525i-2006-N52.pdf

ENGINE
Engine - Repair Instructions - N51, N52, N52K 6-Cylinder
00 ENGINE, GENERAL
00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
Possible symptoms are:
Headaches
Dizziness
Stomach aches
Vomiting
Diarrhoea
Cramps/fits
Unconsciousness
Protective measures/rules of conduct:
Pour oil only into appropriately marked containers
Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
Observe country-specific safety regulations
First aid measures:
Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of
water and consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the
recovery position and seek immediate medical attention.
00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
Danger of injury!
NOTE: Removal and installation procedures apply to 3-Series; 5-Series is similar.
2006 BMW 525i
ENGINE Engine - Repair Instructions - N51, N52, N52K 6-Cylinder
2006 BMW 525i
sábado, 2 de octubre de 2021 11:08:54 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.

Contact with eyes or skin may result in injury!
Possible symptoms are:
Impaired sight
Irritation of the eyes
Reddening of the skin
Rough and cracked skin
Protective measures/rules of conduct:
Wear protective goggles
Wear oil-resistant protective gloves
Observe country-specific safety regulations
First aid measures:
Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-
rinsing bottle. If irritation of the eyes persists, consult a doctor.
Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.
00 SAFETY INSTRUCTIONS FOR HANDLING OIL
Recycling:
Observe country-specific waste-disposal regulations.
Measures if oil is unintentionally released:
Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work
area. Wear personal protective clothing/equipment.
Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems,
pits, cellars, water and the ground.
Limiting spread: Use oil blocks to prevent the surface spread of oil.
Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
NOTE: Do not use solvents/thinners.
WARNING: Danger Of Poisoning if oil is ingested/absorbed through the skin!
Risk Of Injury if oil comes into contact with eyes and skin!
NOTE: Do not flush oil away with water or aqueous cleaning agents.
2006 BMW 525i

11 00 REMOVING AND INSTALLING/REPLACING ACOUSTIC COVER (N52)
Unfasten screws (1 and 3).
If necessary, release oil cap (2) in direction of arrow.
Lift off acoustic cover (4)
Fig. 1: Identifying Oil Cap, Acoustic Cover And Retaining Screws
Courtesy of BMW OF NORTH AMERICA, INC.
E87, E90, E91:
Necessary preliminary tasks:
Remove Microfilter Housing
Unfasten screws.
IMPORTANT: Aluminium-magnesium materials.
No steel screws/bolts may be used due to the threat of electrochemical
corrosion.
A magnesium crankcase requires aluminium screws/bolts exclusively.
Aluminium screws/bolts must be replaced each time they are released.
The end faces of aluminium screws/bolts are painted blue for the purposes of
reliable identification.
Jointing torque and angle of rotation must be observed without fail (risk of
damage ).
2006 BMW 525i

For tightening torque refer to 11 12 7AZ in 11 12 CYLINDER HEAD WITH COVER .
Remove acoustic cover.
Fig. 2: Identifying Acoustic Cover And Mounting Screws
11 .. .. MOUNTING ENGINE ON ASSEMBLY STAND (N52)
Special tools required:
00 1 450
11 3 370
11 4 440
11 9 261
11 9 265
NOTE: For purposes of improved clarity, illustration and descriptions shows wiring
harness and tension strut removed.
corrosion.
2006 BMW 525i

Remove Engine.
Bolt engine or engine block with steel bolts (1) and aluminium bolts (2) to special tool 11 4 440.
To release central bolt, bolt on special tools 11 9 261 and 11 9 265 as well.
Mount engine with special tool 11 3 370 to special tool 00 1 450.
Fig. 3: Identifying Special Tool (11 9 261), (11 9 265), (11 4 440),(00 1 450), Steel Bolts And Aluminium
Bolts
11 00 050 REMOVING AND INSTALLING ENGINE (N52)
11 0 020
damage ).
NOTE: Following procedure is for 3-Series and 5-Series. Specific Z4 information is not
available from manufacturer. It is suggested to use 3-Series information.
corrosion.
2006 BMW 525i

Lift engine hood into Assembly Position.
Remove exhaust system.
Remove Transmission.
Drain Engine Oil.
Disconnect Negative Battery Lead.
Remove Air Cleaner Housing.
Remove fan cowl with electric fan.
Remove Radiator.
Remove Water Pump.
Remove Thermostat.
Detach All Coolant Hoses from engine.
Remove Left And Right Fresh Air Duct.
Remove Intake Air Manifold.
Detach Vacuum Line From Brake Booster.
Unfasten Ignition Wiring Harness and lay to one side.
Unfasten Engine Wiring Harness and lay to one side.
Remove Fuel Injector Rail and place to one side.
Release A/C Compressor (1) and set down on front axle carrier.
Do not disconnect coolant pipe from crankcase.
damage ).
IMPORTANT: A/C lines are pressurized.
Do not disconnect A/C lines.
2006 BMW 525i

Fig. 4: Identifying A/C Compressor
Release power steering pump (1) and set down on front axle carrier.
If Dynamic Drive optional extra is fitted, release bracket.
Fig. 5: Identifying Power Steering Pump
Screw in towing hook (1).
Suspend special tool 11 0 020 from engine crane.
Suspend special tool 11 0 020 from the designated mounting eyelets (2) only.
Lift engine out with crane.
NOTE: Do not disconnect hydraulic lines.
2006 BMW 525i

Fig. 6: Identifying Special Tool (11 0 020), Towing Hook And Engine Mounting Eyelets
Release screws (1).
Remove lines (2) with oil-water heat exchanger in direction of arrow.
Fig. 7: Identifying Oil-Water Heat Exchanger Lines And Retaining Screws
Assemble engine.
Check function of DME.
11 00 610 REPAIRING THREADS ON MAGNESIUM ENGINE BLOCK
NOTE: If automatic transmission optional extra is fitted: Raise engine approx. 10 cm.
IMPORTANT: Any work on the magnesium that creates dust must not be carried out without
2006 BMW 525i

Tape off parts to be cleaned (3) cleanly and protect against chips.
Use core drill bit (2) with hand drill (1).
Installation:
Ensure exact angularity to workpiece.
Blow out core bore cleanly.
No chips are permitted in the drilled hole.
suitable dust extraction apparatus in place.
Magnesium and water can react by forming magnesium hydroxide and
hydrogen.
Do not use any emulsions containing water to lubricate the magnesium
material.
Only engine oil may be used for lubrication.
corrosion.
damage).
2006 BMW 525i

Fig. 8: Identifying Core Drill Bit, Hand Drill And Clean Area
Screw in Helicoil drill bit (2) with die (1).
Installation:
Ensure exact angularity to workpiece.
Fig. 9: Identifying Helicoil Drill Bit And Die
Danger of fire and explosion.
IMPORTANT: Do not allow chips (1) to come into contact with water.
2006 BMW 525i

Fig. 10: Identifying Magnesium Chips
Screw in aluminium Helicoil (1) by hand in direction of arrow as far as it will go.
Adjust spacer (2) approx. 1 mm.
Secure spacer (2) with lock nut (3).
Fig. 11: Identifying Spacer, Lock Nut, Helicoil-Plus And Helicoil
Screw in Helicoil-Plus (1) with preassembled aluminium Helicoil.
2006 BMW 525i

Fig. 12: Identifying Helicoil-Plus
Screw aluminium Helicoil into workpiece (1) as far as it will go.
Remove Helicoil-Plus (2) again after screwing in.
Installation:
Aluminium Helicoil remains in workpiece (1).
Fig. 13: Identifying Helicoil-Plus And Workpiece
Break mounting hook off with mounting mandrel (1).
NOTE: Blow mounting hook out of pocket hole with compressed air.
2006 BMW 525i

