housing gasket BMW 528i 2000 E39 Workshop Manual

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General
Table a. General bolt tightening torques in Nm
(max. permissible)
Bolt Class (according to DIN
267)
Gaskets and seals
Gasket aredesigned to crush and become thinner as the mat-
ing parts are bolted together. Once agasket has been used, it
is no longer capable
;f malting as good a seal as when new,
and is much more likely to leak.
Forthis reason, gaskets
should not be reused.
Some gaskets and seals are
d~rectional. Make sure thatthese
are
~nstalled correctly. In places where a shaft must pass
through a housing,
flex~ble lip seals are used to keep the lubri-
cating
011 or grease from leaking out past the rotatlng shaft.
Seals should never be reused once they have been removed.
When
rernovlng a seal, be careful not to damage the metal
surfaces.
The ltey to seal installation is to get the seal in straight without
damaging it. Use a seal driver that is the same diameter as
the seal housing to gently and evenly install into place.
If a
proper size seal driver is not available, a socket of the right
size will do.
Some seals are directional and special installation instruc-
tions apply. Make sure a seal is installed with the lip facing the
correct way. Note the installation direction of the old seal be-
fore removing it.

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11 0-4
/Engine Removal and Installation
- Disconnect negative (-) cable from battery.
CAUTION- Prior to disconnecting the
batteg read the battery discon-
nection cautions
in 001 General Cautions and Warnings.
- Remove engine hood, or place in service position. See 410
Fenders, Engine Hood.
4 Remove left and right interior ventilation ducts (lefl side
shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic loclting tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclocltwise to
unloclt from bulkhead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring
loclt (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel:
Remove rubber sealing gasket (arrow).
- Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift off panel.
Remove complete air filter housing:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intalte duct
(6) and (where applicable) disconnect idle speed control
valve electrical harness connector.
Disconnect harness connector (C) from mass air flow sen-
sor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

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110-15
Engine Removal and lnstallation
- Installation is reverse of removal, noting the following:
Replace all gaskets. O-rings and seals.
Use new fuel injector seals
Check that engine drive belts properly engage pulley
grooves.
Inspect O-ring seal between mass air flow sensor and air
filter housing. To facilitate reassembly, coat seal with acid-
free grease.
Change engine oil and filter and
check all other fluid levels.
See
020 Maintenance.
Refill and bleed cooling system. See
170 Radiator and
Cooling System.
CAUTION--
When reattaching throttle assembly harness connectoc con-
nector is
fuNy tightened when arrows on connector and plug
line up.
Tightening torques
Coolant drain plug to cylinder block
25 Nm (18 ft-lb)
Engine mount to
subframe (M10) 45 Nm (33 ft-ib)
Exhaust manifold to cylinder head
M6 10 Nm (89 in-lb)
M7 or ME 20 Nm (15 ft-lb)
Intake manifold to cylinder head
M7 15 Nm (I 1 ft-lb)
ME 22 Nm (16 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb)
Radiator drain screw to radiator
2.5 Nm (22 in-lb)

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11 3-9
Cylinder Head Removal and Installation
< Remove left and right interior ventilation ducts (left 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).
Rotate duct counterclockwise to unlock from bulkhead and
remove (arrow).
Disconnect electrical connector from hood switch
(C).
Release spring lock (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel: Remove rubber sealing
gasket (arrow).
0 Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift out panel.
< Remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from
~ntake
duct (6) and disconnect Idle speed control valve electr~cal
harness connector.
Disconnect
electr~cal harness connector (C) from mass alr
flow sensor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.
4 Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jumper post (A).
Loosen and remove battery lead mounting nut.
Remove battery lead and push down through intake mani-
fold.
Remove trim caps (arrows) from fuel injector cover.
Remove cover hold down fasteners and lift off cover.

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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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. ." ".
[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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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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-
I Camshaft Timing Chain - --
Install BMW special tool 11 6 150 (VANOS setup bracket) to
front of cylinder head timing case. Tighten nuts
(arrows) by
hand, and then tighten down uniformly until special tool is in
full contact with cylinder head.
CAUTION-
Male sure all gasket material is removed from face of cylin-
der head. Clean
sealins face and keep free of oil.
Secure camshaft impulse sprockets and wheels:
Pretighten Torx screws
(A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Pretighten mounting nuts
(B) on exhaust and intake
sprocket assemblies to approx.
5 Nm (44 in-lb).
- Torque down Torx screws (A) and nuts (8) to flnal
specifications.
Tightening torques Sprocket assembly
to camshaft
initial torque
5 Nm (44 in-lb)
Sprocket assembly to camshaft
M7 Torx screw (A) 20 Nm (15 fl-lb)
ivl6 mounting nut (B) 10 tdm (89 in-lb)
- Remove flywheel locking tool from transmission bellhousing
so that crankshaft is no longer locked.
- Remove camshaft locking tools from rear of cylinder head.
- Crank engine over twice by hand in direction of rotation until
cylinder
1 intake and exhaust camshaft lobes face each other - again.
- Secure crankshaft with BMW special tool 11 2 300.
4 Place BMW special tool 11 3 240 over camshaft ends and
measure clearance of tool to cylinder head surface.
NOJE-
If the exhaust side of the tool (A) is not flush with the head,
camshaft timing
Is incorrect. Repeat camshaft timing pro-
cedure.
* Due to flexible sprocket design and VANOS control unit tol-
erances and play, the
intake side of special tool 11 3 240
(6) may be up to 1 mm (0.04 in) above the sudace of the
cylinder head. This is normal. Otherwise, repeat camshaft
timing procedure.

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Camshaft Timing chain/
- Tighten accessible sprocket retaining bolts in the following
order:
Leit exhaust camshaft
Right exhaust
camshait
Leit intake camshaft
Right
intalte camshait
Tightening torque
Sprocket bolts to camshaft flange
15 Nm (1 1 ft-lb)
- Remove BMW special tool 11 2 300 from tool bore at bell-
housing and remove
camshaft loclting tools from cylinder
heads.
Using crankshaft center bolt, turn engine over clockwise at
least one
comolete rotation so that remainino camshaft
sprocltet
retaking bolts are accessible. -
- Tighten remaining camshait sprocket retaining bolts
Tightening torque Sprocket bolts to camshaft
flange 15 Nm (I 1 It-lb)
- Remove BMW special tool 11 3 390 from primary timing
chain tensioner bore and reinstall primary chain tensioner
- Remainder of installation is reverse or removal, noting the fol-
lowing:
Remove gasket residue from cylinder head sealing sur-
face.
Apply a thin bead of Three Bond 1209
O sealing com-
pound to joints at cylinder head cover and timing case cov-
er and at half-moon sections at rear of cylinder heads.
Replace cylinder head cover
gaskets if necessary.