1997 BMW 540i Oil

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11 3-1 4
Cylinder Head Removal and Installation
4 Secure camshafts in TDC position using BMW special tool
set
11 3 240.
4 Remove access plugs from VANOS control unit in front of
exhaust camshaft sprocket.
Remove
4 bolts (arrows) from exhaust camshaft sprocket
(Torx E10).
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
eninq or tiqhteninq sprocl(et mounting fasteners. r
Press down on secondary chain tensioner and lock into place
using
BMW special tool 11 3 292 or a similar size pin.
NOTE-
Some tensioners may have a single hole for special tool.
Remove secondary chain tensioner.
Disconnect harness connector and oil line fitting from bottom
of VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
Remove VANOS control unit mounting nuts and bolt at front
of cylinder head.

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I Cylinder Head Removal and Installation I
< Use BMW tool 11 2 110 or torque angle gauge to tighten cyl-
inder head bolts in sequence to stage
2 and 3.
Tightening torques
Cylinder head to cast iron
bloclc
Staoe 1
staie 2
Stage 3
Cyllnder head to aiumlnum block
Stage
1 40 Nm (30 it-lb)
Stage 2 +90°
Staoe 3 -80"
- Tighten cylinder head-to-lower timing chain cover bolts.
Tightening torques
cylinderhead to lower timing chain cover 10 Nm (89 in-lb)
- Inspect secondary chain guide rail and tensioner rail for
grooves caused by chain contact. Replace any part that is
worn.
NOTE-
Inspect timing chain sprocl(ets. Sprockets that have worn
or missing teeth should be replaced.
* If any of the sprockets are being replaced due to wear, the
chain should also be replaced.
If the crankshaft sproclet requir?s replacement, the oil
pump drive sprocket and chain must be removed as de-
scribed under
119 Lubrication System.
The procedure outlined below assumes that the camshafts
and the
cranl(shaft are locledin the TDCposition with special
4 Mount primary timing chain sprocltet to primary chain so that
arrow on sprocket faces up. Mount sprocket to camshaft so
that tapped holes in camshaft are on left side of elongated
holes in sprocltet
Install BMW special tool
1 I 4 220 into primary timing chain
tensioner sleeve. Thread center spindle in finger tight
until
slack is removed from chain.

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- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Install intake camshaft cover and cylinder
head cover.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in 020 Mainte-
nance.
If necessary, adjust accelerator cable.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl

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. - --
j Cylinder Head Removal and Installation
4 Working at throttle housing, unscrew and disconnect electri-
cal harness plug
(arrow).
4 Disconnect electrical harness connector at fuel tank venting
valve
(A) and vent hose at quick disconnect fitting (arrow).
- Working under intake manifold, disconnect the following:
Engine oil dipstick tube support.
Oil separator return line from dipstick tube.
Knock sensor harness connector from support.
4 Working underneath car, remove intake manifold support
mounting nut
(arrow), located adjacent to left engine mount.

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Cylinder Head Removal and Installation
4 If applicable, remove secondary air injection pump:
Disconnect hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
Disconnect electrical harness from bottom of secondary
air injection pump.
Remove mounting bracket from strut tower.
4 Remove ignition coils:
* Disconnect ignition coil harness connectors.
Remove coil mounting fasteners.
Remove coils.
* Remove ground straps.
CA UTIOI\C
Note location of all ground wires. Failure to reinstall grounds
can result in permanent damage to engine control module or
ignition system components.
Set coil harness to side of engine compartment
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
ltets should be reinstalled in their original locations. Male
note of their arrangement during removal.
- Remove spark plugs
4 Remove oil baffle cover from above intake camshaft.

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Cylinder Head Removal and installation - - .- - - - -
4 Disconnect electrical harness connections at exhaust cam-
shaft position sensor and exhaust camshaft VANOS control
valve (arrows).
4 Remove banjo bolt from VANOS unit oil pressure line. Use
banjo bolt to attach
BMW special tool 11 3 450 (compressed
air fitting) to VANOS control unit.
CAUTIOI\C
Oil will drain from pressure line. Have a drain container and
rags ready Do not allow oil to run onto drive belts.
4 Cover oil hole (arrow) in VANOS unit with shop towel to cap-
ture oil which will spray when compressed air is applied.
- Connect compressed air line to air fitting. Apply air pressure
set to
2-8 bar (30-1 15 psi).
4 With compressed air line connected, rotate engine at vibra-
tion damper in direction of rotation (clockwise) at least twice,
until cylinder 1 intake and exhaust camshaft lobes face each
other (arrows) in the top dead center (TDC) position for cyl-
inder
1.
CAUTION--
Do not rotate engine counterclocltwise to reach the top dead
center position. If engine rotated beyond top dead center;
complete another two complete rotations.

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[Cylinderead Removal -. . and Installation -7 - . ..
4 Oil will drain from plugs (arrows) when removed. Have a
container and rags ready. Do not allow oil to run onto drive
belts.
Pull sealing caps straight out of VANOS unit using short nee-
dle nose pliers.
NOTE-
Additional oil may drain from VANOS unit.
Remove set screws (left-hand thread) on ends of intake and
exhaust camshafts.
CAUTION-
Set screws have left-hand threads. Loosen in clocltwise di-
rection.

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- -
-- .- Cylinder ~ead~ernoval and Installation I - -.
Remove VANOS unit:
Remove engine lifting eye.
- Remove VANOS mounting nuts (arrows) and pull VANOS
unit and metal gasket off.
CAUTION-
Do not crank the engine with VANOS unit removed. Pis-
tonhalve inteiference may result.
NOTE-
The VANOS unit will contain a small quantity of oil. Place
shop towel to catch oil as unit is removed or tilted.
CAUTION-
If the VANOS adjustment unit is replaced, or if operations are
completed that may change the timing of
the camshafts, the
camshaft timing must be checked. See
11 7Camshaft Timing
Chain.
4 Remove primary camshaft chain tensioner cylinder (arrow).
CAUTION-
Primary camshaft chain tensioner is under spring pressure.
Press down on secondary chain tensionerand lock into place
using
BMW special tool 11 3 291, or a thin drifl or pin.