exhaust BMW 528i 1999 E39 Manual Online

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Camshaft Timing chain1
VANOS control unit, installing (M52 engine)
CAUTION-
Incorrect installation of the VANOS control unit may result in
damage to the engine.
- Make sure camshafts and crankshaft are loclted in TDC po-
sition with BMW special tools as described during VANOS
removal.
< Rotate exhaust camshaft sprocket clocltwise (as viewed from
front of engine) using BMW special tool
11 5 490, until detent
position stop is reached.
4 Apply a small amount of liquid gasket sealer (Three Bond
1209
8 or equivalent) to VANOS housing alignment dowels
on front of cylinder head. Install a new
gasket.
< Push VANOS piston gear cup (arrow) into VANOS housing
until it bottoms out. Position VANOS control unit in front of
camshafts, but do not engage splines on gear cup.

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11 7-20
Camshaft Timing Chain
4 lnstall BMW special tool 1 I 5 490 on exhaust camshaft.
- Insert the helical-toothed splined shafl (arrow) into the heli-
cal-toothed sprocket while rotating gears and chain counter-
clockwise with special tool.
CAUTION- Ensure
that the first available tooth engages. It is important
that the exhaust camshaft sprocket be turned only the mini-
mum amount necessary to engage the gear cup. If this pro-
cedure is done
incorrectlq: the VANOS system may not fully
function.
- Install and tighten down VANOS control unit fasteners
Tightening torques
VANOS control unit to cylinder head
M6 nuts 10 Nm (89 in-lb)
M8 bolts 22 Nrn (17 ft-lbj
- Press down on secondary timing chain tensioner and remove
lock tool.
Remove primary timing chain tensioner
(arrow)
CAUTION-
Timing chain tensioner is under spring tension.
lnstall adjustable primary chain tensioner
(BMW special tool
11 4 220) and preload timing chain by tightening to 1.3 Nm
(I I in-lb).

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Camshaft Timing Chain/ - - - - - - . - - . - .
Tighten exhaust camshaft sprocket mounting bolts (arrows)
alternately in two stages.
Tightening torques
Secondary timing chain sprocltets to camshafts
Stage
1
Stage 2
5 Nm (44 in-lb)
22 Nm (17 ft-lb)
- Remove crankshaft locking tool and camshaft locking tool
set.
- install camshaft gear bolt access plugs using new sealing
washers and tighten.
- Remove timing chain tensioning tool from side of cylinder
head. Install primary chain tensioner with new sealing wash-
er and tighten.
Tightening torques
Access plugs to VANOS control unit 50 Nm (37 ft-lb)
Primary timing chain tensioner
plug to 70 Nm (52 ft-lb)
tensioner sleeve
- Check adjustment VANOS system, see VANOS timing,
checking and adjusting
(M52 engine).

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4 With crankshaft at TDC position, remove vibration damper
bolts (arrows) and remove vibration damper.
< Mount crankshaft holding tool (BMW special tool 11 2 150
and
11 2 410) to crankshaft hub. Counter hold crankshaft and
loosen crankshaft hub retaining bolt.
Crankshaft hub retaining bolt is torqued to
410 Nm (300 ft-lb).
Do not use flywheel
locliing tool to hold cranl(shait stationary
to loosen or tighten crankshaft hub center bolt. Use only the
special tools specified, or equivalent hub holding tool.
- Remove crankshaft hub.
- Remove cylinder cover mounting fasteners and remove cyl-
inder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original positions. Make
note of their arrangement during removal.
- Drain engine oil, remove oil pan. See 119 Lubrication Sys-
tem.
Remove primary timing chain tensioner (arrow).
CAUTION-
Timing chain tensioner is under spring tension. I
- Remove VANOS control unit. See VANOS control unit, re-
moving
(M52 engine).
- Remove fasteners from intake and exhaust camshaft
sprocket.

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[camshaft Timing Chain
< While pressing down on secondary timing chain tensioner
install locking tool (BMW
11 3 292) or a similar pin.
NOTE-
Two types of secondary timing chain tensioners are used,
with either two holes (shown) or a single hole for the
locking
pin tool.
- Remove intake and exhaust sprockets together with
secondary chain.
< Remove secondary timing chain tensioner bolts (arrows)
and remove tensioner.
- Remove primary timing chain sprocket from exhaust
camshaft.
- Remove sprocket and hang timing chain from end of exhaust
camshaft.
4 Remove secondary chain guide bolts (arrows) and remove
guide.

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1 17-30
I Camshaft Timing Chain
Timing chain, installing
(M52 engine)
CAUTION-
The procedure outlined below assumes that the camshafts
and the crankshaft are
lockedin the TDCposition with BMW
special tools.
- Inspect timing chain and sprocltets and guide rails for wear.
Replace worn parts.
NOTE-
If any of the sprockets are being replaced due to wear, the
chain should also be replaced.
Install primary timing chain
on exhaust camshaft. to crankshait
sprocket and hang
4 Apply a small bead oi silicon sealer (Three Bond 1209 @or
equivalent) to corners where tim~ng cover meets cylinder
head
(arrows).

