1998 BMW 540i locking

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Cylinder Head Removal and Installation
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
(8) 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 camshaft
M7 torx screws (A) 20 Nm (15 ft-lb)
M6 mounting nuts (5) 10 Nm (8 ft-lb)
- Remove crankshaft locking tool from transmission bell hous-
ing so that crankshaft is no longer secured in
TDC position.
- Remove camshaft locking tools from cylinder head.
4 Turn engine over twice in direction of rotation until cylinder 1
intake and exhaust camshaft lobes (arrows) face each other.
- Secure 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.
CAUTION-
- If the exhaust side of the tool (A) is not flush with tlie head,
camshaft timing is incorrect Reset camshaft timing as de-
scribed in
117 Camshaft Timing Chain.
* Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft tim-
ing is set correctly, the intake side of special tool
11 3
240 (6) may be up to 1 mm (0.04 in.) above the surface
of the cylinder head. This is normal. Reassemble en-
gine.
Othe~lise, reset camshaft timing as described in
11 7 Camshaft Timing Chain.
- Remove BMW special tool 11 6 150 from front of cylinder
head.

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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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Cylinder Head Removal and Installation /
4 Remove top engine cover by releasing quick release fasten-
ers (arrows) by pressing down.
NOTE-
Earlier models may have an engine cover with pry off caps
and fasteners
In place of quick release fasteners.
4 Remove left and right interior ventilation ducts (left side
shown):
- Release locking tabs (A) or locking strap (early models, not
shown).
Release spring lock (B).
* Rotate duct inward (arrow) to remove.
Disconnect electrical harness from hood light switch (C).
Release locking clip and remove ventilation housing cover
(D).
Lift out housing from inner fender.
- Removal of right side ventilation housing is similar.
4 Air filter housing assembly, removing:
Disconnect electrical harness connectors from mass air
flow sensor (A) and temperature sensor (B).
Loosen hose clamp (C).
Remove filter housing mounting fastener (arrow) and re-
move filter housing with mass air flow sensor.

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1 13-60
Cylinder Head Removal and Installation
Label and disconnect fuel lines from fuel rail by pressing lock-
ing sleeves
(arrows) in to release lines.
NOTE-
BMW uses three styles of fuel line connections; a single use
clamp; a locking fitting that uses special tool
16 1 050 to re-
lease; and a quick release sleeve
(arrow) that disconnects
the line when depressed.
CAUTION-
Fuel may be expelled under pressure. Do not smoke or
work near heaters or other fire hazards. Keep a fire
exfin-
guisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb
leaking fuel. Plug all
I ooen fuel lines. I
Always unscrew fuel tank cap to release pressure in
tank before
removinq fuel lines.
Cap fuel lines and fuel rail inlets.
Disconnect vacuum lines
(A, B and C) from rear of intake
manifold.
Working at rear of intake manifold, disconnect crankcase
ventilation valve from pipe by prying up on lock
(A) and slid-
ing tube forward
(B).

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11 3-68
Cylinder Head Removal and Installation
< Using BMW special tool 11 3 430, or a 27 mm open-ended
wrench, rotate camshafts to cylinder 1
TDC position (until
markings point upwards).
I I < Install camshaft locltina tool set (BMW soecial tool set 11 2
440) on right cylinder head (cylinders 1-4). Fit on cylinde~
head without gaps.
Install
camshaft locking tool set (BMW special tool set 11 2
440) on left cylinder head (cylinder head 5-8). Fit on cylinder
head without gaps.
4 Using crankshaft center bolt, rotate engine clockwise from
the
45" mark to TDC position (OIT aligns with casting mark
on cylinder block).

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11 3-69
Cylinder Head Removal and Installation
4 Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Boss for special tool 11 3 200 located at rear of engine oil
pan.
4 Working at left cylinder head (driver's side) fit primary sprock-
et and chain to camshaft flange, centering threaded bores.
Insert bolts (arrows) and hand tighten.
?-I I 4 Install BMW special tool 11 3 390 into right timing case cover.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
I - Tighten sprocket retaining bolts in the following order:
All bolts on left cylinder head exhaust camshaft
3 accessible bolts on right cylinder head exhaust camshaft
All bolts on left cylinder head
intake camshaft
3 accessible bolts on right cylinder head intake camshaft r"".."..7n
Tightening torques
Sprocltet bolts to camshait 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 right cylinder head cam-
shafts. Tighten remaining bolts.
Tightening torques Sprocket bolts to camshaft flange 15 Nm
(11 ft-lb)

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11 3-78
Cylinder Head Removal and Installation
4 Using a torque angle gauge, tighten cylinder head bolts to
specified torque angle in stages
2 and 3.
Tiahtenina toraues - -.
Stage I 30 Nm (22 ft-lb)
Stage I1
Stage Ill
4 Using BMW special tool 11 3 430, or a 27 mm open-ended
wrench, rotate camshafts until marker bores (drilled holes)
point upwards
(arrows).
Do not damage cylinder head with wrench. If necessary.
grind outer side of wrench jaws to prevent damaging cylinder
head.
4 Install camshaft locking tool set (BMW special tool set 11 2
440) on right cylinder head. Fit tools on cyllnder heads with-
out gaps.
4 Install camshaft locking tool set (BMW special tool set 11 2
440) on left cylinder head. Fit tools on cylinder head without

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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).