Reverse BMW 528i 1999 E39 User Guide

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
1 16-56
Cylinder Head and Valvetrain
This section covers valve removal and reconditioning, includ-
ing valve guides, seats, springs, and valve stem oil seals.
Valves, leak test
To test the valves for leakage, the cylinder head must be dis-
assembled with camshafts and camshaft carriers removed.
With valve assemblies and spark plugs installed, place the
cylinder head on a workbench with the combustion chamber
facing upward. Fill each combustion chamber with a thin non-
flammable liquid. After fifteen minutes,
check the level of the
fluid. If the fluid level in any cylinder drops, that cylinder is not
sealing properly.
Valves, removing and installing
- Remove cylinder head as described in 113 Cylinder Head
Removal and Installation.
CAUTIOI\C
(M52 TU/M54 engines only) Do not let the hydraulic lifters
fall out as the camshaft carrier is removed. Special suction
cups are available from
BMW to hold the hydraulic lifters in
place during carrier removal.
* Hydraulic cam lifters should be stored m an uprfght po-
sition. If necessary, use a magnetic tool to
aidin remov-
al of the lifters.
- Remove valves using a valve spring compressor.
CAUTIOI\C
Label each valve assembly as it is removed so it can be in-
stalled in its original position.
-
- Remove and discard valve stem oil seals from valve guides.
See Valve stem oil seals later in this section.
- Valve installation is reverse of removal. Remove carbon de- - -
posits from the valves using a wire brush or wire wheel. -
-
Valve specifications are listed in Table c. Valve specifica-
tions.

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing Chain
lnstall vibration damper mounting bolts. Note hub locating
dowel (arrow).
Tightening torque
Vibration damper to crankshaft hub
(ME) 22 Nm (16 ft-lb)
- Installation is reverse of removal noting the following:
Installing drive belts. See 020 Maintenance.
Install cooling fan. See 170 Radiator and Cooling Sys-
tem.
Crankshaft oil seal, replacing
(M52 TU and M54 engines)
The crankshafl front seal IS located in the lower timing cover,
behind the
vibrat~on damper.
- Disconnect negative (-) cable from battery.
Disconnecting the battery may erase fault
code(s) storedin
control module memoy Checlc for fault codes using spe-
cial
BMW diagnostic equipment.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in
001 General Cautions
and Warnings.
- Remove splash guard from beneath engine
- Remove engine cooling fan assembly. See 170 Radiator
and Cooling System.
NOTE- Cooling fan nut
(32 mm wrench) has left-hand threads.
- Remove drive belts. See 020 Maintenance
NOTE-
Mark direction of belt rotation if reusing belt.
- Install crankshaft holding tool (BMW special tool 11 8 19011 1
8 200). Make sure tool locks into place in openings in damper
assembly. While counterholding crankshafl with special tool,
remove crankshaft center bolt.
CAUTIOI\C
Do not use flywheel locling tool to hold crankshaft station-
ary to loosen or tighten
cranl(shaft hub center bolt. Use
only the special tools specified, or equivalent hub holding
tool.
Use care when removing
damper/hub assembly, as ~t is
easy to damage the radiator

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing chain]
4 Coat new seal with oil and position in timing chain cover. Use
BMW special tool 11
3 280 and crankshaft center bolt to draw
seal in flush with timing case cover.
- Align vibration damper assembly with keyway and tap into
place. Insert new center bolt with washer.
CA
UTIOG
Inspect woodruff key for damage before installing hub
assembly.
- Install crankshaft holding tool malting sure tool locks into
place in openings in damper assembly. While counterholding
cranltshaft, tighten crankshaft center bolt.
- Attach special tools 11 8 20011 1 8 190 to damper assembly.
Counterhold damper with 11 8 190 while tightening center
bolt.
Tightening
torque
Vibration damper hub to crankshaft 410 Nm (302 it-ib)
- Installation is reverse of removal noting the following:
Install drive belts. See 020 Maintenance.
Install cooling fan. See 170 Radiator and Cooling Sys-
tem.
Crankshaft oil seal, replacing
(M62 and M62 TU engines)
- Disconnect negative (-) cable from battery
CAUTIOG
Disconnecting the battery may erase fault code(s) storedin
control module memory. Check for fault codes using spe-
cial BMW diagnostic equipment.
* Prior to disconnecting the battery, read the battery dis-
connection cautions in
001 General cautions and
warnings.
- Remove splash guard from beneath engine
- Remove engine cooling fan assembly. See 170 Radiator
and Cooling System.
NOTE
-
Cooling fan nut (32 mm wrench) has left-hand threads.
- Remove drive belts. See 020 Maintenance.
NOTE-
Marlc direction of belt rotation if reusing belt.

