exhaust BMW 528i 1999 E39 Service Manual

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Cylinder Head Removal and Installation /
< Clean contact edges of cylinder head face and VANOS unit
and apply a thin coat of permanently elastic Three Bond
1209 8 or equivalent to suriaces.
CAUTION-
Check locating dowel (A) and dowel sleeve (B) at top of
cylinder head for damage or incorrect installation.
Make sure all gasket material is removed from face of
cylinder head. Clean sealing face and keep free of oil.
If any foreign material is present on the sealing surface,
the camshaft timing will be incorrect.
- Install new steel gasket to front of cylinder head and install
VANOS unit.
NOTE -
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in
11 7 Camshaft Tim-
ing Chain.
- Reinstall engine lifting eye.
Tightening torque
VANOS unit to cylinder head
M6 nut
M7 nut
lo Nm (89 in-lb)
14 Nrn (10 it-lb)
- Reconnect electrical harness connectors to camshaft posi-
tion sensors and VANOS solenoid valves.
4 Insert and tighten down VANOS hydraulic piston set screws
in splined shafts on
intake and exhaust camshafts.
CAUJION-
Set screws have left hand tliread. Tighten counterclockwise.
Tightening torque
Hydraulic piston
to splined shaft 10 Nm (89 in-lb)
< Replace sealing caps inside VANOS unit with short needle
nose pliers.

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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 3-61
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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. .- --
[Cylinder ~ead Removal and Installation
4 Remove cylinder head cover fasteners (arrows) and remove
covers from left and right cylinder heads.
4 Remove oil distribution tubes from camshaft bearing caps
from left and right cylinder heads.
4 Using crankshaft center bolt, turn crankshaft clockwise until
number one cylinder (passenger side front cylinder) is in
TDC overlap position (arrow).
NO JE -
Number one cylinder is at valve overlap when both the intake
and exhaust valves are starting to open (camshaft lobes fac-
ing down).
4 Working at right cylinder head, loosen three accessible cam-
shaft sprocltet fasteners (arrows) on both intake and exhaust
camshafts approximately
'I2 turn.
To prevent valve to piston contact when loosening camshaft
sprocket fasteners, counterhold camshaft with
27 mm open-
end wrench.
If necessary, grind outerside of wrench jaws to
prevent damaging cylinder head.

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11 3-69
Cylinder Head Removal and Installation
4 Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Boss for special tool 11 3 200 located at rear of engine oil
pan.
4 Working at left cylinder head (driver's side) fit primary sprock-
et and chain to camshaft flange, centering threaded bores.
Insert bolts (arrows) and hand tighten.
?-I I 4 Install BMW special tool 11 3 390 into right timing case cover.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
I - Tighten sprocket retaining bolts in the following order:
All bolts on left cylinder head exhaust camshaft
3 accessible bolts on right cylinder head exhaust camshaft
All bolts on left cylinder head
intake camshaft
3 accessible bolts on right cylinder head intake camshaft r"".."..7n
Tightening torques
Sprocltet bolts to camshait flange
15 Nm (11 ft-lb)
- Remove camshaft and crankshaft locking tools from engine.
- Using crankshaft center bolt, turn engine clockwise to access
remaining sprocket retaining bolts of right cylinder head cam-
shafts. Tighten remaining bolts.
Tightening torques Sprocket bolts to camshaft flange 15 Nm
(11 ft-lb)

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. ." . .
I - Cylinder Head Removal - and instard --
4 Remove left cylinder head cover gasket and install spacing
tool (BMW
11 1 412) in place of gasket.
- lnstall lefl cylinder head cover fasteners and tighten uniformly
in
'I2 turn steps.
Tightening torque Cylinder head cover nuts
10 Nrn (7.5 it-lb)
- Tighten left upper timing cover retaining bolts in two passes.
Tightening torque
Timing chain cover to head 10 Nrn (7.5 ft-lb)
- Remove lefl cylinder head cover and BMW special tool 11 4
412.
4 Reinstall cylinder head covers to left and right cylinder heads
using new gaskets.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
03 or equivalent
sealer at corners
(6) of half-moon cutouts.
- Install left cylinder head cover fasteners and tighten uniformly
in
'I? turn steps.
- Install exhaust manifolds using new gaskets and fasteners.
See
180 Exhaust System.

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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 3-74
Cylinder Head Removal and Installation
4 Work at left side cylinder head loosen three accessible cam- shaft sprocket fasteners (arrows) on both intake and exhaust
camshafts approximately
'I2 turn.
Toprevent valve
topiston contact, counterholdcamshaft with
27 mm open-end wrench whenever loosening or tightening
camshaft sprocket fasteners. If
necessarq! grind outer side of
wrench jaws to prevent damaging cylinder head.
4 Rotate crankshaft one complete rotation to TDC overlap.
Right (passenger's side of engine) side camshaft lobes for
number one cylinder should be in overlap position as shown
(arrows).
4 Working at left cylinder head, loosen remaining sprocket fas-
teners (arrows) on both
intake and exhaust camshafts ap-
proximately
'I2 turn.

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11 3-80
Cylinder Head Removal and lnstallation
I I 4 Install BMW special tool 11 7 380
4 Install special tool 11 3 390 into special tool 11 7 380 and
tighten tensioner
(1 1 3 390) to 0.7 Nm (6.3 in-lb) using spe-
cial tool 00
9 250.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
- Tighten sprocket retaining bolts in the following order:
3 accessible bolts on left exhaust camshaft
- All bolts on right exhaust camshaft
3 accessible bolts on left intake camshaft
All bolts on right intake camshaft
Tightening torque
Sprocitet bolts to camshaft flange 15 Nm (11 ft-lb)
- Remove camshaft and crankshaft locking tools from engine.
- Using crankshaft center bolt, turn engine clockwise to access
remaining sprocket retaining bolts of left cylinder head cam-
shafts. Tighten remaining bolts.
Tightening torque
Sprocket bolts
to camshaft flange 15 Nm (11 ft-ib)
- Remove BMW special tool 11 3 390 and 11 7 380 from right
cylinder head.
- Remove used gasket from right timing chain cover, clean
gasket surface.
4 Install new gasket and apply three Bond 1209 @sealant to
joint between cylinder head and timing cover
(arrows).

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1 13-82
1 Cylinder Head Removal and Installation
4 Reinstall cylinder head covers to right and left cylinder heads
using new gaskets.
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
sealer at corners
(B) of half-moon cutouts.
- Install cylinder head cover fasteners and tighten uniformly in
'I2 turn steps.
Tightening torque Cvlinder head cover fasteners
10 Nm (7.5 It-lb)
- Install exhaust manifolds using new gaskets and fasteners.
See
180 Exhaust System.
- Refill and bleed cooling system as described in 170 Radiator
and Cooling System.
- Change engine oil and filter as described in 020 Mainte.
nance.
CA UTIOW-
To prevent damaging engine electricalsystems, be sure to in-
stall all ground wires previously removed.
Tightening
tOrqUeS
Camshaft sprocket to camshaft 15 Nm (1 1 ft-lb)
Coolant manifold to cylinder head lo Nm (7.5 It-lb)
Cylinder head cover nuts 10 Nm (7.5 ft-lb)
Exhaust manifold to head 22 Nm (17 ft-lb)
Engine mount to subframe 42 Nm (30 ft-lb)
Spark plugs to cylinder head 22 Nm (17 ft-lb)