2000 BMW 540i intake

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11 6-26
I Cylinder Head and Valvetrain
4 Before installing camshaft carriers, examine bearing bores
(arrows) on hydraulic lifter bores for signs of wear.
Install camshaft carriers with hydraulic lifters into cylinder
head. Note marks on carriers:
(E) for intake side and (A) for
exhaust side.
4 Center camshaft carrier on pins (arrows) at bearing
aositions 2 and 7.

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-- - . .- -,
Cylinder Head and Valvetrain
4 Rotate camshafts so that intalte and exhaust lobes for cylin-
der
1 face each other (arrows).
CAUJION-
A minimum waiting time is required for the hydraulic lifters to
'bleed down"after installing the camshafts into the cylinder
head, before bringing the piston to TDC. When the camshafts
are removed, the hydraulic lifters can expand. This expan-
sion can cause increased valve lift when the camshafts are
bolted down, possibly resulting in piston interference.
Place bearing caps on cams, but do not install retaining nuts.
4 Fit BMW special tool 11 3 260 (A) and 11 3 270 (B) to cylinder
head over
intalte camshaft and screw long bolts (arrows)
into spark plug threads.
CA UTION-
Do not overtighten bolts into spark plug holes.
< Turn eccentric shaft of special tool to pretension bearing
caps. Install and torque nuts on intake camshaft bearing
caps.
Tightening torque Camshaft bearing cap
to cylinder head (M7) 14 Nm (10 it-ib)
- Release tension on eccentric shaft and remove BMW special
tools
11 3 2601270.
- Repeat procedure for exhaust camshaft.
NOTE-
Observe waiting time for lifter bleed down before continuing
with camshaff installation.
Crankshaft
I valve timing waiting times
68°F (20°C) and higher 5 minutes
50-6S°F(10-20°C) 15 minutes
32-50DF(O-10°C) 30 minutes

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11 6-28
Cylinder Head and Valvetrain
Double
VANOS timing
chain components
1. Impulse wheel mounting nut
2. Exhaust camshaft impulse
wheel
3. Spring plate, exhaust
4. Thrust spacer (T
= 3.5 mm)
5. Splined shaft
6. Torx screw
7. Exhaust camshaft secondary
sprocket
8. Secondary timing chain
9. Splined sleeve
10. Primary sprocket
11. Threaded stud
12. Secondary chain tensioner
13. Secondary chain lower guide
14. Sprocket mounting nut
15. Spring plate, intake
16. Splined shaft
17. Intake camshaft sprocket
18. Locating stud
19. Thrust spacer
20. lntake camshaft impulse wheel

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~ ~. --
Cylinder Head and Valvetrain .-
4 While maintaining tension on timing chain, rotate crankshaft
at vibration dampener from
30" before TDC in direction of ro-
tation (clockwise) until number
1 cylinder is at TDC position
with line between the OIT mark (arrow) on front pulley
aligned with boss on lower timing chain cover.
4 Secure crankshaft in TDC position with BMW special tool
11 2 300 (arrow).
Slide impulse wheel on intake camshaft, aligning boss with
raised portion on camshaft (arrow).
Fit thrust spacer
(A) to intalte camshaft and tighten down with
threaded locating studs (arrows). Place longer threaded por-
tion of studs into camshaft.
Tightening torque
Impulse wheel studs to intake camshaft (M7)
20 Nm (15 ft-lb)

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Cylinder Head and valvetrain1
< Place intake and exhaust sprockets in BMW special tool
11 6 180. Position spline gap on intake sprocket (arrow) as
shown and place secondary chain on
sprocitets.
< Remove chain and sprockets from tool and slide sprockets
on camshafts. Confirm that gap in intalte sprocket splines
lines up with corresponding gap in camshaft splines (arrow).
CAUTIOI\C
Do not alter position of sprockets with respect to chain when
removinq from saecial tool 11 6 180.
4 While aligning locating tooth of shaft with spline gaps on
camshaft and sprocket, slide spiined
shaft onto intalte carn-
shaft until approx. 1 mm (0.04 in.) of splines (arrows) are
visible.
4 lnstall intake camshaft spring plate so that FRONT mark is
visible. install mounting nuts (arrows) finger tight.

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1 16-36
I Cylinder Head and Valvetrain
4 Preload exhaust camshaft spring plate by pressing on im-
pulse wheel while tightening mounting nuts (arrows)
fingel
tight.
4 Install BMW special tool 11 6 150 (VANOS setup bracket) to
front of cylinder head timing case. Install nuts (arrows) finger
tight, then tighten down uniformly until special tool is in full
contact with cylinder head.
CAUTION--
Male sure aNgas1ef material Is removed from face of cyiin-
der head. Clean sealing face and keep free of oil.
4 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 (B) 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 carnshaft
M7 tom screws (A) 20 Nm (15 ft-lb)
M6 mounting sciew (6) I0 Nm (8 ft-lb) - - -
- - Remove crankshaft locking tool from crankcase.
- Remove camshaft locking tools from cylinder head.

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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)