Fig. 14: Identifying Mounting Mandrel
Assemble engine.
11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N52)
00 0 200
00 0 202
00 0 204
00 0 208
11 0 000
Secure Engine Bonnet/Hood In Service Position
Remove cowl panel cover
Remove Both Tension Struts From Spring Strut Dome
Remove Intake Filter Housing
WARNING: Danger of injury!
Observe following instructions relating to special tool:
1. Prior to each use, check the special tools for defects, modifications
and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the special tools!
4. Keep special tools dry, clean and free of grease.
2006 BMW 525i

Remove ignition coil cover
Assemble cross member 00 0 200 with special tools 00 0 202, 00 0 204, 00 0 208.
Fig. 15: Identifying Special Tool (00 0 200)
Fig. 16: Identifying Special Tool (72 15 8 108 670)
NOTE: Use towing hook (72 15 8 108 670).
IMPORTANT: Avoid a change of engine position in the transverse or longitudinal direction.
Always make sure there is sufficient clearance between the engine (or its
attachment parts) and the body.
IMPORTANT: Risk of damage!
2006 BMW 525i

Screw in towing hook (1) and tighten down to approx. 30 Nm.
Secure special tool 11 0 000 to spindle 00 0 202.
Fit suitable chains to special tool 11 0 000 and attach to towing hook (1) or engine lifting eye.
Fig. 17: Identifying Special Tool (00 0 202), (00 0 200), (11 0 000), Towing Hook And Supports
With the aid of an assistant and the supports (2), place cross member 00 0 200
on the screw connections of the side panels.
WARNING: Danger of injury!
Tighten down all adjusting screws and nuts on cross member 00 0 200.
2006 BMW 525i

Unscrew nuts (1).
Raise engine approx. 10 mm with cross member.
Installation:
Replace self-locking nuts.
For tightening torque refer to 22 11 2AZ in 22 11 ENGINE SUSPENSION .
Fig. 19: Identifying Self-Locking Nuts
ENGINE IDENTIFICATION
Drive in engine numbers at marked surface with impact tool.
M47 / M47TU / M47T2
2006 BMW 525i

Fig. 20: Identifying Engine Identification Numbers - M47 / M47TU / M47T2
M57 / M57TU / M57T2
2006 BMW 525i

Fig. 21: Identifying Engine Identification Numbers - M57 / M57TU / M57T2
M67 / M67TU
Fig. 22: Identifying Engine Identification Numbers - M67 / M67TU
N47
2006 BMW 525i

Fig. 23: Identifying Engine Identification Numbers - N47
M52 / M52TU
Fig. 24: Identifying Engine Identification Numbers - M52 / M52TU
M54
2006 BMW 525i

Fig. 25: Identifying Engine Identification Numbers - M54
M56
Fig. 26: Identifying Engine Identification Numbers - M56
N40 / N45
2006 BMW 525i

Fig. 27: Identifying Engine Identification Numbers - N40 / N45
N42 / N46 / N46T
Fig. 28: Identifying Engine Identification Numbers - N42 / N46 / N46T
N51 / N52 / N52K / N53 / N54
2006 BMW 525i

Fig. 29: Identifying Engine Identification Numbers - N51 / N52 / N52K / N53 / N54
N62
N73
2006 BMW 525i

S54
Fig. 32: Identifying Engine Identification Numbers - S54
S85
2006 BMW 525i

Fig. 33: Identifying Engine Identification Numbers - S85
W10 / W11
Fig. 34: Identifying Engine Identification Numbers - W10 / W11
W17
2006 BMW 525i

Fig. 35: Identifying Engine Identification Numbers - W17
Assemble engine.
MOUNTING ENGINE ON ASSEMBLY STAND (N52)
00 1 450
11 3 370
11 4 440
11 9 261
11 9 265
corrosion.
damage).
2006 BMW 525i

Remove Engine.
Bolt engine or engine block with steel bolts (1) and aluminium bolts (2) to special tool 11 4 440.
To release central bolt, bolt on special tools 11 9 261 and 11 9 265 as well.
Mount engine with special tool 11 3 370 to special tool 00 1 450.
Fig. 36: Identifying Special Tool (11 9 261), (11 9 265), (11 4 440), (00 1 450), Steel Bolts And Aluminium
Bolts
12 CYLINDER HEAD WITH COVER
11 12 000 REMOVING AND INSTALLING/SEALING CYLINDER HEAD COVER (N52)
corrosion.
damage).
2006 BMW 525i

Remove acoustic cover.
Remove rod-type ignition coils.
Unclip wiring harness for fuel injectors.
Remove Tension Strut.
Remove Clean Air Duct.
Unlock and detach engine vent hose (1).
If necessary, pull off metal bracket (2) in direction of arrow.
Release screws (3).
For tightening torque refer to 11 37 3AZ in 11 37 VARIABLE VALVE GEAR (N52) .
Remove servodrive (4) in direction of arrow.
If necessary, release nuts (5).
If necessary, remove secondary air valve (6).
Installation:
Replace aluminium screws.
Fig. 37: Identifying Secondary Air Valve, Metal Bracket, Engine Vent Hose, Servodrive And Nuts
Release screws in area (1).
Installation:
2006 BMW 525i

For tightening torque refer to 11 12 4AZ .
Release screws (2).
Installation:
Fig. 38: Identifying Aluminium Engine Screws
Replace seal (1).
Replace seal (2).
Installation:
Clean all sealing surfaces.
Do not clean sealing faces (1 and 2) with a metal cutting tool.
2006 BMW 525i

Fig. 39: Identifying Engine Seals
Assemble engine.
11 12 100 REMOVING AND INSTALLING CYLINDER HEAD (N52)
11 0 320
11 4 420
11 4 430
11 4 471
11 4 472
11 8 580
corrosion.
damage).
2006 BMW 525i

Remove Exhaust System.
Drain Coolant
Drain off Engine Oil.
Remove both Exhaust Manifolds
Remove Intake Air Manifold
Detach coolant hoses from cylinder head
Remove Inlet And Exhaust Adjustment Unit
Release screws (1).
Unclip timing chain module (2) at junction (3) and remove towards top.
Set down timing chain.
Fig. 40: Identifying Engine Timing Chain Module, Junction And Screws
IMPORTANT: Fit new cylinder head screws.
Do not wash off bolt coating.
There must be no coolant, water or engine oil in the pocket holes.
Risk of corrosion and cracking!
IMPORTANT: If the timing chain is stowed in the gearcase, the crankshaft must no longer be
rotated.
This would cause the timing chain on the crankshaft sprocket wheel to jam or
jump.
2006 BMW 525i

Installation:
The timing chain is lifted out with a hook only during assembly.
Release screws (2).
Remove eccentric shaft sensor (1) towards front.
Fig. 41: Identifying Eccentric Shaft Sensor And Mounting Screws
Release screw (1).
Remove magnet wheel (2) towards front.
Fig. 42: Identifying Magnet Wheel And Screw
IMPORTANT: Screw (1) is not magnetic and must be secured against falling down.
2006 BMW 525i

After removing, place magnet wheel (1) in a plastic bag (2) with a seal.
Fig. 43: Identifying Magnet Wheel And Plastic Bag
Pretension eccentric shaft (1) upwards in direction of arrow.
Remove stop screw between 1st and 2nd cylinders.
For tightening torque refer to 11 37 6AZ in 11 37 VARIABLE VALVE GEAR (N52) .
Fig. 44: Identifying Eccentric Shaft Screw
IMPORTANT: Magnet wheel (1) is highly magnetic and must be protected against metal
filings/borings.
2006 BMW 525i

Release bolt (2).
Release screws (1).
Installation:
Fig. 45: Identifying Engine Screws
Release M10 cylinder head bolts (1) with special tool 11 8 580.
Release M9 cylinder head bolts (2) with special tool 11 4 420.
NOTE: Screw (2) can only be released when the timing chain module is pressed
forward slightly.
IMPORTANT: Secure screw (2) with a gripper against falling down.
IMPORTANT: Observe different bolt heads.
NOTE: Picture shows inlet and exhaust camshafts removed.
2006 BMW 525i

