2000 BMW 540i Gasket

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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.

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-
. - - -- 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.

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I Cylinder Head and Valvetrain
- Remove adjustable primary timing chain tensioner tool and
reinstall primary chain tensioner cylinder to cylinder head.
Tightening torque
Primary chain tensioner cylinder
to 70 Nm (52 ft-lb)
cylinder head
- Remove flywheel locking tool from crankcase. Replace spe-
cial tool bore sealing plug.
- Remove camshaft locking tools from cylinder head
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
8 1209 or equivalent
sealing compound at corners
(B) of half-moon cutouts.
Seat gasket and seal corners at VANOS unit with Three
Bond
@ 1209.
Tightening torque Cylinder head cover to cylinder head
(M6) 10 Nm (89 in-lb)
- Installation of the remaininq parts is reverse or removal, not- -
ing the following:
Change engine
011 and f~lter as descr~bed in 020 Mainte-
nance.
Reconnect battery.
To prevent damaging the engine electronic systems, install
all ground wire previously removed, including the ground
wires for the ignition coils.
Tightening torque
-
Radiator cooling fan to coolant pump 40 Nm
(30 ft-ib)
Spark plug to cylinder head
25 Nm (18 ft-ib)

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11 6-54
Cylinder Head and Valvetrain
Replace primary timing chain tensioner O-ring (arrow) in
right cylinder head.
- lnstall right upper timing cover to engine:
Remove old gasket from right timing cover.
Clean gasket groove and install new gasket.
Apply Three Bond
12098sealant to joint between cylinder
head and timing cover. Install remaining timing cover bolts
finger tight.
lnstall left upper timing chain cover to engine:
Remove old gasket from right timing chain cover.
Clean gasket groove and install new gasket.
Insert lower cover timing chain cover retaining bolt (arrow)
to cover, then fit cover to cylinder head.
Apply Three Bond 12098 sealant to joint between cylinder
head and timing chain cover. lnstall upper timing cover
bolts finger tight.
4 Remove cylinder head cover sealing gaskets from right cyl-
inder head cover. lnstall BMW special tool 11
1 41 1 into gas-
ket groove of cylinder head cover.
lnstall right cylinder head cover with BMW special tool
11
1 41 1 to right cylinder head. Fit cylinder head cover retain-
ing nuts to cylinder head cover studs at cylinders
1 and 2
(first two cylinders on right cylinder head).
Tighten nuts uniformly in
'I2 turn steps.
NOTE-
BMW special tool 11 1 41 1 presses upper timing chain cover
to level of cylinder head.
Tightening torque Cylinder head cover nuts
10 Nm (7.5 n-lb)
- Tighten right upper timing cover retaining bolts in two passes.
Tightening torque
Timing chain cover to head
10 Nm (7.5 ft-lb)

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11 6-55
Cvlinder Head and valvetrain1
4 Remove cylinder head cover sealing gasltets from left cylin-
der head cover. Install BMW special tool 11 1 412 into gasket
groove of cylinder head cover.
Install left cylinder head cover. Fit cylinder head cover re-
taining nuts to cylinder head cover studs at cylinders
5 and
6 (first two cylinders on left side cylinder bank).
* Tighten nuts uniformly in 'I? turn steps.
NOTE-
BMW special tool 11 1 4 12presses upper timing chain cover
to level of cylinder head.
Tightening torque Cylinder head cover
nuts 10 Nm (7.5 it-lb)
- Tighten left upper timing chain cover retaining bolts in two
passes.
Tightening torque
Timing chain cover to head
10 Nm (7.5 ft-lb)
- Remove cylinder head covers and remove BMW special
tools 11 4 41 11412 from cylinder head covers.
- Fit new gasket to cylinder head cover without strain.
- Apply Three Bond@ 1209 sealant to joints between cylinder
head and timing cover.
4 Malte sure half-moon cutouts (A) at rear of cylinder heads fit
correctly to cylinder head sealing surface. Apply Three
Bond@ 1209 sealant at corners of half-moon cutouts (B).
- Remainder of installation is reverse of removal.

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Camshaft Timing chain1
VANOS control unit, installing (M52 engine)
CAUTION-
Incorrect installation of the VANOS control unit may result in
damage to the engine.
- Make sure camshafts and crankshaft are loclted in TDC po-
sition with BMW special tools as described during VANOS
removal.
< Rotate exhaust camshaft sprocket clocltwise (as viewed from
front of engine) using BMW special tool
11 5 490, until detent
position stop is reached.
4 Apply a small amount of liquid gasket sealer (Three Bond
1209
8 or equivalent) to VANOS housing alignment dowels
on front of cylinder head. Install a new
gasket.
< Push VANOS piston gear cup (arrow) into VANOS housing
until it bottoms out. Position VANOS control unit in front of
camshafts, but do not engage splines on gear cup.

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Camshaft Timing chain1
Using a drift, drive two locating dowels (arrows) in lower
timing cover toward rear of car.
4 Remove timing cover mounting bolts (arrows).
* Carefully slide cover with water pump forward to remove
CAUTION-
Use care when removing the cover from the cylinder head
gasket If the cover is stuck, use a sharp knife to separate
it from the head gasket.
If cylinder head gasket is damaged, remove cylinder
head and replace head
gaslet. See 113 Cylinder
head and valvetrain.
- Remove timing cover locating dowels by driving them
forward.
- Lift primary chain sprocket off crankshaft sprocket and
remove chain.

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Camshaft Timing chain1
Tap locating dowels into cover until they protrude 2 to 3 mm
from sealing surface.
- Using new gaskets, install lower timing chain cover:
Tap cover into position to engage dowels.
Install timing chain cover fasteners and tighten to
5 Nm (44
in-lb).
Drive dowels in flush to front of cover.
. Tighten cover mounting bolts alternately and in stages.
Install cylinder head to timing chain cover fasteners and
tighten.
Tightening torques Lower timing chain cover to block
M7 15 Nm (1 1 ft-lb)
ME 20 Nm (15 it-lb)
- Replace front crankshaft radial seal. See Crankshaft oil
seal, front, replacing
(M52 engine).
Install engine oil pan using
a new gasket. See 119 Lubrica-
tion System.
Mount primary timing chain sprocket to primary
cha~n so that
arrow on sprocket faces up. Mount sprocket to camshafl so
that tapped holes in camshaft are on left side of elongated
holes in sprocket.
4 Install adjustable timing chain tensioner (BMW special tool
11 4 220). Thread tool in finger tight until slack is removed
from chain.
NOTE-
BMW special tool 11 4 220 is an adjustable timing chain ten-
sioner that simulates the function of the hydraulic tensioner.
- Check that elongated holes in primary sprocket are centered
to bolt holes in camshafl and chain is free of slack.
- Install secondary timing chain guide and secondary chain
tensioner. Tighten mounting bolts (tensioner remains
locited
down).
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