ECO BMW 525i 1997 E39 Service Manual

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11 3-4
Cylinder Head Removal and Installation
4 Camshaft locking tools (cyl. 5-8), V-8
112442 112446 (Tool No. BMW 11 2 44211 1 2 44611 1 2 44311 1 2 444)
4 Camshaft loclting tools (cyl. 1-4), V-8
(Tool No. BMW 11 2 44511
1 2 44111 1 2 44311 1 2 444)
4 Timing chain adjustable tension setup tool, V-8
(Tool No. BMW 11 3 390)
Secondary timing chain tensioner loclting pin, V-8
(Tool No. BMW 11 3 310)
4 Hydraulic lifter securing plugs
(Tool No. BMW 11 3 250)
< Camshaft bearing cap tensioner (6-cylinder)
for
camshaft removal and installation
(Tool No. BMW 11
3 26011 1 3 270)
4 Secondary timing chain tensioner loclt set
(Tool No. BMW 11 3 29111 1 3 292)

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11 3-6
Cylinder Head Removal and Installation
- Disable ignition system by removing DME main relay. See
610 Component Locations for relay location.
WARNING-
. The ignition system produces high voltages that can be fa-
tal. Avoid contact with exposed terminals and use
exfreme
caution when working on a car with the ignition switched on
or the engine running.
Do not touch or disconnect ignition
components while
the engine is running or being cranked by the starter.
Failure to remove the DME main relay or attempting to
disa-
bie the fuel andignition systems by other methods may result
in damaoe to the enoine control module
(ECM).
- - Remove plastic cylinder head cover(s)
,,I . ,. .*,.,,&- - Remove coil grounding straps.
I CAUTION-
I nition system components. I
- Remove coils.
- Remove spark plugs from all cylinders.
NOTE-
Check the spark plugs for oil deposits that may indicate poor
cylinder sealing, then set them aside in order. Used spark
plugs should be reinstalled in the same cylinder from which
they were removed.
4 Install compression gauge in first cylinder spark plug hole,
tight enough to form a good seal.
- With parking brake set, transmission in PARK or NEUTRAL,
and accelerator pedal pressed to floor, crank engine with
starter. Record highest value indicated by gauge.
NOTE-
* The compression gauge reading should increase with
each compression stroke and reach near its maximum
reading in about
4-6 strokes.
All cylinders should reach maximum compression in the
same number of
strolces. If a cylinder needs significantly
more strokes to reach
maximum compression, there is a
problem.

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-
Cylinder Head Removal and Installation c
q Remove secondary air inject~on check valve (arrow).
4 Remove cylinder head top cover:
Remove plastic trim caps (arrows).
Remove engine oil filler cap.
Remove cover hold down fasteners and lift off cover.
4 Remove ignition coils:
Disconnect ignition coil harness connectors.
. Remove coil mounting fasteners.
Remove coils.
Remove ground straps.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
- Remove sparlc plugs.
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original locations. Make
note of their arrangement during removal.

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11 3-1 4
Cylinder Head Removal and Installation
4 Secure camshafts in TDC position using BMW special tool
set
11 3 240.
4 Remove access plugs from VANOS control unit in front of
exhaust camshaft sprocket.
Remove
4 bolts (arrows) from exhaust camshaft sprocket
(Torx E10).
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
eninq or tiqhteninq sprocl(et mounting fasteners. r
Press down on secondary chain tensioner and lock into place
using
BMW special tool 11 3 292 or a similar size pin.
NOTE-
Some tensioners may have a single hole for special tool.
Remove secondary chain tensioner.
Disconnect harness connector and oil line fitting from bottom
of VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
Remove VANOS control unit mounting nuts and bolt at front
of cylinder head.

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113-16
Cylinder Head Removal and Installation
- Remove secondary timing chain and sprockets:
Remove mounting nuts from front of intake camshaft
sprocket. Remove and label shim.
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
ening or tightening sprocket mounting fasteners.
Remove mounting nuts from front of exhaust camshaft
sprocket and remove and label thrust washer.
NOTE-
Where applicable, make note of thrust washerpositions. The
thicker
(0.4 mm) washer is mounted outermost.
- Remove secondary sprockets together with camshaft tim-
ing chain from front of camshafts.
CAUTION-
The camshafts must be locledin the TDCposition using the
special service tool as described earlier: The arrows on the
sprockets should not be used to accurately set the engine to
TDC. The tool holds the camshafts parallel to each other and
NOTE-
Do not remove the sprocl parts are being replaced. Wire tie each sprocket to the chain
to
Iceep the sproclefs timed to each other:
CAUTIOI\C
The crankshaft must not be allowed to rotate once the cam-
shaft timing chain is removed. The pistons can
contact the
valves.
Unscrew timing chain guide and remove.
Lift off primary sprocket with chain.
Secure chain with wire to prevent chain from dropping into
lower timing cover.
Unscrew timing case cover to cylinder head bolts (arrows).
NOTE-
Photo shows timing chain guide in place; it should first be re-
moved as described previously.
Remove crankshaft locking tool
(BMW special tool 11 2 300).
Using the crankshaft vibration damper bolt, turn engine op-
posite of normal direction of rotation (counterclocltwise as
viewed from the front) approximately 30". This prevents ac-
cidental contact between valves and pistons during installa-
tion.

