cool BMW 525i 1997 E39 Owner's Guide

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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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I Cylinder Head Removal and Installation
4 Drain engine coolant and remove coolant hoses:
Remove expansion tank cap on radiator.
Place a
3 gallon pail beneath engine to capture coolant
Remove coolant drain plug (arrow) located on exhaust
side of cylinder
2 of engine block.
4 Drain radiator into a 3 gallon pail by removing plastic drain
plug (arrow) completely.
Use caution when draining and disposing of engine coolant.
Coolant is poisonous andlethal to humans andpets. Pets are
attracted to coolant because of its sweet smell and taste.
Seek medical
attention immediately if coolant is ingested.
NOTE-
Catch and dispose of drained coolant according to local,
state, and federal laws.
4 Remove thermostat housing:
. Disconnect electrical harness connector at thermostat
housing.
. Remove hoses from thermostat hous~ng by releasing loclts
(arrows).
Unbolt
(4 bolts) and remove thermostat hous~ng.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator shroud as described in
170 Radiator and Cooling System.
CAUTIOI\C
32 mm radiator fan mounting nut has left hand threads. r
4 Remove fasteners (arrows) from heater bypass tube. Pull
tube out of cylinder head and set to side, leaving heater hose
connected.
- Unbolt power steering fluid reservoir and pull aside without
disconnecting hoses. Secure to fender with cord or stiff wire.

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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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. ." ".
[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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11 3-56
I Cvlinder Head Removal and Installation
- Installation of the remaining parts is reverse or removal, not-
ing the following:
- 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.
a Reconnect battery.
CAUTION- To prevent damaging the engine electronic systems, installall
ground wire previously removed, including the ground wires
for the
ionition coils.
Tightening torque Coolant drain
pluq to cylinder bloclc 25 Nm (1 8 ft-lb)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb) -
Radiator drain screw to radiator 2.5
Nm (22 in-lb)
spark plug to cylinder head 25
Nm (1 8 ft-lb)
CYLINDER MEAD REMOVAL AND
INSTALLATION (M62 ENGINE)
This procedure covers cylinder head removal and installation
for the
M62 V-8 engine. Procedures forthe M62 TU VANOS
engine are not covered in this manual.
Intake manifold, left cylinder head, and right cylinder head re-
moval and installation are written as separate procedures.
The intake manifold must be removed before the cylinder
heads can be removed.
WARNING
-
Due to risk of personal injuv be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation requires multiple spe-
cial service tools. Read the entire procedure before beginning
the repair.
Intake manifold, removal and installation,
M62 engine
- Disconnect negative (-) battery cable.
CAUTION- Prior to disconnecting the
batterj read the baitery discon-
nection cautions
in 001 General Cautions and Warnings.

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11 3-61
Cylinder Head Removal and installation I
Remove intake manifold fasteners (A).
Carefully lift intake manifold off engine while checking that all
hoses and harnesses have been disconnected.
Left cylinder head, removing, M62 engine
- Remove intake manifold as described earlier
- Remove left side exhaust manifold. See 180 Exhaust Sys-
tem.
- Drain engine coolant, then remove viscous clutch cooling
fan. See
170 Radiator and Cooling System.
WARNING -
Use extreme caution when draining and disposfng of eng~ne
coolant. Coolant is poisonous and lethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste.
Seek med~cal attention immediately if coolant is ingest-
ed.
4 Remove coolant manifold mounting fasteners and carefully
remove manifold.
NOTE-
Engine shown removed from engine bay
4 Remove ignition coil fasteners and coils (noting location of
ground strap).
- Remove spark plugs.

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. .- --
I Cylinder Head Removal and Installation
- Evaluate cylinder head as described in 116 Cylinder head
and valvetrain.
Left cylinder head, installing, M62 engine
- Clean cylinder head and block sealing surfaces of gasket
debris, making sure no debris drops into coolant or oil pas-
sages.
- Clean cylinder head bolt holes and check condition of
threads.
< Check cylinder head locator sleeves (arrows) for damage.
If the cylinder head has been machined, a special
0.3 mm
thicker gasket should be installed. The thicker gasket is avail-
able through an authorized
BMW dealer and should be
marked accordingly.
- Place new cylinder head gasket over locating sleeve on
block.
The word
"OBEN" or "TOP" (arrow) printed on the gasket,
must face up.
Set lefl side cylinder head in position on cylinder block while
pressing oil separator outward.
CAUJION-
Male sure the crankshaft, which had been rotated approxi-
mately
45" opposite the direction of engine rotation from
TDC, is still in thatposition before installing the cylinder head.
All pistons must be out of
TDCposition to prevent valvelpis-
ton contact.
- Install new cylinder head bolts and washers finger tight. Be
sure not to remove coating from new cylinder head bolts.
4 Tighten cylinder head bolts in correct sequence (1-10) to
stage
1 torque values.

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/Cylinder Head Removal and Installation
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Use new gaskets when mounting intake
manifold. Tighten
nuts finger tight first, then torque to specification in stages
working diagonally from center out.
Be sure to reinstall ignition coil ground straps at cylinders
no.
3 and no. 7. See 120 Ignition System.
Reinstall cooling fan and shroud. See
170 Radiator and
Cooling System.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
CA UTIOG
To prevent damaging engine electricalsystems, be sure to in-
stall all ground wires previously removed.
Tightening torques
Camshaft sprocket to camshaft 15
Nm (11 H-lb)
Coolant manifold to cylinder head 10 Nm (7.5 H-lb)
Cylinder head cover nuts 10 Nm (7.5 ft-lb)
Exhaust manifold to head 22 Nm (17 ft-lb)
Engine mounts to subirame 42 Nm (30 ft-lb)
Spark plugs to cylinder head 22 Nm (17 ft-lb)
Right cylinder head, removing, M62 engine
- Remove left side exhaust manifold. See 180 Exhaust Sys-
tem.
- Remove intake manifold. See Intake manifold, removal
and installation,
M62 engine.
- Drain engine coolant. See 170 Radiator and Cooling Sys-
tem.
WARNING-
Use extreme caution when draining and disposing of engine
coolant.
Coolanl is poisonous andlellial lo liumans andpels.
Pets are
altracled to coolant because of 11s sfieet smell and
fasle. Seelc medcal anenfion immed~alely if coolant is ingesl-
. .-
< Remove engine coolant manlold mo~nlng fasreners and
carei~lly remove manifo d.
. I
NOTE
Engine 8s slioivn removed lor clarify

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11 3-73
Cylinder Head Removal and Installation /
1
- Remove viscous clutch cooling fan. See 170 Radiator and
i Cooling System. i i I 4 Remove ignition coil fasteners and coils (noting location of
~ ground strap).
1
Remove sparlc plugs.
i
Remove oil distribution tube fasteners and remove tubes
from both cylinder heads.
4 Using crankshaft center bolt, turn crankshaft cloclcwise until
number one cylinder (front cylinder right side) is in
TDC (ar-
rows).