1997 BMW 540i engine removal

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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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Cylinder Head Removal and Installation / -
< Use a spanner tool to rotate exhaust sprocket until stop on in-
take sprocket is contacted.
- Slide VANOS control unit forward to remove
Remove primary chain tensioner (arrow)
WARNING -
Remove tensioner slowly - it is under spring pressure. I
- Working at the intake side of cylinder 1 :
Detach electrical harness connector for camshaft position
sensor and remove sensor.
Detach electrical harness connector for coolant tempera-
ture sensor.
- Remove exhaust manifolds. D~scard nuts. See 180 Exhaust
System.
Disconnect heating system hoses (arrows) from back of cyl-
inder head.

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113-16
Cylinder Head Removal and Installation
- Remove secondary timing chain and sprockets:
Remove mounting nuts from front of intake camshaft
sprocket. Remove and label shim.
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
ening or tightening sprocket mounting fasteners.
Remove mounting nuts from front of exhaust camshaft
sprocket and remove and label thrust washer.
NOTE-
Where applicable, make note of thrust washerpositions. The
thicker
(0.4 mm) washer is mounted outermost.
- Remove secondary sprockets together with camshaft tim-
ing chain from front of camshafts.
CAUTION-
The camshafts must be locledin the TDCposition using the
special service tool as described earlier: The arrows on the
sprockets should not be used to accurately set the engine to
TDC. The tool holds the camshafts parallel to each other and
NOTE-
Do not remove the sprocl parts are being replaced. Wire tie each sprocket to the chain
to
Iceep the sproclefs timed to each other:
CAUTIOI\C
The crankshaft must not be allowed to rotate once the cam-
shaft timing chain is removed. The pistons can
contact the
valves.
Unscrew timing chain guide and remove.
Lift off primary sprocket with chain.
Secure chain with wire to prevent chain from dropping into
lower timing cover.
Unscrew timing case cover to cylinder head bolts (arrows).
NOTE-
Photo shows timing chain guide in place; it should first be re-
moved as described previously.
Remove crankshaft locking tool
(BMW special tool 11 2 300).
Using the crankshaft vibration damper bolt, turn engine op-
posite of normal direction of rotation (counterclocltwise as
viewed from the front) approximately 30". This prevents ac-
cidental contact between valves and pistons during installa-
tion.

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Cylinder Head Removal -- and lnstallati~i
4 Cylinder head bolt loosening sequence.
- Using BMW special tool 11 2 250 or an equivalent tool, loos-
en cylinder head bolts in sequence. Discard head bolts.
- Separate the cylinder head from the block and remove head.
Evaluate head as described in
116 Cylinder Head and Val-
vetrain.
Cylinder head, installing, M52 engine
If the camshafts were removed and installed while the cylin-
der head was off, a minimum waiting time is required after in-
stalling the camshafts. When the camshafts are removed, the
hydraulic lifters can expand. This expansion can cause in-
creased valve lift when the camshafts are bolted down, result-
ing in open valves.
Camshaft installation waiting times
68" F (20" C) and higher 4 minutes
50.68' F (1 0-20" C) 11 minutes
32-50' F (0-1 0" C) 30 minutes
- Clean cylinder head and gasket surfaces of cylinder block
and all timing chain covers.
CAUTION-
Do not use a metal scraper or wire brush to clean the alumi-
num cylinder head orpistons. If necessary, use a hard wood-
en orplastic scraper. Also available are abrasive discs to be
used in conjunction with an electric drill. Be sure to use the
correct disc for the type of metal being cleaned.
- Remove all debris and fluids from bolt holes and clean with a
thread chaser.
- Check gasket surface of cylinder head and cylinder block for
warpage using a straight edge.
NOTE-
If the cylinder head has been machined, a special 0.3 mm
thicker gasket should be installed. The thicker
gasket is avail-
able from an authorized
BMW dealer.

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I Cylinder Head Removal and Installation
4 Check that two locating dowels are correctly positioned in
block and are not damaged.
- Apply permanently elastic sealing compound Three Bond
1209 8 to joints where cylinder block joins timing case cover.
- Place new cylinder head gasket on cylinder block.
NOTE-
The word "OBEN" or 'TOP': printed on the gasket, should
face up. The cylinder head
gasket will fit correctly in only one
orientation.
- With camshafts locked in TDC oosition with BMW soecial
tools as described during cylinder head removal,
seicylinder
head in position, guiding primary chain through cylinder head
opening.
NOTE-
* The camshafts must be locl(ed in the TDC position at the
rear of the cylinder head with
BMW special tool I1 3 240
before installing the cylinder head.
Make sure the
cranksha% which had been rotated approx-
imately
30" opposite the direction of engine rotation, is still
in that position before lowering the cylinder head into posi-
tion.
- Lightly lubricate new cylinder head bolts. Loosely install bolts
and their washers, then thread them in until they are finger
tight.
NOTE-
. Torx-type cylinder head bolts should not be reused. They
are stretch-type bolts and must always be replaced when-
ever loosened.
Check that all washers for the cylinder head bolts are in
place before installing the bolts. Some of the washers may
be
stalced to the cylinder head.
CAUTIOI\C
Cylinder head bolts for a cast iron engine block are different
length and require different tightening torque than bolts for an
aluminum cylinder bloclc engines
(95 rnm versus 110 rnm
bolts).
- Install cylinder head-to-lower timing chain cover bolts finger
tight.
< Tighten cylinder head bolts in correct sequence to initial
torque value.

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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 Installation
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the hydraulic
tensioner.
- Check that elongated holes in primary sprocket are now cen-
tered to bolt holes in camshaft and chain is free of slack. If
not, reposition sprocket to chain and reinstall.
- lnstall secondary timing chain guide and secondary chain
tensioner. Tighten mounting bolts (tensioner remains locked
down for now using
BMW special tool 11 3 292).
- Install cylinder identification trigger plate to front of intake
camshaft with studs.
- Install spacer to front of intake camshaft.
- Install secondary chain sprockets and chain as an assembly
so that arrows on sprockets are pointing up. Center mounting
holes in sprockets to bolt holes in camshafts.
4 lnstall thrust washers and diaphragm spring to intake cam
sprocket.
I 2hm thrust washer I
- Install shim and torx bolts to exhaust camshaft. Tighten fin-
ger tight; do not torque down.
- Tighten intake sprocket nuts.
CA UTIOG
Hold the camshaft stationary (at hex on camshaft) when loos-
enino or tiahtenino sorocket mounting bolts and studs.
Tightening torque
Intake s~rocket nuts to studs 10 +l Nm (89 +9 in-lb)
- Turn crankshaft approx. 30" in direction of rotation to bring
engine to TDC. Lock crankshaft in TDC position with BMW
special tool
11 2 300.
CAUTION-
The camshafts andcranlshaft must be lockedin the TDCpo-
sition using BMW special tools 11 2 300 and 11 3 240. If the
camshafts and cranl(shaft are not at TDC, the valves can
contact the pistons.

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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