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I Cylinder Head Removal and Installation I
< Use BMW tool 11 2 110 or torque angle gauge to tighten cyl-
inder head bolts in sequence to stage
2 and 3.
Tightening torques
Cylinder head to cast iron
bloclc
Staoe 1
staie 2
Stage 3
Cyllnder head to aiumlnum block
Stage
1 40 Nm (30 it-lb)
Stage 2 +90°
Staoe 3 -80"
- Tighten cylinder head-to-lower timing chain cover bolts.
Tightening torques
cylinderhead to lower timing chain cover 10 Nm (89 in-lb)
- Inspect secondary chain guide rail and tensioner rail for
grooves caused by chain contact. Replace any part that is
worn.
NOTE-
Inspect timing chain sprocl(ets. Sprockets that have worn
or missing teeth should be replaced.
* If any of the sprockets are being replaced due to wear, the
chain should also be replaced.
If the crankshaft sproclet requir?s replacement, the oil
pump drive sprocket and chain must be removed as de-
scribed under
119 Lubrication System.
The procedure outlined below assumes that the camshafts
and the
cranl(shaft are locledin the TDCposition with special
4 Mount primary timing chain sprocltet to primary chain so that
arrow on sprocket faces up. Mount sprocket to camshaft so
that tapped holes in camshaft are on left side of elongated
holes in sprocltet
Install BMW special tool
1 I 4 220 into primary timing chain
tensioner sleeve. Thread center spindle in finger tight
until
slack is removed from chain.

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--
Cylinder Head Removal and Installation
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the hydraulic
tensioner.
- Check that elongated holes in primary sprocket are now cen-
tered to bolt holes in camshaft and chain is free of slack. If
not, reposition sprocket to chain and reinstall.
- lnstall secondary timing chain guide and secondary chain
tensioner. Tighten mounting bolts (tensioner remains locked
down for now using
BMW special tool 11 3 292).
- Install cylinder identification trigger plate to front of intake
camshaft with studs.
- Install spacer to front of intake camshaft.
- Install secondary chain sprockets and chain as an assembly
so that arrows on sprockets are pointing up. Center mounting
holes in sprockets to bolt holes in camshafts.
4 lnstall thrust washers and diaphragm spring to intake cam
sprocket.
I 2hm thrust washer I
- Install shim and torx bolts to exhaust camshaft. Tighten fin-
ger tight; do not torque down.
- Tighten intake sprocket nuts.
CA UTIOG
Hold the camshaft stationary (at hex on camshaft) when loos-
enino or tiahtenino sorocket mounting bolts and studs.
Tightening torque
Intake s~rocket nuts to studs 10 +l Nm (89 +9 in-lb)
- Turn crankshaft approx. 30" in direction of rotation to bring
engine to TDC. Lock crankshaft in TDC position with BMW
special tool
11 2 300.
CAUTION-
The camshafts andcranlshaft must be lockedin the TDCpo-
sition using BMW special tools 11 2 300 and 11 3 240. If the
camshafts and cranl(shaft are not at TDC, the valves can
contact the pistons.

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- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
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 1209
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
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.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl

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Cylinder Head Removal and Installation
4 If applicable, remove secondary air injection pump:
Disconnect hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
Disconnect electrical harness from bottom of secondary
air injection pump.
Remove mounting bracket from strut tower.
4 Remove ignition coils:
* Disconnect ignition coil harness connectors.
Remove coil mounting fasteners.
Remove coils.
* Remove ground straps.
CA UTIOI\C
Note location of all ground wires. Failure to reinstall grounds
can result in permanent damage to engine control module or
ignition system components.
Set coil harness to side of engine compartment
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
ltets should be reinstalled in their original locations. Male
note of their arrangement during removal.
- Remove spark plugs
4 Remove oil baffle cover from above intake camshaft.

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- -
-- .- Cylinder ~ead~ernoval and Installation I - -.
Remove VANOS unit:
Remove engine lifting eye.
- Remove VANOS mounting nuts (arrows) and pull VANOS
unit and metal gasket off.
CAUTION-
Do not crank the engine with VANOS unit removed. Pis-
tonhalve inteiference may result.
NOTE-
The VANOS unit will contain a small quantity of oil. Place
shop towel to catch oil as unit is removed or tilted.
CAUTION-
If the VANOS adjustment unit is replaced, or if operations are
completed that may change the timing of
the camshafts, the
camshaft timing must be checked. See
11 7Camshaft Timing
Chain.
4 Remove primary camshaft chain tensioner cylinder (arrow).
CAUTION-
Primary camshaft chain tensioner is under spring pressure.
Press down on secondary chain tensionerand lock into place
using
BMW special tool 11 3 291, or a thin drifl or pin.