1997 BMW 540i Crankshaft

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Cylinder Head and Valvetrain
< Remove oil baffle cover from above intake camshaft(s)
- Rotate engine at crankshaft vibration damper center bolt in
normal direction of rotation (clockwise) until camshaft lobe of
lifter to be tested points away from the lifter, allowing valve to
be completely closed.
Use a plastic or wooden stick to press down on top of lifter
with approximately 3.5 Nm
(2.25 ft-ib) of force.
If the lifter collapses slightly as though spring loaded, air
may be trapped in the lifter.
NOTE-
Air trapped in hydraulic lifters may result from oil foaming (air
being drawn
in by the oil pump). This may be caused by a
faulty oil pump control valve O-ring; leaking oil pump pickup
gaslcet; or by oil starvation to pump.
Press down on top of lifter for
10 to 15 seconds uslng approx-
lmately 6 to 9 Nm (4.5 to 6.75 ft-lb) of force.
If anv clearance is created between the lifter and the
cam-
shafi lobe, the check valve in the lifter is not closing. Re-
place lifter.
- To replace a hydraulic lifter, remove appropriate camshaft.
Refer to camshaft removal procedures given in Camshaft
and lifter removal and installation.
Once camshaft is removed, withdraw faulty
lifter(s) and re-
place with new
lifter(s). Inspect lifter bores for wear and scor-
ing at arrows.
- Reinstall camshafts. See Camshaft and lifter removal and
installation.

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116-15
Cylinder Head and Valvetrain
4 Remove primary timing chain tensioner plug (arrow) and pri-
mary tensioner.
CAUTION-
Primary timinq chain tensioner is under sarina aressure.
4 Remove primary timing chain sprocket and timing chain from
exhaust camshaft.
- Remove crankshaft locking tool (BMW 11 2 300) from
flywheel (installed during
VANOS removal).
Lift timing chain (holding under tension) and rotate engine
counterclockwise 30" from
TDC.
- Suspend timing chain with mechanic's wire

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11 6-23
Cylinder Head and Valvetrain
Place timing
chain on end of exhaust camshaft
4 Do not remove end spline retaining screws from camshafts
(arrows).
CAUTION-
The end spline retaining screws precisely locate the end
splines to the camshafts. Do not loosen these screws.
Remove locating studs (arrows) from
intake camshaft. Lift
off intake
camshaft thrust spacer (A) and impulse wheel (B)
4 Remove cylinder head cover mounting studs (arrows) from
center of cylinder head.
- Remove crankshaft locking tool (BMW special tool 11 2 300)
from cranltcase.

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Cylinder Head and Valvetrain
NOTE-
The camshaft bearing caps are coded with a letter and a
number. For example, "A
1" is the first exhaust camshaft
bearing cap
at the front of the engine, and "El "is the intake
camshaft bearing cap at the front of the engine.
-. -
The camshafts are stamped with a code letter - "E for the
intake side and
'X" for the exhaust side.
"E is for Einlap. (German for intake) and 'XA7s for Auspuff.
(German for exhaust).
- Repeat procedure for exhaust camshaft
< Secure hydraulic lifters in lifter bores using BMW special tool
11 3 250, or remove lifters using a magnetic pick-up tool.
I CAUTION-
Used liydraulic lifters must be reinstalled in original lifter
1 bores.
4 Remove lower camshaft bearing carriers from cylinder head.
CAUTION- Camshaft bearing carriers must be reinstalled in their original
locations
(E for intalce and A for exhaust).
NOTE- Do not allow hydraulic lifters to fall out of camshaft carriers.
Hydraulic lifters should be stored in an upright position.
Camshafts and lifters, installing (M52TU and M54 engine)
Lubricate camshafts, camshaft carriers, bearing caps, hy-
draulic lifters, friction washers, splined shafts and
spline hubs
with assembly
lubricant before installation.
CAUTION-
Make sure the crankshaft, which had been rotated approxi-
mately
30" opposite the direction of engine rotation from
TDC, is
stillin thatposition before lowering the camshafts into
position. Allpistons must be out of
TDCposition to prevent
valve/piston inteiference when the carnshafis are installed.
- Lift timing chain and place exhaust cam onto exhaust cam-
shaft carriers. Place
intake camshaft on camshaft carrier.

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-- - . .- -,
Cylinder Head and Valvetrain
4 Rotate camshafts so that intalte and exhaust lobes for cylin-
der
1 face each other (arrows).
CAUJION-
A minimum waiting time is required for the hydraulic lifters to
'bleed down"after installing the camshafts into the cylinder
head, before bringing the piston to TDC. When the camshafts
are removed, the hydraulic lifters can expand. This expan-
sion can cause increased valve lift when the camshafts are
bolted down, possibly resulting in piston interference.
Place bearing caps on cams, but do not install retaining nuts.
4 Fit BMW special tool 11 3 260 (A) and 11 3 270 (B) to cylinder
head over
intalte camshaft and screw long bolts (arrows)
into spark plug threads.
CA UTION-
Do not overtighten bolts into spark plug holes.
< Turn eccentric shaft of special tool to pretension bearing
caps. Install and torque nuts on intake camshaft bearing
caps.
Tightening torque Camshaft bearing cap
to cylinder head (M7) 14 Nm (10 it-ib)
- Release tension on eccentric shaft and remove BMW special
tools
11 3 2601270.
- Repeat procedure for exhaust camshaft.
NOTE-
Observe waiting time for lifter bleed down before continuing
with camshaff installation.
Crankshaft
I valve timing waiting times
68°F (20°C) and higher 5 minutes
50-6S°F(10-20°C) 15 minutes
32-50DF(O-10°C) 30 minutes

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~ ~. --
Cylinder Head and Valvetrain .-
4 While maintaining tension on timing chain, rotate crankshaft
at vibration dampener from
30" before TDC in direction of ro-
tation (clockwise) until number
1 cylinder is at TDC position
with line between the OIT mark (arrow) on front pulley
aligned with boss on lower timing chain cover.
4 Secure crankshaft in TDC position with BMW special tool
11 2 300 (arrow).
Slide impulse wheel on intake camshaft, aligning boss with
raised portion on camshaft (arrow).
Fit thrust spacer
(A) to intalte camshaft and tighten down with
threaded locating studs (arrows). Place longer threaded por-
tion of studs into camshaft.
Tightening torque
Impulse wheel studs to intake camshaft (M7)
20 Nm (15 ft-lb)

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1 16-36
I Cylinder Head and Valvetrain
4 Preload exhaust camshaft spring plate by pressing on im-
pulse wheel while tightening mounting nuts (arrows)
fingel
tight.
4 Install BMW special tool 11 6 150 (VANOS setup bracket) to
front of cylinder head timing case. Install nuts (arrows) finger
tight, then tighten down uniformly until special tool is in full
contact with cylinder head.
CAUTION--
Male sure aNgas1ef material Is removed from face of cyiin-
der head. Clean sealing face and keep free of oil.
4 Secure camshaft sprockets and impulse wheels:
Tighten mounting screws (A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Tighten mounting nuts (B) on exhaust and intake sprocket
assemblies to approx.
5 Nm (44 in-lb).
Torque down mounting screws (A) and nuts (B) to final
specifications.
Tightening torques Sprocket assembly to camshaft initial torque
5 Nm (44 in-lb)
Sprocket assembly wheel to carnshaft
M7 tom screws (A) 20 Nm (15 ft-lb)
M6 mounting sciew (6) I0 Nm (8 ft-lb) - - -
- - Remove crankshaft locking tool from crankcase.
- Remove camshaft locking tools from cylinder head.

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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.