Downloaded from www.Manualslib.com manuals search engine
-
Camshaft Timing Chain -. -
Measure gap (B) between secondary timing chain tensioner
and intake camshaft sensor wheel. Make note of distance.
To determine VANOS control travel:
Distance
I3 - distance A = a minimum of 8.5 mm
CAUTION-
If the adjustment travel is less than 8.5 mm the VANOS ad-
justment unit must be removed and readjusted. See
VANOS
control unit, removing (M52 engine)
and VANOS con-
trol unit, installing
(M52 engine).
Remove special tools:
Cranltshaft locking tool.
Camshaft
loclting tool set.
Air fitting.
* VANOS cable adaptor.
- Install VANOS oil line with new seal
- Install oil baffle cover above intake camshaft.
- Install cylinder head cover mounting studs to rear of head.
- Install cylinder head cover,
Tightening
torques
Cylinder head cover 10 Nrn (89 in-lb)
VANOS oil line
32 Nm (24 R-lb)
VANOS solenoid to control unit 30 Nrn (22 ft-lb)
- Installation of remaining parts is reverse of removal.

Downloaded from www.Manualslib.com manuals search engine
-- Camshaft Timing Chain -- -
Tightening torque
Vibration damper hub to crankshaft
410 Nm (300 ft-lb)
4 Install cranltshaft hub and vibration damper while aligning
locating hole (arrow) in damper with dowel pin in hub.
Tightening torque
Vibration damper and
pulley to
cranltshaft hub
22 Nm (17 ft-lb)
- Turn engine over by hand in direction of rotation at least two
full rotations. Reinstall camshaft and crankshaft locking
toois
to recheck engine timing. Remove locking tools if no faults
are found.
- Remove BMW special tool 11 3 390 (dummy tensioner) from
side of cyiinder head.
- Install primary chain tensionerso that cutout in tensioner pis-
ton engages chain rail.
Tightening torque
Timing chain tensioner to tensioner sleeve
70 Nm (52 ft-ib)
- Install cylinder head cover mounting studs, camshaft cover,
and cylinder head cover.
Tightening torque Cylinder head cover to cyiinder head
M6 nut 10 Nm (89 in-lb)
MB bolt 22 Nm (17 ft-lb)
- installation of remaining parts is reverse of removal, noting
the following:
When installing thermostat, make sure arrow or vent hole
faces up, if applicable.
Refill cooling system as described in
170 Radiator and
Cooling System.
Fill engine with oil and install new
oil filter as described in
020 Maintenance.
Tightening torque Upper timing chain cover to cylinder head
M6 nut 10 Nm (89 in-lb)
MB bolt 22 Nm (17 ft-lb)
VANOS oil supply pipe to VANOS control
unit banjo bolt
32 Nm (24 ft-ib)

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing Chain
- Connect electrical harness connectors to camshaft position
sensors and VANOS solenoid valves.
- Remove BMW special locking tools from rear of cylinder
head.
- Remove cranltshaft locking tool and replace sealing plug.
Install intake camshaft baffle and cylinder head cover.
Checlc 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
(B) of half-moon cutouts.
Similarly, seat gasket and
seal corners in front of cylinder
head, at VANOS control unit.
Tightening torque
Cylinder head cover to cylinder head
(M6) 10 Nm (89 in-lb)
- Remainder of installation is reverse of removal.
Tightening torques
Radiator fan (viscous clutch) to
coolant pump 40
Nm (30 ft-lb)
Spark plug to cylinder head
25 Nrn (18 ft-lb)
VANOS timing, checking and adjusting
(M52 TU and M54 engines)
Use this procedure to check and, if necessary, adjust cam-
shaft timing. This procedure assumes that the cylinder head
cover and intake
camshaft plastic baffle have been removed.
Also, be sure the cooling fan and the spark plugs have been
removed.
Remove primary camshaft chain tensioner cylinder
(arrow).
~~ ~ ~~ ~--~
CA UTlOAC
Primary camshaft chain tensioning piston is under spring
pressure.

