2000 BMW 528i installing AC

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113-8
[cylinder Head Removal and Installation 1
Cylinder leak-down test
The most conclusive diagnosis of low compression symp-
toms requires a cylinder leak-down test. Using a special
tester and compressed air, each cylinder, in turn, is pressur-
ized. The rate at which the air leaks out of the cylinder, as well
as where the air leaks out, can accurately pinpoint the magni-
tude and location of the leakage.
Before attempting any repair that requires major engine dis-
assembly, use a leak-down test to confirm low compression.
~YL~NDER HEAD REMOVAL AND
~NSTALLATION (M52 ENGINE)
WARNING-
Due to rislc of personal fnjur~: be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation is a time consuming
repair procedure requiring multiple special
service tools.
Read the entire procedure before beginning the repair.
This procedure includes the following steps:
Cylinder head, removing,
M52 engine
Cylinder head, installing,
M52 engine
Cylinder head, removing, M52 engine
- Disconnect negative (-) cable from battery in luggage com-
partment.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions in 001 General Cautions and Warnings.
-

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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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- -.
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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1 13-22
Cylinder Head Removal and Installation
CYLINDER HEAD REMOVAL AND
~NSTALLATION (M52 TU AND N154
ENGINES)
WARNING -
Due to risk ofpersonal injur)c be sure the engine is cold be-
fore
beqinning the removal procedure.
Cylinder head removal and installation is a time consuming
repair procedure requiring multiple special service tools.
Read the entire procedure before beginning the repair.
This topic includes the following procedures:
* Cylinder head, removing, M52 TU and M54 engines
Cylinder head, installing,
M52 TU and M54 engines
Cylinder head, removing,
M52 TU and M54 engines
Allow engine to cool before beginning this procedure.
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions in
001 General Cautions and Warnings.
4 Remove left and right interior ventilation ducts (left side
shown):
Release ventilation filter cover latch
(A) and remove cover.
Release plastic locking tab
(6) or release locking tabs on
top of duct (later models).
= Turn duct counterclocltwise to unlock from bullthead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring lock fastener
(D).
- Slide filter housing away from inner fender to remove.
Removal of right side ventilation
dud
Remove rear bulkhead panel:
Lift off rubber sealing
gasket (arrow)
- Remove 3 mounting clips (A).
Remove 4 retaining screws (6).
Lift off panel.
: is similar

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. - -- -
Cylinder Head Removal and Installation --
Remove bolts (arrows) holding timing chain cover to cylinder
head. (Photo shows camshafts and camshaft bearing caps in
place).
4 Using BMW special tool 11 2 250 or equivalent, loosen cylin-
der head bolts in several stages, in sequence shown. Discard
head bolts.
NOJE-
BMW special tool 11 2 250 is a thin-walled Torx El2 socket
with an extended reach. The cylinder head bolts are re-
cessed into the head below the
camshaft towers with little
working space.
- Lift off cylinder head. Refer to 116 Cylinder Head and Val-
vetrain for cylinder head reconditioning information.
Cylinder head, installing, M52 TU and M54
engines
Clean cylinder head and gasket surfaces of cylinder bloclc
and all timing chain covers.
CAUTION- Remove foreign matter and liquid from bolt holes. Trapped oil
or coolant in bolt holes can cause damage to
blocl~,
CAUJION-
Do not use a metal scraper or wire brush to clean the alumi-
num cylinder head or pistons. 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.
Evaluate cylinder head as shown in
116 Cylinder Head and
Valvetrain.
NOTE- If the cylinder head has been machined, a special 0.3
mm
(0.01 1 in.) thicker gasket should be installed. The thicker
gasket is available from an authorized
BMW dealer and
should be marked accordingly
Cylinder head and valve specifications are covered in 116
Cylinder Head and Valvetrain.

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11 3-40
I Cylinder Head Removal and Installation
Lubricate camshafts, camshaft carriers, bearing caps, hy-
draulic lifters, friction washers, splined shafts and spline hubs
with assembly lubricant before installation.
4 Check that two cylinder head aligning sleeves (arrows) are
correctly positioned in block and are not damaged.
- Apply elastic sealing compound Three Bond 1209 8 to cor-
ner joints on cylinder block to timing chain cover.
- Place new cylinder head gasket on cylinder block.
NOTE-
The word "OBEN" or "TOP printed on the gasket, should
face up. The cylinder headgaslet will fit correctly in only one
orientation.
- Set cylinder head in position, guiding primary chain through
cylinder head opening.
CAUJION-
Make sure the crankshaft, which had been rotated approxi-
mately 30" opposite the direction of engine rotation from
TDC, is still in thatposition before lowering the cylinder head
into position. All pistons must be out of TDC position to pre-
vent
valve/piston interference when the camshafts are in-
stalled.
- Lightly lubricate new cylinder head bolts and washers with
oil. Install bolts and washers finger tight. Install cylinder head
to lower timing chain cover bolts finger tight.
NOJE-
Cylinder head bolts should not be reused. They are
stretch-type bolts and must be replaced whenever loos-
ened.
* Aluminum cylinder blocls use different length cylinder
head bolts and torque values than cast iron blocks.
Check that all washers for
Nle head bolts are in place be-
fore installing the bolts. Some of the washers may be
staked to the cylinder head.
I 12 10 4 2 6 8 141 Tighten cylinder head bolts in correct sequence (1-14)
CA U TIOW-
The bolts should be tightened in three stages as listed below
The final stages require the use of a BMW special tool
11 2
110 or a suitable protractor to tighten the bolts to a specified
torque angle.

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1 13-42
I Cylinder Head Removal and Installation
4 Before installing camshaft carriers, examine bearing points
(arrows) on hydraulic lifter bores for signs of wear.
4 Center camshaft carrier with hydraulic lifters on pins (ar-
rows) at bearing positions 2 and 7.
Note marks on carriers: (E) for intake side and (A) for exhaust
side.
Lift timing chain and put exhaust cam onto exhaust camshaft
carrier. Place intake camshaft on camshaft carrier.