Fig. 46: Identifying Special Tool (11 4 420) And (11 8 580)
Release M9 cylinder head bolts (1 and 3) with special tool 11 4 420.
Release M10 cylinder head bolts (2) with special tool 11 8 580 from outside inwards.
Fig. 47: Identifying Engine Cylinder Head Bolts
IMPORTANT: Observe different M9 bolt lengths (1 and 3).
IMPORTANT: All cylinder head bolts (1, 2 and 3) must be replaced.
Jointing torque and angle of rotation must be observed without fail.
2006 BMW 525i

Risk of damage!
Secure special tool 11 0 320 with existing cylinder head cover bolts (1).
Fig. 48: Identifying Special Tool (11 0 320) And Cylinder Head Cover Bolts
Insert special tool 11 4 430 into bores.
IMPORTANT: Removing and install cylinder head with a second person helping.
Weight of cylinder head with add-on parts is approx. 40 kg.
Do not set cylinder head down on sealing face, risk of damage to valves.
2006 BMW 525i

Remove coarse residues on sealing faces with special tool 11 4 471 from cylinder head and crankcase.
Remove fine residues on sealing faces with special tool 11 4 472 from cylinder head and crankcase.
Clean all pocket holes.
Replace Cylinder Head Gasket.
IMPORTANT: Do not use any metal-cutting tools.
IMPORTANT: Do not use any metal-cutting tools.
There must be no coolant, water or engine oil in the pocket holes.
Risk of corrosion and cracking!
2006 BMW 525i

Fit new cylinder head screws.
Insert cylinder head bolts (1 to 10) with special tool 11 8 580.
Insert cylinder head bolts (11 to 14) with special tool 11 4 420.
Fig. 52: Identifying Cylinder Head Bolt Tightening Sequence
Observe sequence for tightening cylinder head bolts without fail.
Installation:
Jointing torque:
All cylinder head bolts 1 to 14 to 30 Nm
1st angle of rotation:
All cylinder head bolts 1 to 14 to 90°
IMPORTANT: Observe sequence for tightening cylinder head bolts without fail.
NOTE: Picture shows inlet and exhaust camshafts removed.
IMPORTANT: The 2nd torsion angle relates only to cylinder head bolts 1 to 10.
2006 BMW 525i

2nd angle of rotation:
Only cylinder head bolts 1 to 10 to 90°
3rd angle of rotation:
All cylinder head bolts 1 to 14 to 45°
Insert bolts (1).
Insert bolt (2).
Installation:
Fig. 53: Identifying Engine Cylinder Head Bolts
Assemble engine.
11 12 101 REPLACING CYLINDER HEAD GASKET (N52)
11 4 430
11 4 470
IMPORTANT: Secure bolt (2) with a gripper against falling down.
2006 BMW 525i

Remove Cylinder Head.
Insert special tool 11 4 430 into bores.
Remove head gasket.
Fig. 54: Identifying Special Tool (11 4 430) And Special Tool (11 4 430)
corrosion.
damage).
IMPORTANT: Check identification (1) on cylinder head gasket (B25 or B30).
B= petrol/gasoline engine
30= displacement (3 liters)
Do not mix them up as this will cause engine damage.
2006 BMW 525i

Remove remnants of oil and dirt from pocket holes (1).
Fig. 55: Identifying Engine Pocket Holes
Identification (1) of head gasket.
Gasket (3) is a sheet-metal gasket
Fig. 56: Identifying Sheet-Metal Gasket, Rubber Coating And Head Gasket Identification
IMPORTANT: Work on sealing face on engine block and on cylinder head with special tool 11
4 470 only.
Do not use any metal-cutting tools.
IMPORTANT: Rubber coating (2) on cylinder head gasket must not under any circumstances
be damaged (electrochemical corrosion).
2006 BMW 525i

Check adapter sleeves (1) for damage and firm seating.
Place head gasket (2) in direction of arrow on engine block.
Fig. 57: Identifying Head Gasket And Adapter Sleeves
11 12 527 REMACHINING A VALVE SEAT - DISASSEMBLING CYLINDER HEAD (N52)
00 5 380
11 9 001
Remove Inlet Camshaft.
Remove Exhaust Camshaft.
Remove All Valves.
Place cylinder head on special tool 11 9 001.
Inset pilot from special tool 00 5 380 5 mm into a valve stem.
Select a suitable valve seat milling cutter (1).
NOTE: Check cylinder head for Deviation From Flatness.
Check cylinder head for Water Leaks.
Assemble engine.
2006 BMW 525i

Turn the milling cutter clockwise while applying low pressure. When the milling operation is finished, perform
a further 2 turns without applying pressure to the cutter.
Assemble engine.
Fig. 58: Identifying Special Tools (11 9 001), (00 3 580) And Valve Seat Milling Cutter
11 12 595 CHECKING A VALVE GUIDE FOR WEAR (N52)
Remove All Valve Springs.
To measure tilt clearance, install a new valve so that end of valve stem is flush with valve guide.
Attach dial gauge and measure tilt clearance.
Max. permissible tilt clearance 0.5 mm.
IMPORTANT: If necessary, perform inner and outer seat corrections. See 11 12 CYLINDER
HEAD WITH COVER N52 B25
NOTE: See illustration in Fig. 59.
2006 BMW 525i

Fig. 59: Measuring Tilt Clearance Using Dial Gauge
Is the valve guide is outside the tolerance, the cylinder head must be replaced.
Assemble engine.
11 12 719 RESURFACING CYLINDER HEAD SEALING FACE (N52)
Remove Exhaust Camshaft.
Remove Intermediate Lever on inlet side.
Check evenness of cylinder head sealing faces with a standard straight-edge (1).
NOTE: Max. deviation from level (longitudinal) 0.10 mm
2006 BMW 525i

Fig. 60: Identifying Evenness Of Cylinder Head Sealing Faces Using Standard Straight-Edge
Check evenness of cylinder head sealing faces with a standard straight-edge (1).
Fig. 61: Identifying Evenness Of Cylinder Head Sealing Faces Using Standard Straight-Edge
Check cylinder head for Water Leaks.
Assemble engine.
11 12 729 CHECKING CYLINDER HEAD FOR WATER LEAKS (N52)
11 4 341
11 4 342
NOTE: Max. deviation from level (transversal) 0.05 mm
2006 BMW 525i

11 4 343
Disassemble cylinder head.
Set up special tool 11 4 341 with existing cylinder head bolts.
Installation:
1 cyl is marked.
Fit special tool 11 4 342, insert knurled screw (1) in direction of arrow.
Sealing flange must rest flat.
Fit special tool 11 4 343.
NOTE: Compressed air at valve (2) must not exceed 3 bar.
Heat cylinder head to 60°.
Visually inspect for formation of bubbles.
2006 BMW 525i

Fig. 63: Identifying Special Tool (11 4 342), (11 4 343), Knurled Screw And Valve
Assemble engine.
13 OIL SUMP
11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (N52)
Remove engine splash guard.
Secure engine in Installation Position.
Lower Front Axle.
corrosion.
damage).
NOTE: The lines must be detached from the engine oil sump in the case of the optional
extra automatic transmission; if necessary, detach vane pump and place to one
2006 BMW 525i

Release bolts (3) on transmission.
Detach return hose (2).
Release screws along line (1).
For tightening torque refer to 11 13 1AZ in 11 13 OIL PAN (N52) .
Installation:
If necessary, release bolts (4), remove oil level sensor.
Installation:
Replace all seals.
Fig. 64: Identifying Oil Level Sensor, Return Hose, Retaining Screws And Bolts
Assemble engine.
11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (N52) AWD
side.
corrosion.
2006 BMW 525i

