[andy_06xi]

I just cleaned, swapped and re-installed my vanos solenoids. One issue that I had was with new (oiled) O-rings -- it was very hard to re-install the solenoids. I couldn't get the solenoid to sit 'flat'. (Yes -- the old o-ring was removed). I've seen some videos where it required a good deal of force/twisting to get the O-rings inserted in the block.

Instead -- I just screwed in the hold-down bolt (the threads still caught despite the 'gap') thinking that this is as good a tool as any to apply the right force in a rather awkward angle. Seemed to work and the bolts continued to screw in fairly easily. I can't get a great view of both solenoids -- but they seem to be sitting flat. No oil leaks, rough idle or codes thrown.

Is this how other people did it -- or are they just stronger than me?

[theMeeks]

You probably already installed them one way or another since this is a month old, but I had the same issue recently and searched everywhere for something like this...

Even after adding a substantial amount of oil on the o-ring, the ring wouldn't go into the housing and sit flush. I did what you did as well and ended up bending the vanos solenoid top; luckily was able to bend it back.

What I did to fix it was placed the o-ring at the very end of the solenoid, opposite of where the connector goes and where it will eventually seat. There is an indent at one end of the solenoid that helps it stay. This then helps push the o-ring in place. I checked the clearance of the solenoid and ring so there's no concern with the o-ring bending or going into the engine.

[andy_06xi]

Well I guess I got lucky -- as the solenoids appear to be sitting flat and I don't have any Vanos issues or codes.

One idea that I saw after I installed mine was to simply install the o-rings into the block first -- then insert the solenoids and tighten them. It seems like this would be a good solution. It is similar to your eventual solution.

[Suvorovo]

I believe you have to install the solenoid at 1/8 rotation clockwise and then after pushing the solenoid in you rotate it counter clockwise so the holes line up. Nothing should be forced. The bentley manual has the procedure.