Correction
CORRECTIONIn the affected vehicles, replace the connecting rod bearings. Reprogram DME control module.
Following completion of this Service Action, the following engine break-in instructions must be observed by customers: for the first 1,200 miles engine speed should not exceed 5,500 rpm or road speed should not exceed 105 mph.
Engine oil service is NOT required afier the completion of engine break-in period.
PROCEDURE
Detailed Service Action repair instructions can be found on the CD ROM "SIP S54 Connecting Rod Bearings Replacement", which was included in the Oil Pump Kit w/con. rod bearings (p/n 11 41 0 301 359) used for the previous M3 engine campaign # 356 (SI B11 02 03). It takes approximately 15 minutes to review the content of the CD.
FAMILIARIZE YOURSELF WITH THE CONTENT OF THE INSTRUCTION CD PRIOR TO STARTING THE REPAIR. ALL STEPS MUST BE CARRIED OUT AS PRESENTED.
The connecting rod bearings will be replaced without removing the engine from the vehicle. In order to remove the oil pan, the complete front axle carrier must be detached from the body and lowered by approximately 100 mm.
Since the front strut top mounts are not being disturbed in the process, there is no need to perform a wheel alignment check after the repair is completed.
All parts required to perform this Service Action are included in the Connecting Rod Bearings Kit (p/n 11 41 0 395 192), with the exception of the oil pan gasket (p/n 11 13 1 437 237), M10 x 1.25 connecting rod bolts (p/n 11 24 7 834 310) for vehicles from 12/13/2002 production and a gasket for oil sump cover (p/n 1113 7 834 886) for vehicles from 04/2003 production, which should be ordered separately.
1. Remove front wheels.
2. Remove intake filter housing. For removal instruction refer to RA 13 71 000 found in BMW TIS.
3. Detach guide tube (1) for oil dipstick from the intake manifold
4. Install special tool p/n 88 88 6 00 0 200 ("engine brace") in engine compartment in order to support engine during the repair.
For installation instructions refer to RA 11 13 000
5. Remove engine splashguard. Remove thrust (3) plate on front axle support. For removal instructions refer to RA 51 71 374.
6. Drain engine oil.
IMPORTANT:
When reinstalling thrust plate, use a set of new M10x30x1.5 screws provided in the parts kit. Then, the reinforcement plate screws must be tightened in two stages:
- first, torque with 59 Nm
- then, angle torque to 900 using Torque Angle Measuring Tool p/n 90 88 6 009 120 (available through the Automatic Tools Shipment Program)
7. Remove dipstick holder (1) from the oil sump, and remove dipstick.
8. Detach oil condensate return hose (2).
IMPORTANT:
^ When reinstalling the oil dipstick, replace the 0-ring (as indicated by black arrow) included in the parts kit.
9. Detach steering spindle from the steering rack by removing clamping screw.
IMPORTANT:
Use the new clamping screw M8 x 33 (provided in the parts kit) when reinstalling steering spindle. Tightening torque should be 22 Nm.
10. Detach oil lines from the power steering pump bracket.
11. Remove drive belt from the power steering pump belt pulley. In order to do this, remove the plastic cover from the belt tensioner pulley. Using a 6 mm Allen key, compress tensioner by rotating it clockwise until p/s belt can be removed.
12. Remove power steering pump without disconnecting power steering lines. Secure steering pump to the body by using plastic wire ties.
13. Unfasten two nuts at the bottom of the engine mounts.
14. Release retaining brackets for front stabilizer bar.
15. Detach brackets for left and right wishbone lower control arms.
16. Support front axle carrier with a suitable hydraulic support jack (e.g. Universal Hydraulic Stand p/n 88 88 6 00 2 030).
17. Release 4 bolts securing front axle carrier and lower the whole axle by approximately 100 mm.
IMPORTANT:
There is no need to detach the steering rack from the front axle during this procedure.
18. Detach return hose (1) from oil sump.
19. Remove cover (2) from oil sump.
20. Disconnect oil level sensor connector.
IMPORTANT:
Replace gasket for sump cover (2) when reinstalling oil sump (gasket is provided in the parts kit)
For vehicles up to 04/2003 production, gasket (p/n 11 13 7 832 023) is provided in the parts kit.
For vehicles from 04/2003, the new design gasket (p/n 11 13 7 834 886) has to be ordered separately.
21. Unfasten oil sump screws and carefully remove oil pan.
IMPORTANT:
Three screws on the left side of the oil pan (near the oil condensate return hose) are 5 mm longer then the rest of them. On SMG transmission equipped vehicles, if necessary, disconnect bracket for engine oil lines to unsure sufficient clearance for oil sump movement. When reinstalling, use new oil pan gasket p/n 11 13 1 437 237 (ordered separately). Also, apply a small amount (bead approximately 3 mm wide and 2 mm high) of HYLOMAR Sealing Compound (p/n 81 22 9 400 339) in areas around timing cover/engine block/bell housing joints. Detailed procedure can be found in the instructional CD. Then, torque down oil pan screws (M6) to 10 Nm when reinstalling.