Remove engine splash guard.
Secure engine in Installation Position.
Lower Front Axle.
Remove left drive shaft.
Remove right drive shaft.
Remove front axle differential.
Release bolts (3) on transmission.
Detach return hose (2).
Release screws along line (1).
Installation:
Replace all seals.
If necessary, release bolts (4), remove oil level sensor.
damage).
NOTE: The lines must be detached from the engine oil sump in the case of the optional
extra automatic transmission; if necessary, detach vane pump and place to one
side.
NOTE: Fig. 65 shows N52.
2006 BMW 525i

Fig. 65: Identifying Oil Level Sensor, Return Hose, Retaining Screws And Bolts
Assemble engine.
14 HOUSING COVER
11 14 005 REPLACING FRONT CRANKSHAFT RADIAL SEAL (N52)
11 9 221
11 9 222
11 9 223
11 9 224
11 9 231
11 9 232
11 9 233
Remove Vibration Damper.
If the central bolt is released, the sprocket wheels of the timing chain and the oil pump will no longer be
nonpositively connected to the crankshaft. The camshafts to the crankshaft can warp (risk of damage).
IMPORTANT: Do not release central bolt.
2006 BMW 525i

Fig. 66: Identifying Central Bolt For Warning
Turn back special tool 11 9 222.
Push special tool 11 9 221 onto crankshaft.
Insert screws (special tool 11 9 224) and tighten down to approx. 20 Nm.
Fig. 67: Identifying Special Tool (11 9 224), (11 9 222) And (11 9 221)
Insert screws (special tool 11 9 223) and screw in until they make contact without play.
IMPORTANT: When screws are tightened down (special tool 11 9 224), radial seal is pressed
inwards approx. 1 mm and thus slackened for subsequent removal.
IMPORTANT: Do not overload special tool 11 9 223 (metal screws).
2006 BMW 525i

Fig. 68: Identifying Special Tool (11 9 223) And Screws
Remove screws (special tool 11 9 224).
Fig. 69: Identifying Special Tool (11 9 224) And Screws
Insert screw (special tool 11 9 222) carefully and slowly and withdraw radial seal (1).
2006 BMW 525i

Fig. 70: Identifying Special Tool (11 9 222) And Radial Seal
Installation:
Clean sealing surface (1) and degrease thoroughly in area of housing partition.
Apply a light coat of oil to running surface (2) of radial shaft seal.
Fig. 71: Identifying Shaft Seal And Radial Shaft Seal Running Surface
NOTE: Support sleeve (1) is supplied with radial seal (2).
When radial seal (2) is installed, only support sleeve (1) may be used as a slip
sleeve.
Radial seal (2) has a groove on both left and right sides.
2006 BMW 525i

Fig. 72: Identifying Radial Seal And Support Sleeves
Attach support bushing (2) with radial shaft seal (1). Push on radial shaft seal (1) in direction of arrow.
Fig. 73: Identifying Radial Shaft Seal And Support Bushing
Pay attention to opening on radial shaft seal (1) on left and right.
Remove support bushing (2).
IMPORTANT: After installation, the grooves must be filled with sealing compound.
2006 BMW 525i

Fig. 74: Identifying Radial Shaft Seal And Bushing
Remove screw caps (1) from injector (2).
Screw on metering needle.
Insert piston for pressing out.
Injector (2) contains the sealing compound Loctite, manufacturer's number 128357.
Bottle (3) contains the primer Loctite, manufacturer's number 171000.
IMPORTANT: The following text describes installation and sealing between the engine block
and radial seal.
The engine block will not be leakproof at the outside of the radial seal if you fail
to comply with the individual work steps and the work sequence.
NOTE: The required parts are available from the BMW Parts Service (EPC).
2006 BMW 525i

Fig. 75: Identifying Screw Caps, Injector And Loctite Sealing Compound (128357)
Fit special tool 11 9 232.
Coat both grooves on radial shaft seal with Loctite primer, manufacturer's number 171000, and expose to air for
approx. one minute.
Draw in radial shaft seal with special tool 11 9 231 in conjunction with special tool 11 9 233 until flush.
2006 BMW 525i

Before filling with sealing compound:
Insert brush with Loctite primer, manufacturer's number 171000, as far as possible into grooves (1) on radial
shaft seal and coat housing partition on engine block.
Fig. 78: Identifying Radial Shaft Seal Groove
Using injector (2), fill both grooves (3) flush with Loctite sealing compound, manufacturer's number 128357.
2006 BMW 525i

Fig. 79: Identifying Radial Shaft Seal Groove And Loctite Injector
Fig. 80: Identifying Radial Shaft Seal Groove
Assemble engine.
11 14 010 REPLACING VACUUM PUMP SEALING COVER (N52)
11 4 361
11 4 362
NOTE: Loctite primer, manufacturer's number 171000, binds the Loctite sealing
compound, manufacturer's number 128357, and prevents leakage.
Coat surface of sealing compound in both grooves (1) with Loctite primer,
manufacturer's number 171000.
2006 BMW 525i

11 4 363
11 4 364
11 9 200
Remove fan cowl.
Remove Alternator Drive Belt.
Remove Tensioner For Drive Belt.
Fig. 81: Identifying Radial Shaft Seal
Convert special tool 11 9 200 (see Fig. 82).
Screw special tool 11 9 200 onto end cover.
NOTE: Procedure is identical to that for radial shaft seal.
Expose removal openings on sealing cover.
NOTE: Insert screws until flush only with special tool 11 9 200.
2006 BMW 525i

Screw in special tool 11 4 362.
Attach special tool 11 4 361 to Bedplate screw connection (see arrow in Fig. 84).
Secure with knurled screw (1).
Screw special tool 11 4 364 into special tool 11 9 200 and screw out in direction of arrow.
NOTE: For purposes of clarity, illustrations show alternator and servo pump.
2006 BMW 525i

Fig. 84: Identifying Special Tool (11 4 361), (11 4 364), (11 9 200) And Knurled Screw
Prepare new sealing cover (1) with special tool 11 9 200 without screws.
Screw in sealing cover with special tool 11 4 363 until it is flush.
Fig. 85: Identifying Special Tool (11 4 363), (11 9 200) And New Sealing Cover
Assemble engine.
11 14 151 REPLACING CRANKSHAFT RADIAL SEAL (N52)
11 9 181
11 9 182
11 9 183
2006 BMW 525i

11 9 184
11 9 200
Remove Flywheel.
Fig. 86: Identifying Radial Seal
Fig. 87: Identifying Radial Seal Rubber Coating And Removal Opening
NOTE: Radial seal has six removal openings for removal with special tool 11 9 200.
NOTE: If necessary, remove rubber coating (1) on top side of radial seal and expose a
removal opening (2) (see Fig. 87).
2006 BMW 525i

Fit special tool 11 9 200. Insert metal screws into removal opening of radial seal and initially tighten without
play (do not overtighten metal screws).
Screw in spindle (1) slowly and carefully and detach radial seal.
Fig. 88: Identifying Special Tool (11 9 200) And Crankshaft Radial Seal Spindle
Installation:
Clean sealing surface (1) and degrease thoroughly in area of housing partition.
Apply a light coat of oil to running surface (2) of radial shaft seal.
Fig. 89: Identifying Radial Shaft Sealing And Running Surface
NOTE: Support sleeve (4) is supplied with radial shaft seal (1).
When radial shaft seal (1) is installed, only support sleeve (4) may be used as a
2006 BMW 525i

Fig. 90: Identifying Radial Shaft Seal, Groove And Sleeve
Remove screw caps (1) from injector (2).
Screw on metering needle.
Insert piston for pressing out.
Injector (2) contains the sealing compound Loctite, manufacturer's number 128357.
Bottle (3) contains the primer Loctite, manufacturer's number 171000.
slip sleeve.
Radial shaft seal (1) has a groove (2) on both left and right sides.
IMPORTANT: After installation, grooves (2) must be filled with sealing compound.
IMPORTANT: The seal between the engine block and radial seal is described below.
The engine block will not be leakproof at the outside of the radial seal if you fail
to comply with the individual work steps and the work sequence.
NOTE: The required parts are available from the BMW Parts Service (EPC).
2006 BMW 525i

