1999 BMW 540i check engine

Downloaded from www.Manualslib.com manuals search engine
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)

Downloaded from www.Manualslib.com manuals search engine
11 6 Cylinder Head and Valvetrain
........................... General ............................ 1 16-2 Valves 116-56
.................... Special Tools ........................ 11 6-2 Valves. leak test 11 6-56
......... Valves. removing and installing 11 6-56 Cylinder Head ..................... .I1 6.5 ....................... Valve guides 11 6-57
Valves. leak test ...................... 11 6-6
Valve stem oil seals .................. 11 6-58 ...... ..""""."""ll 6.6 Valveseats ........................ 116-59 Hydraulic lifters, checking and replacing .. .I1 6-7 Valve ....................... 6-60 . .
Camshaft andLifter Removal
and Installation
.................... 11 6-1 1
Camshaft and lifter removal and
installation
(M52 engine) ............. .I1 6.12
Camshaft and lifter. removal and
installation (M52
TU and M54 engine) .... 11 6-1 9
Double VANOS timing chain components
. 11 6-28
Camshaft removal and installation
(M62 engine)
....................... 11 6-39

Downloaded from www.Manualslib.com manuals search engine
11 6-5
I Cylinder Head and valvetrain1
4 Timing chain tensioner bracket (V-8)
(Tool No. BMW
11 7 380)
CYLINDER HEAD
This section provides the specifications and special recondi-
tioning information necessary to repair the cylinder heads
covered by this manual.
The disassembled cylinder head should be inspected for
warpage and cracks. Check the valve guides and valve seats
for wear before machining a warped head. Always decarbon-
ize and clean the head before inspecting it.
Visually inspect the cylinder head for craclts.
If a cracked cyl-
inder head is suspected and no
craclts are detected through
the visual Inspection, have the head further tested for cracks
by an authorized BMW dealer or an ASE certified machinist.
A cracked cylinder head must be replaced.
NOJE-
When disassembling and inspecting the cylinder head, be
sure to
checlc the camshaft carrier bearing surfaces using a
straight edge for
warpage, and check the lifter bores for wear.
A high-quality straight edge can be used to
checlc for
warpage. A warpage of 0.05 mm (0.002 in.) is acceptable
without machining. A warped cylinder head can be machined
provided no more than 0.3
mm (0.012 in.) of material is re-
moved.
If further machining is required, the head should be
replaced. Removing more than this amount will reduce the
size of the combustion chamber and adversely affect engine
performance. A 0.3 mm
thicker head gasket for machined
heads is available from an authorized BMW parts depart-
ment.

Downloaded from www.Manualslib.com manuals search engine
11 6-6
Cylinder Head and Valvetrain
4 Before machining the head to correct for warpage, measure
the total height
(A) (thickness of the cylinder head). Minimum
height specifications are given in Table a. Cylinder head
height.
NOTE-
6 cylinder and V-8 engines share cylinder head height spec-
ifications.
Table a. Cylinder head height
New Minimum height
(A)
140.0 rnrn (5.512 in.) 139.7 rnrn (5.500 in.)
Valves, leak test
To test the valves for leakage, the cylinder head must be dis-
assembled with camshafts and camshaft carriers removed.
With valve assemblies and spark plugs installed, place the
cylinder head on a workbench with the combustion chamber
facing upward. Fill each combustion chamber with a thin non-
flammable liquid. After fifteen minutes, check the level of the
fluid. If the fluid level in any cylinder drops, that cylinder is not
sealing properly.
Camshaft wear
Camshaft wear is usually caused by insufficient lubrication.
Visually inspect camshaft lobes and journals for wear. Cam-
. ~~ shaft wear specifications are given in Table b. Camshaft
wear specifications.
CA UTIOI\C
If the camshaft is being replaced due to cam lobe wear, it is
recommended that the corresponding lifters should also be
replaced to avoid damaging the new camshaft
Table b. Camshaft wear specifications
6 cylinder engines V-8 engines
Axlal play 0.150-0.330 rnrn 0 200-0 360 rnrn - .-
(0.0060-0 013 in.) (0.008 - 0.014 in ) - - Radlal play 0.020-0.054 rnrn 0.040-0.074 rnrn
(0.0008-0.0021 in.) (0.016 - 0.029 in.)

Downloaded from www.Manualslib.com manuals search engine
Cylinder Head and valvetrain1
Hydraulic lifters, checking and replacing
Self-adjusting hydraulic lifters (A) keep the valve clearances
within a limited working range. Hydraulic lifters are sealed
units and require no maintenance. Section view of camshaft
(6) and valve with conical valve spring (C) shown.
Under some circumstances, such as a cold start, the cam fol-
lowers may emit noise. Hydraulic lifter noise is usually a
high-
pitched tapping or chattering noise. In most instances, this is
considered normal as long as the noise goes away in a few
minutes (maximum
20 minutes). If the noise does not go
away, either the lifter is faulty or the oil pressure to the lifter is
low. Hydraulic lifter replacement requires that the camshaft
first be removed.
NOTE-
Before checking hydraulic lifters, male sure engine oil is
fresh and at the proper level.
Sticky lifters can be the result of
sludge build up in the cylinder head and lifters.
- Run engine until it reaches normal operating temperature.
Shut off engine.
- Working inside luggage compartment, disconnect negative
battery cable.
CAUTION-
Prior to disconnecting battery cable, read the baltery dls-
connection cautions given In 001 General Cautions and
Warnings.
Disconnecting the battery may erase fault
code(s)
stored in control module memory Check for fault codes
4 Remove left and right interior ventilation duct (left side
shown):
Release plastic locking tab
(A) or release loclting tabs on
top of duct (later models).
Rotate duct counterclockwise to
unloclt from bulithead and
remove (arrow).

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
11 6-31
Cylinder Head and Valvetrain
< Install primary timing chain on timing chain sprocket and
place on exhaust camshaft so that pointer on sprocket
(arrow) lines up with cylinder head sealing surface.
4 Insert BMW special tool 11 4 220 into timing chain tensioner
bore and bring center spindle into contact with tensioning rail.
Tighten until slack is removed, but do not pretension timing
chain.
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the tensioner.
- Recheck arrow on primary sprocket is aligned with upper
edge of cylinder head. Reposition sprocket if necessary.
4 Insert and tighten threaded locat~ng studs (arrows) in ex-
haust camshaft.
Tightening
torques
Exhaust camshaft locating stud 20 Nm (15 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
-
. - - -- 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.