AC line BMW 540i 2001 E39 Repair Manual

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[Cylinder Head Removal and Installation - .. - -1 -
4 Insert and secure VANOS sealing plugs (arrows) with new
sealing O-rings.
Tightening torque Sealing
plug to VANOS 50
Nm (37 ft-lb)
4 Install coolant pipe fasteners at base of cylinder head and
tighten fasteners (arrows).
NOTE-
Use new sealing O-ring on coolant pipe.
- lnstall VANOS oil line banjo bolt with new seals. Attach oil
line to VANOS unit.
Tightening torque Oil line to VANOS unit
(banjo bolt) 32
Nm (24 ft-ib)
- Remove adjustable timing chain tensioner tool and reinstall
chain tensioner.
Tightening torque Primary chain tensioner cylinder to
cylinder head 70
Nm
(52 fi-ib)
- Remove flywheel locking tool from transmission bell housing.
Replace special tool bore sealing plug.
- Remove camshaft locking tools from cylinder head
4 lnstall intake camshaft cover and cylinder head cover.
0 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
sealant at corners
(B) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
Tightening torque
Cylinder head cover to cylinder head
(M6) 10 Nm (89 in-lb)

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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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1 13-60
Cylinder Head Removal and Installation
Label and disconnect fuel lines from fuel rail by pressing lock-
ing sleeves
(arrows) in to release lines.
NOTE-
BMW uses three styles of fuel line connections; a single use
clamp; a locking fitting that uses special tool
16 1 050 to re-
lease; and a quick release sleeve
(arrow) that disconnects
the line when depressed.
CAUTION-
Fuel may be expelled under pressure. Do not smoke or
work near heaters or other fire hazards. Keep a fire
exfin-
guisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb
leaking fuel. Plug all
I ooen fuel lines. I
Always unscrew fuel tank cap to release pressure in
tank before
removinq fuel lines.
Cap fuel lines and fuel rail inlets.
Disconnect vacuum lines
(A, B and C) from rear of intake
manifold.
Working at rear of intake manifold, disconnect crankcase
ventilation valve from pipe by prying up on lock
(A) and slid-
ing tube forward
(B).

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11 3-70
Cylinder Head Removal and Installation
- Remove adjustable timing chain tensioner tool from timing
case cover and install primary timing chain tensioner with
new sealing washer.
Tightening torque Chain tensioner cylinder to timing cover
65 Nm (48 ft-lb)
4 Install oil supply lines and mounting nuts (arrows) to both
heads.
Tightening torque
Oil supply line nuts 10 Nm (7.5 ft-lb)
- Remove old gasket from lefl timing cover, and clean gasket
surface.
4 Apply Three Bond 1209 8 sealant to joint between cylinder
head and timing cover (arrows).
Using a new gasket, install lefl timing cover with lower inner
fastener inserted in cover (arrow). Position cover in place
and tighten cover fasteners finger tight.
NOTE-
It is not possible to install lower inner fastener after cover is
in place.

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Cylinder Head Removal and Installation 1
Replace sealing O-ring (arrow) in right cylinder head before
installing upper timing chain cover.
4 Install oil supply lines and mounting nuts on both heads (ar-
rows).
- Using a new gasket, install upper timing chain cover on right
head and tighten cover fasteners finger tight.
4 Remove right cylinder head cover gasket and install spacing
tool
(BMW 11 1 41 1) in place of gasket.
- Install right cylinder head cover fasteners and tighten uni-
formly in
'1, turn steps.
Tightening torque Cylinder head cover fasteners
10 Nm (7.5 ft-lb)
- Tighten right upper timing cover retaining fasteners in two
passes.
I Tightening torque
Upper timing chain cover
10 Nm (7.5 ft-lb)
- Reinstall primary timing chain tensioner with new sealing
washer.
Tightening torque
Chain tensioner to timing cover
65 Nm (48 ft-lb)
- Remove right cylinder head cover and remove special spac-
ingtooi 11 4411.