Fig. 91: Identifying Screw Caps, Injector And Bottle Of Loctite (171000)
Installation:
Fit support sleeve (4) with radial shaft seal (1) on crankshaft.
Align groove (2) centrally to housing partition (3).
Coat both grooves (2) on radial shaft seal (1) with Loctite primer, manufacturer's number 171000, and expose to
air for approx. one minute.
Push radial shaft seal (1) by hand as far as possible onto running surface.
Carefully remove support sleeve (4).
Fig. 92: Identifying Support Sleeve, Radial Shaft Seal, Groove And Housing Partition
NOTE: Spacer ring (1) is supplied with radial shaft seal.
2006 BMW 525i

Screw special tool 11 9 182 with screws (special tool 11 9 184) to crankshaft.
Fit spacer ring (1) on preassembled radial shaft seal
Draw in radial shaft seal with special tool 11 9 181 in conjunction with special tool 11 9 183 until flush.
Then remove spacer ring again.
Before filling with sealing compound:
Insert brush with Loctite primer, manufacturer's number 171000, as far as possible into grooves (1) on radial
shaft seal and coat housing partition on engine block.
2006 BMW 525i

Fig. 95: Using Loctite Sealing Compound (171000) On Groove (1 of 3)
Fill both grooves (1) flush with Loctite sealing compound, manufacturer's number 128357.
Fig. 96: Using Loctite Sealing Compound (171000) On Groove (2 Of 3)
Coat surface of sealing compound in both grooves (1) with Loctite primer, manufacturer's number 171000.
NOTE: Loctite primer, manufacturer's number 171000, binds the Loctite sealing
compound, manufacturer's number 128357, and prevents leakage.
2006 BMW 525i

Fig. 97: Using Loctite Sealing Compound (171000) On Groove (3 Of 3)
Assemble engine.
21 CRANKSHAFT WITH BEARING
11 21 500 REPLACING CRANKSHAFT (N52)
00 2 510
00 9 120
11 4 370
11 4 440
11 9 360
corrosion.
damage).
2006 BMW 525i

Remove Engine.
Mount engine on Assembly Stand.
Remove Vibration Damper.
Removing Oil Pan.
Remove Oil Pump.
Remove Triangular Drive for oil pump.
Remove Timing Chain Module.
Remove Flywheel.
Remove all Pistons.
Release screws (1).
For tightening torque refer to 11 13 5AZ in 11 13 OIL PAN (N52) .
Installation:
Remove oil deflector (2).
Fig. 98: Identifying Oil Deflector And Mounting Screws
Release screws (1).
For tightening torque refer to 11 11 2AZ in 11 11 ENGINE BLOCK (N52) .
Release screws (2).
2006 BMW 525i

Installation:
Fig. 99: Identifying Engine Screws
Release screws (1).
Release screws (2).
Installation:
Release steel screws (1 to 14) from outside inwards.
2006 BMW 525i

Fig. 100: Identifying Tightening Sequence Of Crankshaft Screws
Release screws (1).
Installation:
Lift out bedplate.
Fig. 101: Identifying Radial Shaft Mounting Screws
Remove both radial shaft seals (1).
NOTE: Illustrations show N46.
2006 BMW 525i

Fig. 102: Identifying Radial Shaft Seals
Remove Main Bearing Shells (2 and 3), replace if necessary.
Remove and install crankshaft (1) in direction of arrow.
Fig. 103: Identifying Main Bearing Shells And Crankshaft
Check guide sleeves (1) for damage and correct seating.
Reinstall crankshaft.
Installation:
IMPORTANT: Remove crankshaft with aid of a second person.
Weight of crankshaft approx. 23 kg.
2006 BMW 525i

Lubricate all bearing points with engine oil.
Clean all sealing surfaces.
Fig. 104: Identifying Crankshaft Guide Sleeves
Tighten steel screws (1 to 14) from inside outwards.
Tighten screws (2) from inside outwards.
Tighten screws (1).
Installation:
2006 BMW 525i

Fig. 105: Identifying Tightening Sequence Of Crankshaft Screws
Tighten aluminium screws exclusively with special tool 00 9 120.
Set up stand with magnetic base on special tool 11 4 440.
Set up special tool 00 2 510 on stand.
Position special tool 00 2 510 on crankshaft.
Move crankshaft in direction of arrow.
Determine Bearing Play.
IMPORTANT: In the case of aluminium screws, jointing torque and angle of rotation must be
observed without fail.
2006 BMW 525i

Drive in both nozzles (1) with special tool 11 9 360 on left and right into crankcase.
Installation:
Always replace nozzles (1).
Fig. 108: Identifying Special Tool (11 9 360) And Crankcase Nozzle
Installation:
Prepare sealing compound (1) in special tool 11 4 370.
Screw on nozzle for injecting sealing compound.
Slowly insert sealing compound (1) with special tool 11 4 370 in direction of arrow.
2006 BMW 525i

Replace radial shaft seal at Front.
Replace radial shaft seal at Rear.
Assemble engine.
11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARINGS (N52)
00 2 590
11 4 251
11 4 252
11 4 470
corrosion.
damage).
2006 BMW 525i

Remove Crankshaft.
Check setting of oil spray nozzles, adjusting if necessary:
Attach special tool 11 4 251 to screw connection on main bearing.
Special tool 11 4 252 must be pre-installed at the seventh main bearing block.
Remove bearing shells (2) and (3).
NOTE: See Fig. 110.
NOTE: Guide bearing shell (3) is a thrust bearing.
Observe Bearing Classification.
2006 BMW 525i

Fig. 111: Identifying Bearing Shells And Crankshaft
Installation:
Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.
Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bedplate).
Fig. 112: Identifying Bearing Shell With And Without Lubricant Groove
Surface (1) for identification.
Seven-digit part number (2).
Bearing classification (3) of crankshaft as per table (values 1 to 3).
Reworking (4) as per table (main bearing).
2006 BMW 525i

B= build date 1 (-0.25mm).
B= build date 2 (-0.50mm).
Reworking (5) as per table (lift bearing).
B= construction stage 1 (-0.25mm).
C = construction stage 2 (-0.50mm)
Fig. 113: Identifying Bearing Classification Tag
Bearing classification (1) in crankcase as per table (values of A/B/C).
Installation:
When all the letters and number code have been determined, the bearing shell colour must be allocated, see
BEARING SPECIFICATION table.
2006 BMW 525i

Fig. 114: Identifying Bearing Classification In Crankcase
BEARING SPECIFICATION
Insert all bearing shells (2 and 3).
Clean sealing faces with special tool 11 4 470 only.
Determine bearing play with special tool 00 2 590.
Installation:
All measuring points must be free from oil and grease.
Use used screws to determine bearing play.
Set up Bedplate with bearing shells.
IMPORTANT: Engine damage will result if a small bearing play is determined.
The colour combination Yellow and Red must not be fitted.
Possible colour combinations, see BEARING SPECIFICATION.
(A1) Bedplate / Yellow (B1) Bedplate / Yellow (C1) Bedplate / Green
(A1) Crankcase / Yellow (B1) Crankcase / Green (C1) Crankcase / Green
(A2) Bedplate / Green (B2) Bedplate / Green (C2) Bedplate / Green
(A2) Crankcase / Yellow (B2) Crankcase / Green (C2) Crankcase / Red
(A3) Bedplate / Green (B3) Bedplate / Red (C3) Bedplate / Red
(A3) Crankcase / Green (B3) Crankcase / Green (C3) Crankcase / Red
IMPORTANT: Clean sealing surfaces.
Do not clean sealing faces with a metal-cutting tool.
2006 BMW 525i

