2000 BMW 540i sensor

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11 3-38
I Cylinder Head Removal and Installation
< Turn eccentric shaft of special tool to pretension intake cam-
shaft bearing caps. Remove nuts on all intake camshaft bear-
ing caps.
- Slowly release tension on eccentric shaft and remove BMW
spec~al tools. Remove bearing caps and set as~de in order.
Remove camshaft and store safely.
- Repeat procedure for exhaust camshaft.
4 Secure hydraulic lifters in lifter bores using BMW speclal tool
11 3 250, or remove lifters using a magnetic pick-up tool.
With lifters secure or removed, lift out camshaft bearing car-
riers from cylinder head.
Use care to not let hydraulic lifters fall out as camshaft car-
rier is removed.
Hydraulic lifters should be stored
ln an uprightpositlon.
Used hydraulic lifters must be reinstalled into their orig-
inal lifter bores.
4 Remove intake camshaft position sensor (arrow) from side
of cylinder head.
4 Remove secondary chain lowerguide bolts (arrow). Remove
chain guide.

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. - ..
Cylinder Head Removal and installation] --
- Secure cylinder head bolts by torquing an additional 90"
each for Stage 2 and 3.
Tightening torques
Cylinder head to engine block
(aluminum block)
Stage
1 40 Nm (30 it-lb)
Stage 2 +90°
Stage 3 80'
4 lnstall intake camshaft position sensor (arrow).
4 Install lower secondary chain guide. Tighten tom bolts to
specifications. The bolt on the intake camshaft side is long
and extends into the engine block.
4 Install and tighten cylinder head-to-lower timing chain cover
bolts (arrows). (Photo shows camshafts in place).
Tightening torque Secondary chain guide to cylinder head
10 Nm (89 in-lb)
Cylinder head to lower timing chain cover
M6 10 Nm (89 in-lb)
M7 15 Nm (1 1 it-lb)

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Cylinder Head Removal and Installation /
< Clean contact edges of cylinder head face and VANOS unit
and apply a thin coat of permanently elastic Three Bond
1209 8 or equivalent to suriaces.
CAUTION-
Check locating dowel (A) and dowel sleeve (B) at top of
cylinder head for damage or incorrect installation.
Make sure all gasket material is removed from face of
cylinder head. Clean sealing face and keep free of oil.
If any foreign material is present on the sealing surface,
the camshaft timing will be incorrect.
- Install new steel gasket to front of cylinder head and install
VANOS unit.
NOTE -
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in
11 7 Camshaft Tim-
ing Chain.
- Reinstall engine lifting eye.
Tightening torque
VANOS unit to cylinder head
M6 nut
M7 nut
lo Nm (89 in-lb)
14 Nrn (10 it-lb)
- Reconnect electrical harness connectors to camshaft posi-
tion sensors and VANOS solenoid valves.
4 Insert and tighten down VANOS hydraulic piston set screws
in splined shafts on
intake and exhaust camshafts.
CAUJION-
Set screws have left hand tliread. Tighten counterclockwise.
Tightening torque
Hydraulic piston
to splined shaft 10 Nm (89 in-lb)
< Replace sealing caps inside VANOS unit with short needle
nose pliers.

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Cylinder Head Removal and Installation
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Tightening torque Exhaust
maniiold to cylinder head (M7)
20 Nm (15 ft-lb)
- Install electrical harness connectors for oil pressure sender
and coolant temperature sensor before installing
intalte man-
ifold.
7 Install intake manifold:
1. Manifold mounting nuts: tighten to 15 Nm (1 1 ft-lb)
2. Fuel pipe bracltet
3. Fuel pipe bracltet
4. Vacuum pump bracltet
5. Manifold mounting bracltet
6.
Tank venting valve bracltet
7. Mounting bracket to manifold bolt (M6)
8. Mounting bracket to cylinder block nut (MIO), tighten to
47 Nm (33 fi-lb)
Intake manifold installation is reverse of removal, noting the
following:
* Use new fuel injector seals.
Carefully
check intake manifold gasket and replace if nec-
essary.
Inspect O-ring seal between mass air flow sensor and air
filter housing. To facilitate reassembly, coat seal with
acid-
free grease.
Use new fuel injector seals.
Carefully check intake manifold gasket and replace if
necessary.
CA UTIOPI-
When reattaching throttle assembly harness connector, con-
nector is fully tightened when arrows on connector
andplug
line up.
Tightening torque
lntalte manifold to cylinder
head (M7)
15 Nm (1 1 it-lb) ~ ~- Mounting bracket to cylinder bloclt (M10) 47 Nm (33 ft-lb)
Mounting bracket to intake manifold (MI?) 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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- .-
.. Cylinder Head Removal and Installation I -
< Disconnect the following electrical harness connectors:
Knock sensors
(A).
Thermostat (6).
Throttle position sensor and idle valve (C).
Camshaft position sensor (D).
Ignition coils (E).
< Remove mounting nuts (arrows) from wiring harness ducts.
4 Release fuel injector connectors by releasing spring clip
(arrow) on each injector.
Lift up and remove electrical ducts and set to one side

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1 13-75
Cylinder Head Removal and Installation I
4 Loosen and remove primary timing chain tensioner (arrow)
from right cylinder head.
Remove camshaft position sensor (arrow)
chain cover on right cylinder head.
Remove dip
stick tube support fastener. from
upper
Remove upper timing chain cover fasteners
(A) and
cover from right cylinder head. timing
remove

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-8" ."
Cylinder Head Removal and Installation --
Using crankshaft center bolt, rotate engine clockwise from
the
45" before TDC up to TDC position (OIT aligns with cast-
ing mark on cylinder block).
< Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Special tool boss located at the rear of upper engine oil pan.
- Working at right cylinder head (cylinder 5-8) fit primary
sprocltet and chain to camshaft flange.
!
I
4 Press timing chain tensioner rail against timing chain (white
arrow) to check that fastener holes are centered in sprocket
slots (black arrows).
NOTE-
If necessary, remove sprocl Fit sensor gear with mark pointing up (arrow).
Insert bolts and hand tighten.