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-- -
Chain 1
- Install cylinder identification trigger plate to front of intake
camshaft.
- 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 spring plate to intake cam
sprocket.
Tighten intake camshaft sprocket nuts.
- Install VANOS control unit, see VANOS control unit, install-
ing
(M52 engine).
Tightening torque
Intake camshaft sprocket nuts to studs
(ME) 1011 Nm (8919 In-lb) 502117068
- Unlock and release secondary chain tensioner,
4 Preload primary timing chain by torquing adjustable primary
chain tensioner (BMW special tool
11 4 220) to 1.3 Nm
(11 in-lb).
- Tighten exhaust camshaft sprocket bolts in two stage
Tightening torque Exhaust camshaft sprocket bolls (M7)
Stage 1
5 Nrn (44 in-lb)
Stage
2 22 Nm (17 ft-lb)
- Remove crankshaft locking tool and camshaft locking tools.
< Align hub with keyway and tap into place. Insert new center
bolt with washer shoulder (arrow) facing hub.
CAUTION-
Inspect woodruff ley for damage before installing hub.
- Attach crankshaft holding tool (BMW special tools 11 2
15011 1 2 410) to hub. Counterhold hub with tool while tight-
ening center bolt.
CAUTION-
Do not use flywheel locling tool to hold crankshaft stationary
to loosen or tighten
cranlshaft hub center bolt. Use only the
special tools specified, or equivalent hub holding tool.

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1 17-34
1 Camshaft Timing Chain
DOUBLE VAMOS SYSTEM
(M52 TU AND M54 ENGINES)
Double VANOS system function
The M52TU and M54 6-cylinder engines are equipped with a
Double VANOS system that varies intake and exhaust cam-
shaft timing.
The main components of the Double VANOS system are:
lntalte and exhaust camshafts with helical spline inserts.
Camshaft sprockets with adjustable gears.
VANOS actuators (two position piston housing with
inter-
nallexternal helical spline cup).
Three-way solenoid switching valves.
Camshaft position impulse wheels.
Hall effect camshaft position sensors.
Camshaft position
IS varied based on engine rpm, throttle po-
sition signal, intake air and coolant temperature.

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Camshaft Timing Chain
1 VANOS I 4 When engine is started, camshafts are in deactivated
camshaft
retarded Engine I i oil supply
position:
. lntalte camshaft is held in RETARDED position by oil
pressure.
Exhaust camshaft is held in ADVANCED position by
preload spring and oil pressure.
VANOS
Piston out
ECM Piston in Within 2
- 5
seconds (50 engine revolutions), the ECM begins
monitoring and controlling camshaft positions.
The Double VANOS system allows full variability of camshaft
timing up to the limits of the system. When the ECM detects
that the camshafts are in optimum position, the solenoids are
modulated at approximately 100
- 220 Hz to maintain oil pres-
sure on both sides of the actuator pistons to maintain timing.
In models with DME
MS 43.0 (model year2001 and newer),
the engine control module (ECM) detects camshaft position
before the engine starts, thereby adjusting camshaft timing
immediately upon start-up.
NOTE-
. VANOS system troubleshooting and diagnostics is best
accomplished using a scan tool.
. Diagnostic Trouble Codes (DTCs) pertaining to the
VANOS system are listed
in the following table. See also
OED On-Board Diagnostics.
Elevated oil temperatures can cause VANOS to deactivate.
Oil that is too thick (high viscosity) may cause
a DTC to be
set
in the ECM. If VANOS is deactivated (limp-home
mode), there will be a noticeable loss of power.
VANOS fault codes
BMW code P-code Fault description
19
PI529 VANOS solenoid valve activation,
exhaust
21
PI525 VANOS solenoid valve activation,
intake
103
PI519 VANOS faulty reference value
intake
104
PI520 VANOS faulty reference value
exhaust
105
PI522 VANOS stuck (Bank I) intake
106
PI523 VANOS stuck (Bank 2) exhaust

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1 17-36
Camshaft Timing Chain
1 Double VANOS control unit
1. BoltM6
2. Exhaust camshaft position
sensor
3. Sealing ring
4. Camshaft end sealing plug
-tighten to 50 Nm (37 ft-lb)
5. Camshaft seal cap
6. VANOS hydraulic piston set
screw -CAUTION: left hand
thread -tighten to
10 Nm
(89 in-lb)
7. Nut M7 -tighten to
14 Nm
(1 0 ft-lb)
8. Engine lifting hook
9. Stud M7
10. Nut
M6 -tighten to 10 Nm
(89 lb-in)
11. Gasket
12. Cylinder head
13. Sealing ring
14. Intake camshaft sensol
15. Bolt M6
16. VANOS control unit
17. Copper sealing ring
18. VANOS oil feed line
19. Banjo bolt -tighten to 32 Nm
(24ft-lb)