Fig. 115: Identifying Bearing Shells And Crankshaft
Remove bedplate.
Read off bearing play at width of flattened plastic thread and measurement scale.
Crankshaft bearing clearance radial.
Installation:
Remove plastic thread.
Apply a light coat of oil to bearing shells and crankshaft.
Fig. 116: Identifying Crankshaft Bearing Clearance Radial
Install Bedplate.
2006 BMW 525i

Assemble engine.
22 FLYWHEEL
11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL (N52)
11 4 180
11 9 260
11 9 265
Remove Clutch.
Block flywheel (1) with special tool 11 9 260, use an old transmission screw for this purpose.
Installation:
Unfasten flywheel screws.
For tightening torque refer to 11 22 1AZ in 11 22 FLYWHEEL (N52) .
Installation:
Flywheel (1) is secured with an alignment pin.
corrosion.
damage).
2006 BMW 525i

Fit new flywheel screws.
Clean crankshaft thread for flywheel screws.
Fig. 117: Identifying Special Tools (11 9 260), (11 9 263), (11 9 264) And Flywheel
Secure flywheel with an old transmission screw (1) and special tools 11 9 260 and 11 9 265.
Installation:
Release flywheel screws with special tool 11 4 180.
Installation:
Flywheel is secured with a dowel pin.
Fit new flywheel screws.
For tightening torque refer to 11 22 2AZ in 11 22 FLYWHEEL (N52) .
2006 BMW 525i

Fig. 118: Identifying Special Tools (11 9 265), (11 9 260), (11 4 180) And Flywheel Transmission Screw
Assemble engine.
11 22 513 REPLACING ROLLER BEARING FOR DUALMASS FLYWHEEL
21 2 051
21 2 052
Using hydraulic press (1) and special tool 21 2 051, press out dual-mass flywheel downwards on engine side.
NOTE: Flywheel removed!
IMPORTANT: Risk of damage:
Roller bearing must not be driven out.
2006 BMW 525i

Fig. 119: Identifying Special Tool (21 2 051) And Hydraulic Press
Push roller bearing (2) onto special tool 21 2 052.
Using hydraulic press (1), press roller bearing into dualmass flywheel as far as it will go on clutch side.
Fig. 120: Identifying Special Tool (21 2 052), Roller Bearing And Hydraulic Press
IMPORTANT: Risk of damage:
Observe press-in instruction:
Roller bearing must not be driven in.
Roller bearing mounting force/travel monitored:
Min. 2000N 1 mm before end of pressing in.
Max. 15000N during entire press-in procedure.
2006 BMW 525i

11 22 513 REPLACING ROLLER BEARING FOR DUALMASS FLYWHEEL WITH HYDRAULIC
PRESS
00 5 500
11 2 010
11 2 343
11 2 350
Position special tool 11 2 010 in roller bearing.
Twist out roller bearing with special tool 11 2 343.
Assemble special tools 11 2 350 and 00 5 500.
Drive in roller bearing with special tools 11 2 350 and 00 5 500 in direction of arrow as far as it will go.
2006 BMW 525i

Assemble engine.
11 22 513 REPLACING ROLLER BEARING FOR DUALMASS FLYWHEEL MANUALLY
00 5 500
11 2 010
11 2 343
11 2 350
Position special tool 11 2 010 in roller bearing.
Twist out roller bearing with special tool 11 2 343.
2006 BMW 525i

Assemble special tools 11 2 350 and 00 5 500.
Drive in roller bearing with special tools 11 2 350 and 00 5 500 in direction of arrow as far as it will go.
Assemble engine.
23 VIBRATION DAMPER
11 23 010 REMOVING AND INSTALLING OR REPLACING VIBRATION DAMPER (N52)
Detach Front Underbody Protection.
Remove Drive Belt.
2006 BMW 525i

Release screws (1).
For tightening torque refer to 11 23 1AZ in 11 23 VIBRATION DAMPER (N52) .
Remove vibration damper (2).Vibration Damper
Fig. 125: Identifying Vibration Damper And Mounting Screws
Assemble engine.
24 CONNECTING ROD WITH BEARING
11 24 571 REPLACING ALL CONNECTING ROD BEARINGS (N52)
00 2 590
00 9 120
Remove all Pistons.
Reworking (5) as per table (lift bearing).
IMPORTANT: All crank pins are connected with the crankshaft.
Modified procedure; the bearing shell colours are the same at the top and
bottom.
Blue / Red bearing shell colours are no longer used in combination.
IMPORTANT: Note Grinding Stages On Crankshaft.
2006 BMW 525i

B = construction stage 1 (- 0.25 mm)
C = construction stage 2 (- 0.50 mm)
Fig. 126: Identifying Bearing Identification Tag
Possible classifications per connecting rod at top and bottom:
r: Red
b: Blue
Fig. 127: Identifying Crankshaft Crank Pins
Only one colour may be fitted per big end and connecting rod shank.
In direction of arrow from (1 to 2) crank pin (1 to 6).
IMPORTANT: All crankshaft crank pins are classified.
2006 BMW 525i

Example:
Possible classification: rbbrrb.
Cylinder classification Red.
1:
Cylinder classification Blue.
2:
3:
4:
5:
6:
Install new conrod bearing shells.
In each case insert only one colour of bearing shell (1 and 2) for each conrod.
Fig. 128: Identifying Connecting Rod Bearing Shells
2006 BMW 525i

Check conrod bearing clearance.
Piston in BDC position.
Fit special tool 00 2 590 (Plastigage Type PG 1) to oilfree crankshaft.
Fit bearing cap so that pairing letters match up.
Fig. 129: Locating Conrod Bearing Clearance
Use the old conrod bolts to check conrod clearance. Tighten down conrod bolts with special tool 00 9 120. For
tightening torque refer to 11 24 1AZ in 11 24 CONNECTING RODS AND BEARINGS (N52) .
Remove bearing cap. Read off bearing clearance at width of crushed plastic thread with aid of measuring scale.
Conrod Bearing Clearance.
IMPORTANT: Do not distort conrods or crankshaft.
2006 BMW 525i

Remove plastic thread.
Coat crankshaft and bearing shells with oil.
Install new conrod bolts and tighten down with special tool 00 9 120.
For tightening torque refer to 11 24 1AZ in 11 24 CONNECTING RODS AND BEARINGS (N52) .
Fig. 131: Checking Connecting Rod Bearing Clearance With Measuring Scale
Assemble engine.
25 PISTON WITH RING AND PIN
11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N52)
00 9 120
11 4 491
2006 BMW 525i

11 4 492
11 4 493
11 6 241
11 6 261
11 8 330
11 9 493
11 9 494
Remove Engine.
Mount engine on Assembly Stand.
Remove Intake Air Manifold.
Remove Engine Oil Sump.
Remove Oil Pump.
WARNING: Protective goggles must be worn when working on the piston pin circlip.
IMPORTANT: If pistons, conrods and bearing shells are reused, they must be reinstalled in
the same places.
Individual conrod replacement is not permitted; they are classified according to
weight categories.
Conrods and conrod bearing caps are denoted with the same pairing letters;
mixing them up will result in engine damage.
Piston and piston pins are paired and must not be fitted individually.
NOTE: In event of heavy oil carbon residue:
Carefully remove oil carbon residue from cylinder wall.
2006 BMW 525i

Fig. 132: Identifying Engine Cylinder Wall
Do not release screw (1).
Oil Spray Nozzle (2) must not be maladjusted or bent.
If necessary, Readjust (risk of damage).
Fig. 133: Identifying Oil Spray Nozzle And Mounting Screw
Release conrod bolts (1).
Remove conrod bearing cap (2) in direction of arrow.
IMPORTANT: Conrods and conrod bearing caps are denoted with the same pairing letters;
mixing them up will result in engine damage.
2006 BMW 525i

