has full
movement against the timing belt
2A