22. Using M17 mm socket remove oil pump sprocket nut (1).
IMPORTANT:
Left-hand threads (turn clockwise to loosen).
23. IMPORTANT:
To reduce tension exerted by the oil pump chain when loosening the sprocket nut, remove all slack existing in the chain. It can be done by tightening chain around the sprocket (as shown on the illustration) with approx. 7" of soft wire (e.g., from a wire hanger). This will protect plastic tensioner from possible damage while loosening the sprocket nut.
24. Press back the chain tensioner (2). Detach sprocket wheel (3) from oil pump shaft.
IMPORTANT:
When reinstalling, align teeth of the sprocket wheel and oil pump shaft. Torque down sprocket nut to 25 Nm.
25. Remove oil pump return pipe (1) and suction pipe (2). Remove oil pump.
26. Remove two fastening screws (1) for oil cooler. Detach oil cooler (2) from the bottom of radiator without disconnecting oil hoses. Secure oil cooler to the body by means of plastic wire ties.
Connecting rod bearings bolts can be accessed from the bottom, in the following sequence: cylinders 1 and 6, cylinders 3 and 4, finally cylinders 2 and 5, when rotating crankshaft in clockwise direction.
27. Using a special tool PN 90 88 6 115 100 at the crankshaft vibration damper pulley, turn crankshaft clockwise until number 1 cylinder connecting rod bolts are accessible.
28. Remove connecting rod bolts (use M12 mm, 12-point socket on vehicles with M11x1.25 bolts; or Torx E12 on vehicles equipped with M10x1.25).
IMPORTANT:
On vehicles produced up to 12/13/2002, the M11X1.25 connecting rod bolts (A) will be reused with the new bearings . It is essential to mark them and then reinstall them in the same order (e.g. BOLT FROM THE EXHAUST SIDE MUST BE REINSTALLED AGAIN ON THE EXHAUST SIDE, etc).
On vehicles produced from 12/13/2002, the new design M10x1.25 connecting rod bolts (B) have to be replaced with the new connecting rod bearings . The M10x1.25 bolts have to be ordered separately (p/n 11 24 7 834 310 - 12 bolts per vehicle).
29. Cut off a strip (1) from a clean and fiber-free cardboard with approximate dimensions of 20 mm x 150 mm.Use such a cardboard strip to protect crankshaft bearing surface.
30. After removing connecting rod cap, gently push connecting rod upwards, and then after securing enough clearance from the crankshaft, slowly pull it down in order to remove the upper bearing shell (2).
IMPORTANT:
Do not use sharp tools to pry out the bearing shells out of the connecting rod or cap.
NOTE:
If the removed connecting rod bearings exhibit signs of excessive wear (e.g.: exposed shiny, copper bedding on the inner surface; missing, sheared-off locking tabs; or deep, shiny grooves on the outer surface indicating "spinning"), then contact the Technical Hotline Drivetrain for further instructions.
IMPORTANT:
When pulling down pistons for connecting rod bearing shell disassembly, make sure not to damage oil spray nozzles, which are located at the bottom side of the block (between crank bearing supports).
One classification of connecting rod bearings will be used in this Service Action.
Connecting rod bearings are color-coded:
- BLUE (1) for the connecting rod side
- RED (2) for the cap side.
IMPORTANT:
IN ORDER TO UNSURE ENGINE RELIABILITY, IT IS ESSENTIAL TO INSTALL BEARING SHELLS IN THE ORDER SPECIFIED ABOVE.
31. Clean connecting rod bearing surface with fiber-free cloth, then install "blue" bearing shell and moisten it with clean 10 W-60 engine oil.
32. Then, carefully push the connecting rod (1) upwards and over the crankshaft journal (2), making sure that crankshaft surface is not scratched in the process.
33. Install "red" bearing shell in the corresponding connecting rod cap and moisten it with clean 10 W-60 engine oil.
34. Install connecting rod cap in the proper position, with matching serial numbers stamped on cap and rod as shown on the illustration.
35. On vehicles produced up to 12/13/2002, install the original M11x1.25 connecting rod bolts in the same positions as when removed. On vehicles produced from 12/13/2002, install new set of M10 x1.25 connecting rod bolts (p/n 11 24 7 834 310).
36. With help of a second person, torque the connecting rod bolts in the following sequence:
Vehicles with M11x1.25 conrod bolts,
- settling torque: 5 Nm
- initial torque: 30 Nm
- angle torque to 70°, in one single stroke. Use the Torque Angle Tool p/n 90 88 6 00 9 120 (available through the Automatic Parts Shipment Program).
37. On vehicles from 12/12/2002 production, the M10x1.25 conrod bolts must be tighten at least THREE times in order to reach its maximum tensile strength.
Not adhering to the tightening specifications detailed below, will result in serious engine damage. Vehicles with M10x1.25 conrod bolts; FIRST TIGHTENING OF CONROD BOLTS:
- settling torque: 5 Nm
- initial torque: 30 Nm
- angle torque to 105°, in one single stroke. Use the Torque Angle Tool p/n 90 88 6 00 9 120 (available through the Automatic Parts Shipment Program). Then, release the torque by backing off conrod bolts by approximately one turn and then retighten them again.