Fig. 134: Identifying Connecting Rod Bearing Cap And Bolts
Attach special tool 11 8 330 in conrod big end.
Press out conrod and piston to cylinder head side.
Preliminary work:
Clamp special tool 11 4 491 in a vice.
Secure piston (1) with conrod to special tool 11 4 491.
IMPORTANT: Risk of damage to oil spray nozzle.
2006 BMW 525i

Fig. 136: Identifying Special Tool (11 4 491) And Piston
Lever out piston circlip with special tool 11 4 492 in direction of arrow.
If necessary, replace connecting rods.
WARNING: Protective goggles must be worn for the next work step.
WARNING: Protective goggles must be worn.
IMPORTANT: Connecting rods are divided into weight categories and are only available as a
set.
2006 BMW 525i

Installation:
The piston pin must be able to be pressed through the liner by hand with little force and must not display any
significant play.
Fig. 138: Identifying Piston Pin In Connecting Rod
Measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90° to
the axis of the piston pin.
Piston diameter at measuring point A.
Old and new connecting rods must not be installed in mixed combinations.
2006 BMW 525i

Fig. 139: Measuring Piston Clearance
Adjust micrometer to cylinder bore of engine block. Set internal caliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
Diameter of cylinder bore.
Piston installation clearance.
Total Permissible Wear Tolerance.
If necessary, replace piston.
2006 BMW 525i

Fig. 140: Measuring Diameter Of Cylinder Bore Of Engine Block
Insert piston circlip (2) into groove (1) of special tool 11 4 493.
Bring piston circlip into assembly position.
2006 BMW 525i

Fig. 141: Identifying Special Tool (11 4 493), Piston Circlip And Groove
Guide lug and cutout on special tool 11 9 493 must point to the piston crown; only then can special tool 11 9
494 be correctly fitted.
When special tools 11 9 493 and 11 9 494 are correctly positioned, the piston pin circlip must be driven in with
a plastic hammer in the direction of the arrow.
NOTE: See Fig. 142.
NOTE: B 30.
2006 BMW 525i

Install all Piston Rings.
Install all Bearing Shells.
Coat piston and piston rings with oil.
Pre-install piston (2) in special tool 11 6 261.
Attach special tool 11 8 330 in conrod (1).
Fig. 143: Identifying Special Tool (11 8 330), (11 6 261), Piston And Conrod
Installation:
Check protective lugs (1) on special tool 11 8 330 for correct position and damage.
Install all Piston Rings.
Install all Bearing Shells.
Coat piston and piston rings with oil.
Pre-install piston (2) in special tool 11 6 241.
Attach special tool 11 8 330 in conrod (1).
NOTE: B 25.
2006 BMW 525i

Fig. 144: Identifying Special Tool (11 8 330), (11 6 241), Piston And Conrod
Installation:
Check protective lugs (1) on special tool 11 8 330 for correct position and damage.
Insert piston with conrod in cylinder.
Insert piston (1) so that arrow (2) on piston crown points to camshaft drive.
Press in piston (1) with special tools 11 6 261/11 6 241.
IMPORTANT: Risk of damage to oil spray nozzle.
Danger of piston ring failure.
Press in piston with finger pressure only, do not drive in (see arrows in Fig.
145).
2006 BMW 525i

Fig. 145: Identifying Special Tools (11 6 261) And Piston
Fig. 146: Identifying Conrod Bearing Cap Pairing Letters
Apply a light coat of oil to crank pin.
Assemble conrod and crank pin.
Detach special tool 11 8 330.
IMPORTANT: Conrod and conrod bearing cap are identified with pairing letters (1) and must
not be mixed up.
Mixing them up or incorrectly fitting the conrod bearing cap on the big end will
result in engine damage.
2006 BMW 525i

Fit bearing caps (2) so that pairing letters match up.
Install new conrod bolts (1).
Fig. 148: Identifying Conrod Bearing Caps And Bolts
Adjust torsion angle of conrod with special tool 00 9 120 (see Fig. 149).
For tightening torque refer to 11 24 1AZ in 11 24 CONNECTING RODS AND BEARINGS (N52)
Assemble engine.
11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (N52)
2006 BMW 525i

Remove all Pistons.
Measuring axial clearance of piston rings in piston ring groove.
Technical Data.
Fig. 150: Measuring Axial Clearance Of Piston Rings In Piston Ring Groove
Remove compression ring and stepped ring upwards with piston ring pliers.
Oil scraper ring comprises two steel band rings and a support spring.
NOTE: It is not possible to measure the axial clearance of the oil scraper rings.
NOTE: Oil scraper ring cannot be removed with piston ring pliers.
Put aside piston rings in correct sequence and installation position.
2006 BMW 525i

Fig. 151: Identifying Compression Ring With Piston Ring Pliers
Installation:
New pistons may only be installed together with new piston rings.
Determine Gap with a feeler gauge.
It might not be possible to find the identification on used piston rings.
2006 BMW 525i

Fig. 152: Checking Piston Ring Gap With Feeler Gauge
Installation:
Piston rings with "TOP" identification must point to piston crown.
1. Plain compression ring
2. Stepped compression ring "Top"
3. Two-part oil scraper ring
NOTE: Schematic representation of piston rings.
2006 BMW 525i

Fig. 153: Identifying Piston Rings Components And Position
Installation:
Insert support spring (2) into piston ring groove and then fit steel band rings (1) so that contact points are offset
by approx. 120°.
Fig. 154: Identifying Piston Support Spring And Steel Band Rings
Offset the contact points (1) of the piston rings by approx. 120° to each other but do not position above the
piston pin boss.
NOTE: Oil control ring comprises two steel band rings (1) and a support spring (2).
NOTE: See Fig. 155.
2006 BMW 525i

Fig. 155: Identifying Offset Contact Points Of Piston Rings
Assemble engine.
28 V-RIBBED BELT WITH TENSIONER
11 28 010 REPLACING ALTERNATOR DRIVE BELT (N52)
11 3 340
Remove fan cowl.
Mark the direction of rotation of the drive belt if it is to be reused.
Turn belt tensioner (4) in direction of arrow until bore (2) is flush on housing.
corrosion.
damage ).
2006 BMW 525i

Hold belt tensioner (4) under tension.
Fig. 156: Identifying Belt Tensioner And Bore
Secure belt tensioner with special tool 11 3 340.
Fig. 157: Identifying Special Tool (11 3 340) And Belt Tensioner
Remove drive belt (1) towards top.
NOTE: Illustration N42.
2006 BMW 525i

Fig. 158: Identifying Drive Belt And Tensioner
Assemble engine.
Installation:
Check that drive belt for is in correct installation position - risk of damage.
11 28 020 REPLACING ALTERNATOR DRIVE BELT TENSIONER (N52)
11 3 340
Remove Drive Belt.
corrosion.
damage ).
2006 BMW 525i

Remove special tool 11 3 340.
Release screw (3).
For tightening torque refer to 11 28 1AZ in 28 V-RIBBED BELT WITH TENSION AND DEFLECTION
ELEMENT .
Installation:
Fig. 159: Identifying Belt Tensioner, Screw And Belt Drive
Assemble engine.
31 CAMSHAFT
11 31 005 CHECKING CAMSHAFT TIMING
11 0 300
11 4 281
11 4 282
11 4 283
Remove Cylinder Head Cover.
Remove front splash guard.
Remove fastener (1) in direction of arrow.
2006 BMW 525i

Installation:
Install fastener (1) with bore facing outwards.
Fig. 160: Identifying Crankshaft Fastener
Rotate crankshaft at central bolt into TDC position.
Slide in special tool 11 0 300 in direction of arrow and block crankshaft.
If the flywheel is secured in the correct bore with special tool 11 0 300, the engine can no longer be moved at
the central bolt.
Secure special tool 11 4 283 on cylinder head with screws (1).
IMPORTANT: On engines with automatic transmissions, there is shortly before the special
tool bore for the TDC position a large bore which can be confused with the
special tool bore.
2006 BMW 525i

