1997 BMW 540i 120

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. ." ".
[Cylinder Head Removal and Installation - .. - -1 -
4 Insert and secure VANOS sealing plugs (arrows) with new
sealing O-rings.
Tightening torque Sealing
plug to VANOS 50
Nm (37 ft-lb)
4 Install coolant pipe fasteners at base of cylinder head and
tighten fasteners (arrows).
NOTE-
Use new sealing O-ring on coolant pipe.
- lnstall VANOS oil line banjo bolt with new seals. Attach oil
line to VANOS unit.
Tightening torque Oil line to VANOS unit
(banjo bolt) 32
Nm (24 ft-ib)
- Remove adjustable timing chain tensioner tool and reinstall
chain tensioner.
Tightening torque Primary chain tensioner cylinder to
cylinder head 70
Nm
(52 fi-ib)
- Remove flywheel locking tool from transmission bell housing.
Replace special tool bore sealing plug.
- Remove camshaft locking tools from cylinder head
4 lnstall intake camshaft cover and cylinder head cover.
0 Check for correct seating of half-moon seals (A) in back of
cylinder head cover.
Use a small amount of Three Bond
1209 8 or equivalent
sealant at corners
(B) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
Tightening torque
Cylinder head cover to cylinder head
(M6) 10 Nm (89 in-lb)

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11 3-70
Cylinder Head Removal and Installation
- Remove adjustable timing chain tensioner tool from timing
case cover and install primary timing chain tensioner with
new sealing washer.
Tightening torque Chain tensioner cylinder to timing cover
65 Nm (48 ft-lb)
4 Install oil supply lines and mounting nuts (arrows) to both
heads.
Tightening torque
Oil supply line nuts 10 Nm (7.5 ft-lb)
- Remove old gasket from lefl timing cover, and clean gasket
surface.
4 Apply Three Bond 1209 8 sealant to joint between cylinder
head and timing cover (arrows).
Using a new gasket, install lefl timing cover with lower inner
fastener inserted in cover (arrow). Position cover in place
and tighten cover fasteners finger tight.
NOTE-
It is not possible to install lower inner fastener after cover is
in place.

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. ." . .
I - Cylinder Head Removal - and instard --
4 Remove left cylinder head cover gasket and install spacing
tool (BMW
11 1 412) in place of gasket.
- lnstall lefl cylinder head cover fasteners and tighten uniformly
in
'I2 turn steps.
Tightening torque Cylinder head cover nuts
10 Nrn (7.5 it-lb)
- Tighten left upper timing cover retaining bolts in two passes.
Tightening torque
Timing chain cover to head 10 Nrn (7.5 ft-lb)
- Remove lefl cylinder head cover and BMW special tool 11 4
412.
4 Reinstall cylinder head covers to left and right cylinder heads
using new gaskets.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
03 or equivalent
sealer at corners
(6) of half-moon cutouts.
- Install left cylinder head cover fasteners and tighten uniformly
in
'I? turn steps.
- Install exhaust manifolds using new gaskets and fasteners.
See
180 Exhaust System.

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/Cylinder Head Removal and Installation
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Use new gaskets when mounting intake
manifold. Tighten
nuts finger tight first, then torque to specification in stages
working diagonally from center out.
Be sure to reinstall ignition coil ground straps at cylinders
no.
3 and no. 7. See 120 Ignition System.
Reinstall cooling fan and shroud. See
170 Radiator and
Cooling System.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
CA UTIOG
To prevent damaging engine electricalsystems, be sure to in-
stall all ground wires previously removed.
Tightening torques
Camshaft sprocket to camshaft 15
Nm (11 H-lb)
Coolant manifold to cylinder head 10 Nm (7.5 H-lb)
Cylinder head cover nuts 10 Nm (7.5 ft-lb)
Exhaust manifold to head 22 Nm (17 ft-lb)
Engine mounts to subirame 42 Nm (30 ft-lb)
Spark plugs to cylinder head 22 Nm (17 ft-lb)
Right cylinder head, removing, M62 engine
- Remove left side exhaust manifold. See 180 Exhaust Sys-
tem.
- Remove intake manifold. See Intake manifold, removal
and installation,
M62 engine.
- Drain engine coolant. See 170 Radiator and Cooling Sys-
tem.
WARNING-
Use extreme caution when draining and disposing of engine
coolant.
Coolanl is poisonous andlellial lo liumans andpels.
Pets are
altracled to coolant because of 11s sfieet smell and
fasle. Seelc medcal anenfion immed~alely if coolant is ingesl-
. .-
< Remove engine coolant manlold mo~nlng fasreners and
carei~lly remove manifo d.
. I
NOTE
Engine 8s slioivn removed lor clarify