Downloaded from www.Manualslib.com manuals search engine
-- - -- - -- Camshaft Timing chain1
- Remove camshaft locking tools from rear of camshafts
- Remove BMW special tool 11 4 220 (adjustable primary
chain tensioner). Reinstall primary chain tensioner.
Tightening torque Primary chain tensioner to cylinder head
70
Nm (52 it-lb)
- Remove crankshaft locking tool from transmission bellhous-
ing. Reinstall sealing plug.
- Remove VANOS setup bracket from front of cylinder head
- lnstall VANOS control unit as described earlier in this group.
- Remove compressed air fitting (BMW special tool 11 3 450)
from VANOS control unit.
- Fit VANOS oil line banjo bolt with new seals. Attach oil line to
VANOS control unit.
Tightening torque
Oil line to VANOS control unit (banjo bolt) 32 Nm (24 H-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
lnstall spark plugs.
* lnstall intake camshaft plastic baffle prior to installing cylin-
der head cover. lnstall ignition coil packs and connect elec-
trical harness connectors.
Install radiator cooling fan.
- lnstall air filter housing and top engine cover.
Tightening torque Radiator cooling fan
(VISCOUS clutch) to 40 Nm (30 ft-lb)
coolant pump
Cyitnder head cover to cylinder head 10 Nm (89 in-lb)
Sparlc plug to cylinder head 25 Nm (18 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
11 7-66
I Camshaft Timing Chain
4 install 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 8 or equivalent
sealant at corners
(B) of half-moon cutouts. Seal corners
in front of cylinder head at VANOS control unit.
Tightening torque
Cylinder head cover to cylinder head
10 Nm (89 in-lb)
- Remainder of reassembly is reverse of removal, noting the
following:
Secure all coolant hoses, thermostat housing, engine cool-
ant drains.
Install new engine oil filter and oil. See
119 Lubrication
System.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling system.
Use scan tool to check VANOS operation with engine
idling.
Tightening torques Coolant drain plug to cylinder block
25 Nm (18 ft-lb)
Radiator cooling fan (viscous clutch)
to coolant pump
40 Nm (30 ft-lb)
Radiator drain screw to radrator 2.5 Nm (22 in-lb)
Vibration damper hub to crankshaft 41 0 Nm
(300 ft-ib)
TIMING CHAIN
(M62 ENGINE TO 911998)
Timing chains, removing
(M62 engine to 911 998)
Camshaft timing chain removal requires that the engine oil
pan be removed.
Special
BMW service tools are needed for timing chain re-
moval and installation procedures. The special tools assure
propertiming of thevaivetrain. Precise marks to set the timing
on the camshafts are not provided for reassembly. Read the
procedures through before beginning the job.
CAUTION-
Special BMW service tools are needed for this procedure.
Read the procedure through before beginning the job. If the
camshafts are notproperly timed, the pistons can contact the
valves.

Downloaded from www.Manualslib.com manuals search engine
[camshaft Timina Chain
< Remove cylinder head cover sealing gaskets from lefl cylin-
der head cover. Install
BMW special tool 11 1 412 into gasket
groove of cylinder head cover.
Install lefl 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
'I2 turn steps
Tightening torque
Timing case cover to head
15 Nm (1 1 ft-lb)
- Remove special tool 11 1 41 2 and install new gaskets to cyl-
inder head cover:
Clean gasket groove and install new gasket.
Apply Three Bond
12098sealant tojoint between cylinder
head and timing cover and at half-moon shaped cut-outs.
Tighten cylinder head cover nuts.
Tightening torque Cylinder head cover to head
I5 Nm (1 1 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Where applicable remove protective film from gaskets.
Use new gaskets when mounting intake manifold. Tighten
nuts finger tight first, then torque to specification in stages
worlting diagonally from center out.
Ground straps for ignition coil harnesses are at cylinders
no.
3 and no. 7. See 120 Ignition 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.
CAUTIOI\C
To prevent damaging engine electrical systems, be sure to in-
stall ail ground wires previously removed.