Mount special tool 11 4 281 on inlet and exhaust camshafts.
Fig. 162: Identifying Special Tool (11 4 281), (11 4 282), (11 4 283) And Screws
The timings are correct when the part number (2) can be read from above on the camshafts (1).
Fig. 163: Identifying Inlet Camshaft And Part Number Position
With 1st cylinder in firing TDC position, cams of inlet camshaft (1) at 1st cylinder point upwards at an angle.
NOTE: Fit special tool 11 4 282 underneath on inlet side.
2006 BMW 525i

Fig. 164: Identifying Inlet Camshaft TDC Position
With 1st cylinder in firing TDC position, cams of exhaust camshaft (3) at 6th cylinder point downwards at an
angle.
Roller cam follower (1) is not actuated.
Fig. 165: Identifying Roller Cam Follower And Exhaust Camshaft
Assemble engine.
11 31 025 REMOVING AND INSTALLING/REPLACING INLET CAMSHAFT (N52)
11 4 281
11 4 481
NOTE: If the timing is checked while the engine is installed, the position of the
camshaft can only be checked with a mirror.
2006 BMW 525i

Remove Adjusting Unit for inlet camshaft.
Remove Intermediate Lever.
Adjust Valve Timing.
Bearing cap (1) is a thrust bearing.
Release screws of bearing caps (1 and 2).
Set all bearing caps down in special tool 11 4 481 in a tidy and orderly fashion.
All bearing caps are identified from 1 to 6.
For tightening torque refer to 11 31 1AZ in 11 31 CAMSHAFT (N52) .
Fig. 166: Identifying Thrust Bearing Screws And Cap
corrosion.
damage ).
2006 BMW 525i

Lift out camshaft (2).
Installation:
Clean all bearing points and lubricate with oil.
Check plain compression rings (1) for damage and replace if necessary.
Fig. 167: Identifying Camshaft And Compression Rings
If necessary, replace plain compression rings (1).
The plain compression rings have catches at the joint.
Press plain compression rings (1) apart upwards and downwards and removed towards front.
Fig. 168: Identifying Compression Rings
IMPORTANT: Plain compression rings (1) can easily break.
2006 BMW 525i

A Exhaust camshaft.
E Inlet camshaft.
Fig. 169: Identifying Exhaust Camshaft And Inlet Camshaft
Insert camshaft (1) so that part number on twin surface points upwards.
Position inlet camshaft (1) so that cams point upwards at an angle.
Attach special tool 11 4 281 to twin surface.
Fig. 170: Identifying Inlet Camshaft Position
Assemble engine.
IMPORTANT: Both camshafts have different identifications.
Mixing up the two camshafts will result in engine damage.
2006 BMW 525i

11 31 028 REMOVING AND INSTALLING / REPLACING EXHAUST CAMSHAFT (N52)
00 9 120
11 4 350
11 4 461
11 4 462
11 4 463
11 9 000
Risk of damage!
The upper and lower bearing banks must be pretensioned with a total of six special tools 11 4 461.
Remove exhaust adjusting unit for exhaust camshaft.
Adjust Valve Timing.
Release bearing cap screw connections from outside inwards.
Lift out lower and upper bearing banks (1) with camshaft.
Remove upper bearing bank (1).
Remove exhaust camshaft from lower bearing bank.
Fig. 171: Identifying Upper Bearing Bank
IMPORTANT: It is absolutely essential to follow an exact procedure for removing and
installing the exhaust camshaft.
2006 BMW 525i

A Exhaust camshaft.
E Inlet camshaft.
Fig. 172: Identifying Exhaust Camshaft And Inlet Camshaft
Check plain compression rings (1) for damage and replace if necessary.
Plain compression rings (1) are engaged at joint.
Press plain compression rings (1) apart upwards and downwards and removed towards front.
Fig. 173: Identifying Plain Compression Rings
IMPORTANT: Both camshafts have different identifications.
Mixing up the two camshafts will result in engine damage.
IMPORTANT: Plain compression rings (1) can easily break.
2006 BMW 525i

Installing camshaft bearing bank:
Pre-install special tool 11 4 462 on cylinder 2.
Insert special tool 11 4 463 in screw connection of cylinder head cover.
Press down roller rocker arms (3) on 2nd cylinder with spindle nut (2) of special tool 11 4 462.
Fig. 174: Identifying Special Tools (11 4 463), (11 4 462), Roller Rocker Arms And Cylinder
Installation:
Before installing exhaust camshaft, make sure roller rocker arm is correctly seated HVCA element and valve.
Refer to Removing and installing roller rocker arms.
IMPORTANT: Removal on engine:
Set engine to firing TDC at 1st cylinder.
Removed cylinder head:
When using special tool 11 9 000, it will be necessary to remove the aluminium
profile insert.
IMPORTANT: Special tool 11 4 463 is a special screw.
2006 BMW 525i

Fig. 175: Identifying Rocker Arms Position
Position lower bearing bank (1) with exhaust camshaft (2) on roller rocker arms.
Align exhaust camshaft (2).
Cylinders 2 and 4 are at overlap.
Cams (3) on 1st cylinder point upwards at an angle.
Part number (4) on dihedron points upwards.
Fig. 176: Identifying Lower Bearing Bank, Camshaft, Exhaust Camshaft, Cams And Part Number
Join exhaust camshaft to lower and upper bearing banks (1) with torque wrench (2) from inside outwards to 8
Nm.
Release all screws of bearing bank (1) from outside inwards by 90°.
2006 BMW 525i

Fig. 177: Identifying Lower, Upper Bearing Banks And Torque Wrench
Installation:
Lower and upper bearing banks must be aligned to each other at ground surfaces (1 and 2).
Bring thrust piece and legs of special tool 11 4 461 into contact at milled surfaces.
Fig. 178: Aligning Mark Of Lower Bearing Bank And Upper Bearing Banks
NOTE: Schematic depiction of special tool 11 4 461 at lower bearing bank (1) and upper
bearing bank (2).
IMPORTANT: Tighten screw (3) on thrust piece to 2 Nm.
2006 BMW 525i

Fig. 179: Identifying Special Tool (11 4 461), Lower Bearing Bank And Upper Bearing Bank
Position special tool 11 4 461 over screw connection of bearing banks.
Make sure that legs come into exact contact on ground surfaces, lower bearing bank (1) and upper bearing bank
(2).
Fig. 180: Identifying Special Tool (11 4 461, Lower Bearing Bank And Upper Bearing Bank)
Initially tighten screw of special tool 11 4 461 to ground surfaces of lower bearing bank (1) and upper bearing
bank (2).
IMPORTANT: Tighten screws on thrust piece to 2 Nm.
2006 BMW 525i

Fig. 181: Identifying Special Tool (11 4 461), Lower Bearing Bank And Upper Bearing Bank
Pretension all special tools 11 4 461 with special tool 11 4 350 only.
Fig. 182: Identifying Torque Wrench
Mount special tools 11 4 461 with screw (1) to inside of cylinder head.
On cylinder 2 mount special tool 11 4 461 with screw (1) facing outwards.
Position special tools 11 4 461 so that screw connections (2) of bearing bank are easily accessible.
IMPORTANT: Set special tool 11 4 350 to 2 Nm.
2006 BMW 525i

Fig. 183: Identifying Special Tools (11 4 461), (11 4 350), Screw And Connections
Tighten lower and upper bearing banks with special tool 00 9 120.
For tightening torque refer to 11 31 1AZ in 11 31 CAMSHAFT (N52) .
Fig. 184: Identifying Special Tools (11 4 461) And (00 9 120)
Assemble engine.
11 31 051 REPLACING TIMING CHAIN (N52)
11 0 300
11 4 280
IMPORTANT: Remove special tool 11 4 461 only when camshaft screw connection is
completed.
2006 BMW 525i

525i-2006-N52.pdf

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525i-2006-N52.pdf