SECOND TIGHTENING OF CONROD BOLTS:
- settling torque: 5 Nm
- initial torque: 30 Nm
- angle torque to 105° in one single stroke.
Then, back off conrod bolts again by approximately one turn and finally retighten them again.
THIRD TIGHTENING OF CONROD BOLTS:
- settling torque: 5 Nm
- initial torque: 30 Nm
- angle torque to 105° in one single stroke
38. Reinstall all previously removed components.
39. Replace oil filter and refill engine with 6.5 liters of fresh 10W-60 oil (Castrol Formula RS, or Castrol TWS Motorsport BMW p/n 07 51 0 009 420).
NOTE:
With the removal of oil pan, some minor quantity of oil (which otherwise would stay inside pan during regular oil/filter service) is disposed during draining and cleaning of oil pan from inside. To compensate for this loss, the additional 1.0 liter of motor oil (to the total of 6.5 liters) was allocated for this Service Action repair.
IMPORTANT:
S54B32 engine oil refill capacity used during scheduled oil service (with oil filter replaced) is 5.5 liters (5.8 quarts) of Castrol 10 W-60 Synthetic Oil (PN 07 51 0 009 420). For the proper procedure of checking oil level follow procedure below, from SIB 11 03 03 (04/2003)
Engine Oil Level Checking Procedure:
1. Park the vehicle on a level surface.
2. With engine warmed to its normal operating temperature (one yellow LED illuminated on the tachometer), allow it to idle for at least 15 seconds, then switch off.
3. After approximately 1 minute, pull the dipstick out and wipe it off with a clean lint-free cloth, paper towel, or similar material.
4. Carefully push the dipstick into the guide tube and pull it out again.
5. The oil level should be between the two marks on the dipstick.
With 6.5 liter of fresh oil, and when correctly checked, the oil level should be between the two marks on the dipstick. It is not necessary, nor recommended to bring oil level to the "max" mark on the dipstick.
NOTE:
The oil volume between two marks on the dipstick corresponds to approximately 1.3 liters (1.4 quarts).
Do not fill beyond the upper mark on the dipstick. Excess oil will induce excessive oil consumption, and may damage the engine.
Reprogram DME control module using DISPlus/GT1 with CD 38.0 or higher.
To reprogram DME:
^ Connect vehicle to the BMW approved battery charger.
^ Connect DISplus/GT1 loaded with CD 38.0, or higher.
^ Select: BMW Coding/Programming.
^ Select: 5 Programming, then right arrow.
^ Select: 3 DME Programming, then right arrow.
^ Select: 2 Exchange control unit, then right arrow.
^ Display appears First determine and then program basic control unit, then right arrow.
^ Select 1 Determine basic control unit, then right arrow. Automatic determination is going to be performed.
^ DME, is the faulty control unit still installed in the car?, select YES.
^ Start automatic determination?, select YES.
^ Display appears: Compare chassis number displayed with number in the car. Chassis number..... Do numbers correspond? Select YES.
^ Part number basic control unit .....|..... are displayed, then scroll down.
^ Display appears: Followed part numbers (basic control unit) can likewise be used. A new program version is also programmed for these part numbers. Duration depends on control unit between 4 - 16 minutes, then scroll down.
^ At this point vehicle data is stored in the tester for the automatic identification.
^ Disregard screen prompt which refers to obtaining and installing a new basic control unit and scroll to the left.
^ Select: 2 Program basic control module, then right arrow.
^ Follow instruction: Chassis number, enter the last 7 characters of VIN. Is the number correct? Select YES.
^ Disregard the next instruction: Install new basic control module, just go forward by pressing right arrow.
^ Display will appear: There is new program version and new data version for this control unit. Depending on the control unit, programming may last between 4-16 minutes. First programming and then data are programmed. After programming, with diagnosis program, the fault memories have to be cleared. EWS alignment is automatically carried-out with reprogramming. The adaptation values must be cleared after programming, then right arrow.
^ The next screen displays: The control module can be programmed X times, then right arrow.
^ Follow the command: Please enter reading mileage ..... Entry correct?. Select: YES.
^ Start automatic programming? Select: YES.
^ When programming starts, the following message is displayed: MSS54 Program programming active. Voltage terminal 30 .....
^ After programming part is finished , the following message is displayed: M5554 data programming active. Voltage terminal 30 .....
^ After successful programming, message is displayed: Programming completed.
^ Next, follow-up screen instructions for EWS alignment and for clearing of adaptation values.
^ Obtain one "Break-in procedures" label (SD92-246, strip of 10). Using a ball-point pen, write the appropriate mileage (current mileage + 1,200 miles) on the label, and apply to the upper left corner of the windshield. Initial quantity (50 labels per center) has been shipped to every BMW Service Center. Additional quantities can be ordered online at BMWTIS.