N63 Stem, Injector, & Timing Seals with VC Gaskets, PCV Valves & Hoses

STEP 1

Before starting Valve Stem Seal Replacement, please complete the following steps.

Tools Needed to Complete Preliminary Work:

If you have access to the BMW TIS, or through All Data, Mitchell, etc., follow the step-by-step instructions. If you are using the AGA direct fuel injector tool kit and cam timing kit, please refer to the instructions provided with your kit.

STEP 2

Install a yellow cap onto each of the injectors (1) and the high-pressure fuel supply rail (2).

Install one orange cap onto the supply high-pressure pump supply port (3).

Part #: AGA-CI-Y12 (yellow)

Part #: AGA-CP-0-14 (orange)

Always store the high-pressure pumps in a clean location to avoid contamination.

STEP 3

Wrap cylinder bank #1 timing chain with a small shop towel to protect it from contamination.

STEP 4

Gently clean the upper portion of the injector bores with the brush before installing the fuel injector-sealing plug.

Part #: AGA-HB-8-34

STEP 5

5. Install the fuel injector sealing plugs (1) into the cylinder 1 and 2 injector bores (2).

Part #: AGA-FISP-N63

STEP 6

Reinstall the injector hold-down bracket and torque the M7 hex bolt to 13 Nm. (1)

STEP 7

Install the two red plugs into the remaining open injector bores (1), so that debris does not fall into the cylinders while performing the repairs.

Part #: AGA-IBPP-N63

STEP 8

Install the eight supplied plug brushes (1) into the eight oil drain back holes (see arrows) in the cylinder head, located on either side of the head bolts.

If a collet is dropped, use a magnet to retrieve the collet from around the brush. Do not remove the brushes until all collets are accounted for.

Part #: AGA-N63-PB-34

STEP 9

Install the U-bend plug brush (1) into the cylinder head drain back hole just below the exhaust camshaft (see arrow).

If a collet is dropped, use a magnet to retrieve the collet from around the brush. Do not remove the brushes until all collets are accounted for.

Part #: AGA-N63-UP8-34

STEP 10

There are four drain back holes in the cylinder head near the hydraulic valve lash adjusters (HVA). See arrows.

STEP 11

Block all four holes with a standard white lithium grease. See arrows.

Always use a standard white lithium grease that can be applied with a brush that has been stored properly in its container and not contaminated with foreign materials.

Using a white lithium grease in a spray can will not provide the same functions in this procedure.

Overview of the plug brushes (1) and the white lithium grease (2)

STEP 12

Exhaust camshaft position: Using two of the four bolts that hold the high-pressure pump housing, install the cam bracket (1) and a compression plate (2) onto the front of the cylinder head, above the cylinder 1 ignition coil bore.

Use a T45 and hand-tighten the bolts.

Part #: AGA-CB-N63 (Cam Bracket)

Part #: AGA-CP-N63 (Compression Plate)

STEP 13

Exhaust camshaft position: Reinstall the “LA5” exhaust camshaft bearing cap (1) with a compression plate (2) onto the rear of the cylinder head.

Use a T45 and hand-tighten the bolts.

Part #: AGA-CP-N63 (Compression Plate)

STEP 14

Intake camshaft position: Reinstall the “LE2” intake camshaft bearing cap (1) with a compression plate (2) onto the front of the cylinder head.

Use a T45 and hand-tighten the bolts.

Part #: AGA-CP-N63 (Compression Plate)

STEP 15

Intake camshaft position: Reinstall the “LE5” intake camshaft bearing cap (1) with a compression plate (2) onto the rear of the cylinder head.

Use a T45 and hand-tighten the bolts.

Part #: AGA-CP-N63 (Compression Plate)

STEP 16

Screw four of the black plastic spark plug TDC tools (1) into each of the spark plug holes (see arrows) to avoid debris from falling into the cylinders.

Hand-tighten the tool (1) using tool number 12 1 220 and short 3/8 extension.

Insert the TDC flag into cylinder 1 (2).

Part #: AGA-SPT12-125

STEP 17

Hold the timing chain in one hand (1) and rotate the engine slowly in the clockwise direction (see arrow) while keeping the tension on the chain with one hand (1).

Do not allow the timing chain to fall down into the engine.

Stop turning the engine when TDC is reached.