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11 3-80
Cylinder Head Removal and lnstallation
I I 4 Install BMW special tool 11 7 380
4 Install special tool 11 3 390 into special tool 11 7 380 and
tighten tensioner
(1 1 3 390) to 0.7 Nm (6.3 in-lb) using spe-
cial tool 00
9 250.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
- Tighten sprocket retaining bolts in the following order:
3 accessible bolts on left exhaust camshaft
- All bolts on right exhaust camshaft
3 accessible bolts on left intake camshaft
All bolts on right intake camshaft
Tightening torque
Sprocitet bolts to camshaft flange 15 Nm (11 ft-lb)
- Remove camshaft and crankshaft locking tools from engine.
- Using crankshaft center bolt, turn engine clockwise to access
remaining sprocket retaining bolts of left cylinder head cam-
shafts. Tighten remaining bolts.
Tightening torque
Sprocket bolts
to camshaft flange 15 Nm (11 ft-ib)
- Remove BMW special tool 11 3 390 and 11 7 380 from right
cylinder head.
- Remove used gasket from right timing chain cover, clean
gasket surface.
4 Install new gasket and apply three Bond 1209 @sealant to
joint between cylinder head and timing cover
(arrows).

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1 13-82
1 Cylinder Head Removal and Installation
4 Reinstall cylinder head covers to right and left cylinder heads
using new gaskets.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond
1209 8 or equivalent
sealer at corners
(B) of half-moon cutouts.
- Install cylinder head cover fasteners and tighten uniformly in
'I2 turn steps.
Tightening torque Cvlinder head cover fasteners
10 Nm (7.5 It-lb)
- Install exhaust manifolds using new gaskets and fasteners.
See
180 Exhaust System.
- Refill and bleed cooling system as described in 170 Radiator
and Cooling System.
- Change engine oil and filter as described in 020 Mainte.
nance.
CA UTIOW-
To prevent damaging engine electricalsystems, be sure to in-
stall all ground wires previously removed.
Tightening
tOrqUeS
Camshaft sprocket to camshaft 15 Nm (1 1 ft-lb)
Coolant manifold to cylinder head lo Nm (7.5 It-lb)
Cylinder head cover nuts 10 Nm (7.5 ft-lb)
Exhaust manifold to head 22 Nm (17 ft-lb)
Engine mount to subframe 42 Nm (30 ft-lb)
Spark plugs to cylinder head 22 Nm (17 ft-lb)

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Cylinder Head and Valvetrain
4 Install intake camshaft oil baffle cover and cylinder head cov-
er:
= Checlc for correct seating of half-moon seals (A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
@or equivalent
sealant at corners
(B) of half-moon cutouts and corners in
front of cylinder head at joint to timing chain cover.
Align cover at front and rear, then alternatively tighten fas-
teners from inside to outside.
Tightening torque
Sparic plug to cylinder head 25 Nm (18 it-lb)
Ignition coils to cylinder head 10 Nrn (7.5 ft-lb)
Cylinder head cover to cylinder iiead 10 Nrn (89 in-lb)
fM6 screws)
CAMSHAFT AND LIFTER REMOVAL
AND ~NSTALLATION
The camshafts can be removed with the cylinder heads
mounted on the engine (in the car).
On 6-cylinder engines there are two different procedures giv-
en, depending on whether the engine is equipped with single
VANOS (M52 engine) or double VANOS
(M52TU or M54 en-
gine).
For V-8 engines, camshaft removal and installation proce-
dures are
only included for the non-VANOS (M62) engine.
Camshaft removal and installation for the
VANOS eq;ipped
V-8 (M62TU) is not covered in this manual.
Special BMW service tools should always be used to remove
and install the camshafts. Removal of the camshafts without
the special tools can result in cylinder head damage and cam-
shaft breakage.

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-
. - - -- Cylinder Head and valvetrain]
Turn engine over twice in direction of rotation until cylinder 1
intake and exhaust camshaft lobes (arrows) face each other.
- Lock crankshaft in TDC position with BMW special tool
11 2 300.
4 Place BMW special tool set 11 3 240 over camshafts and
measure clearances.
NOTE-
@ If the exhaust side of the tool (A) is not flush with the head,
camshaft timing is incorrect. Reset camshaft timing as de-
scribed in 11
7 Camshaft Timing Chain.
Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft timing
is set correctly, the intake side of special tool set
11 3 240
(B) may be up to 1 mm (0.04 in.) above the suiface of the
cylinder head. This is normal. Reassemble engine. Other-
wise, reset camshaft timing as describedin 1
l?Camshaft
Timing Chain.
- Remove BMW special tool 11 6 150 from front of cylinder
head.
4 Clean contact edges of cylinder head face and VANOS unit
and apply a thin coat of Three Bond
12090 or equivalent
sealing compound to surfaces.
CAUTION-
Male sure all gasket material is removed from face of cyl-
inder head. Clean sealing face and keep free of oil.
Check locating dowel
(A) and dowel sleeve (B) at top
of cylinder head for damage or incorrect installation.
- Using a new steel gasket, install VANOS unit to front of cyi-
inder head. See 117 Camshaft Timing Chain.
NOTE-
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in 117 Camshaft Tim-
ing Chain.
- Reinstall engine lifting eye.
- Reconnect electrical harness connectors to camshaft posi-
tion sensors and
VANOS solenoid valves.