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Cylinder Head and Valvetrain
4 Secure hydraulic lifters in lifter bores using BMW special tool
11 3 250, or remove lifters using a magnetic pick-up tool.
4 Remove camshaft bearing carrier from cylinder head.
CA UTION-
Camshaftbearing carriers must be reinstalledin their original
/ locations (E for ir;fal<e and A for exhaust).
NOTE-
Do not let hydraulic lifters fall out as the camshaft carrier is
removed.
Hydraulic lifters should be stored in an upright position.
Used hydraulic lifters
must be replaced into original lifter
bores.
Camshafts and lifters, installing
(M52 Engine)
Lubricate camshafts, camshaft carriers, bearing caps, hy-
draulic liflers, friction washers, splined shafts and spline hubs
with assembly lubricant before installation.
Make sure
the cranltshaft, which had been rotated approxi-
mately
30" opposite the direction of engine rotation from
TDC, is still in thatposition before lowering the
camshaffs into
position. All pistons must be out of TDC position to prevent
valve/piston interference when the camshalts are installed.
Before installing camshaft carriers, examine bearing bores
(arrows) on hydraulic lifter bores for signs of wear.

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I_
-.
Cylinder Head and Valvetrain
Remove torx
(arrows). screws
from
exhausl
: camshaft : sprocket
Lift off exhaust and intalte sprockets together with secondary
chain, thrust spacer
(A) from exhaust camshaft, and splined
shaft (B) from intake camshaft.
CAUTIOf+
Splined shafts share the same part number for both intake
and exhaust camshafts. Used splined shafts must be rein-
stalled in their
oriqinal locations.
Place intalte and exhaust sprockets in
BMW special tool 11 6
/ 180. Position spline gap on intake sprocket (arrow) as
shown.
4 Remove exhaust camshaft splined sleeve (A) and shaft (B).

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11 6-23
Cylinder Head and Valvetrain
Place timing
chain on end of exhaust camshaft
4 Do not remove end spline retaining screws from camshafts
(arrows).
CAUTION-
The end spline retaining screws precisely locate the end
splines to the camshafts. Do not loosen these screws.
Remove locating studs (arrows) from
intake camshaft. Lift
off intake
camshaft thrust spacer (A) and impulse wheel (B)
4 Remove cylinder head cover mounting studs (arrows) from
center of cylinder head.
- Remove crankshaft locking tool (BMW special tool 11 2 300)
from cranltcase.

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Cylinder Head and Valvetrain
NOTE-
The camshaft bearing caps are coded with a letter and a
number. For example, "A
1" is the first exhaust camshaft
bearing cap
at the front of the engine, and "El "is the intake
camshaft bearing cap at the front of the engine.
-. -
The camshafts are stamped with a code letter - "E for the
intake side and
'X" for the exhaust side.
"E is for Einlap. (German for intake) and 'XA7s for Auspuff.
(German for exhaust).
- Repeat procedure for exhaust camshaft
< Secure hydraulic lifters in lifter bores using BMW special tool
11 3 250, or remove lifters using a magnetic pick-up tool.
I CAUTION-
Used liydraulic lifters must be reinstalled in original lifter
1 bores.
4 Remove lower camshaft bearing carriers from cylinder head.
CAUTION- Camshaft bearing carriers must be reinstalled in their original
locations
(E for intalce and A for exhaust).
NOTE- Do not allow hydraulic lifters to fall out of camshaft carriers.
Hydraulic lifters should be stored in an upright position.
Camshafts and lifters, installing (M52TU and M54 engine)
Lubricate camshafts, camshaft carriers, bearing caps, hy-
draulic lifters, friction washers, splined shafts and
spline hubs
with assembly
lubricant before installation.
CAUTION-
Make sure the crankshaft, which had been rotated approxi-
mately
30" opposite the direction of engine rotation from
TDC, is
stillin thatposition before lowering the camshafts into
position. Allpistons must be out of
TDCposition to prevent
valve/piston inteiference when the carnshafis are installed.
- Lift timing chain and place exhaust cam onto exhaust cam-
shaft carriers. Place
intake camshaft on camshaft carrier.

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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