It is good practice to turn the engine 1-2° past TDC (clockwise), so that the compressed air does not turn the engine backwards.

Do not apply compressed air to the cylinder yet.

STEP 18

Install the timing chain holder (1) onto the opposite cylinder bank timing chain guide rail.

Installing this tool will prevent the engine from rotating when the compressed air is applied to the cylinders using a leak-down tester.

Make sure the teeth on the tool match the chain teeth (2) before tightening.

Tighten gently with just one hand.

Part #: AGA-CH-N63

STEP 19

Use a cylinder leak-down tester to supply air pressure to the cylinder. The air pressure will hold the valve in the closed position while removing the valve spring retainer, valve spring, and keepers.

A leak-down tester already has a predetermined pressure, so that no damage occurs to the engine.

Never apply shop air directly to the cylinder.

STEP 20

Assemble the compression block (1) onto the compression nut and compression screw (2).

Install the ratcheting box wrench (3) and the locator handle (4).

Use the laminated card in the kit to identify which compression foot (5) is required, based on the location of the valve spring in the cylinder head.

For example: The cylinder 1 exhaust front spring position requires the compression foot marked with an “R” = right (5).

LAMINATED CARD OVERVIEW

STEP 21

Slide the compression lever rod (1) into the compression plates (2) located on the camshaft bearing caps.

Slide the compression block (3) onto the compression lever rod (1) in the direction of the arrows.

Part #: AGA-CLR-N63

STEP 22

Rotate the compression nut (1) counter clockwise until the compression foot (2) contacts the valve spring retainer (3).

Hold the locator handle (4) firmly to keep the compression foot properly centered on the valve spring retainer (3).

STEP 23

When the valve stem and keepers are exposed (1), the keepers can be removed with a magnet (2).

STEP 24

Rotate the compression nut (1) clockwise until the compression foot (2) releases the valve spring retainer (3).

Hold the locator handle (4) firmly to keep the compression foot properly centered on the valve spring retainer (3).

STEP 25

Remove the compression lever rod (1) from the compression plates (2), located on the camshaft bearing caps.

Remove the compression block (3) from the compression lever rod (1) in the direction of the arrows.

STEP 26

Remove the valve retainer (1) and valve spring (2) to expose the valve seal.

STEP 27

Remove the valve seal (1) with the seal pliers (2) included in the kit.

Part #: AGA-SRP-N63

STEP 28

nstall the valve stem protection sleeve (1) supplied with the valve seal kit. Apply a light coating of white lithium grease (2) to the sleeve exterior to help lubricate the valve seal installation.

STEP 29

Install the new valve seal (1) with the seal pliers included in the kit (2).

Push firmly to seat the valve seal.

STEP 30

Install the valve spring retainer (1) and valve spring (2).

STEP 31

Slide the compression lever rod (1) into the compression plates (2) located on the camshaft bearing caps.

Slide the compression block (3) onto the compression lever rod (1) in the direction of the arrows.

STEP 32

Rotate the compression nut (1) counter clockwise until the compression foot (2) depresses the valve spring (3)

Hold the locator handle (4) firmly to keep the compression foot properly centered on the valve spring retainer (3).

STEP 33

When the valve stem is exposed (1), apply a small amount of white lithium grease (2) with a brush to assist in holding the keepers in place.

STEP 34

Install the keepers (1) into the N63 valve keeper tool (2) supplied in the kit.

Part #: AGA-N63-6mm-VKT

STEP 35

Apply a small amount of white lithium grease to the keeper grooves (1).

STEP 36

Place the N63 keeper tool with keepers (1) over the valve stem (2), and move the tool gently side to side to release the keepers (see arrow).

Gently lift the tool straight up, and the keepers will be left behind on the valve stem.

STEP 37

Inspect the position of the keepers on the valve stem to make sure they are in the proper position.

Do not wipe away any grease.

STEP 38

Rotate the compression nut (1) clockwise until the compression foot (2) releases the tension on the valve spring retainer (3).

Hold the locator handle (4) firmly to keep the compression foot properly centered on the valve spring retainer, so that the valve keepers seat correctly in the retainer (3).

STEP 39

Remove the compression lever rod (1) from the compression plates (2) located on the camshaft bearing caps.

Remove the compression block (3) from the compression lever rod (1) in the direction of the arrows.

STEP 40

Wipe away excess grease.

Inspect the valve stem (1), keepers (2), and the spring retainer (3) for the proper alignment before continuing.

If the alignment is not correct, you will have to repeat steps 32-40.

STEP 41

Repeat steps 19 through 40 for the remaining valve seals on cylinder 1.

STEP 42

When cylinder 1 is complete, release the air supply from that cylinder and repeat steps 17 through 40 for cylinders 2, 3 and 4.

Fuel injector sealing plugs Part #: AGA-FISP-N63 needs to be moved to cylinders 3 and 4 when needed.

Injector bore plastic plugs Part #: AGA-IBPP-N63 needs to be moved to cylinders 1 and 2 when needed.

STEP 43

When cylinder bank 1 valve seal replacement is complete, the crankshaft has to be positioned 150° before cylinder 1 TDC. Hold the timing chain with one hand (1) and rotate the engine (2) in the direction of the arrow. Do not allow the timing chain to get jammed. Do not forget to remove the brushes from the oil return holes. Clear the oil return holes covered with grease, using a small brush or cotton swab.

STEP 44

When the crankshaft is positioned correctly, install AGA-11-8-570 Crank holder and AGA-11-9-190 Pin, or BMW equivalent tools.

STEP 45

With cylinder 1 at 150° before TDC:

Cylinder 5 exhaust camshaft (A) lobes will point to the left. See arrow and line.

Cylinder 5 intake camshaft (E) lobes will point downward. See arrow and line.

Note: For purposes of clarity, the illustration shows the inlet and exhaust adjustment units removed.

Intake camshaft (A)

Exhaust camshaft (E)

STEP 46

Cam Timing is correct when timing chain is in correct tension with AGA chain tensioner tool (AGA 11-9-900), or BMW equivalent, and cam plates (AGA-11-9-893-IN-N63) & (AGA-11-9-893-EX-N63) rests without gap on the cylinder head.

STEP 47

Reinstall the camshafts on cylinder bank 1, and reinstall the VANOS gears before starting the procedure on cylinder bank 2.

Use AGA’s Cam Timing Tool (AGA-CTK-N63) and instructions or BMW equivalent tools, to install and to set the cam timing on the R side (Bank 1), before removing cams on L side (Bank 2)

See AGA’s cam tool instructions, or this process is described in BMW TIS or Simular as: 11 33 054 “Removing and installing/renewing rocker arms on R side (N63).” For further instructions, watch “AGA BMW N63 Cam Timing Tool”

STEP 48

After cylinder bank 1 is reassembled, remove the VANOS gears and camshafts on cylinder bank 2.

Repeat steps 1 through 37 on cylinder bank 2.

Note: Cylinder numbers start at the front of the cylinder head on cylinder bank 2.

Example: Cylinder 1 = Cylinder 5

STEP 49

When cylinder bank 2 valve seal replacement is complete, the crankshaft has to be positioned 150° before cylinder 1 TDC.

Rotate the engine in the direction of the arrow. Do not allow the chain to get jammed. Hold the timing chain with one hand (1).

Do not forget to remove the brushes from the oil return holes.

Clear the oil return holes covered with grease, using a small brush or cotton swab.

STEP 50

When the crankshaft is positioned correctly, install AGA-11-8-570 Crank holder and AGA-11-9-190 Pin, or BMW equivalent tools.

STEP 51

With cylinder 1 at 150° before TDC:

Cylinder 1 exhaust camshaft (A) lobes point at an angle upwards. See arrow and line.

Cylinder 1 intake camshaft (E) lobes point at an angle upwards. See arrow and line.

Note: For purposes of clarity, the illustration shows the inlet and exhaust adjustment units removed.

Intake camshaft (A)

Exhaust camshaft (E)

Use AGA’s Cam Timing Tool (AGA-CTK-N63) and instructions or BMW equivalent tools, to install and to set the cam timing on the L side (Bank 2.)

With cylinder 1 at 150° before TDC:

See AGA’s cam tool instructions, or this process is described in BMW TIS or Simular as: 11 33 052, “Removing and installing/renewing rocker arms on left side (N63).” For further instructions, watch “AGA BMW N63 Cam Timing Tool.

Reassemble the remaining portion of the vehicle per the repair instructions.