Head removal BMW 540i 1998 E39 Workshop Manual

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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.

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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.

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Table d. Valve guide specifications
Specifications
All engines (1997-2002)
Valve guide wear, maximum 0.5 mrn (0.020 in)
(valve tilt clearance
measured
with new valve)
Valve guide inside diameter,
installed
(tolerance per IS0 allowance H7)
Standard 6.0 mm (0.236 in)
Oversize
1 6.1 mrn (0.240 in)
Oversize 2 6.2
mm (0.244 in)
Valve stem oil seals
The purpose of the valve stem oil seal is to prevent excess oil
from entering the combustion chamber. The sign of faulty
valve stem oil seals is excessive oil consumption and smoke
from the exhaust immediately after starting and during decel-
eration.
NOTE-
Valve stem oil seals should not be reused. If valves are re-
moved, new valve stem oil seals should be installed.
Valve stem oil seal replacement requires that the cylinder
head be disassembled and the valves removed as described
above under Valves, removing and installing.
NOTE-
BMW special tools are available to remove the valve stem oil
seals. As an alternative, standard valve seal removal tools
are available from most automotive parts stores.
Lubricate new seal and install using hand pressure only. Be
sure to install valve spring
seat(s) before installing seal.

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1 17-2
Camshaft Timing Chain
This repair group covers timing chain and VANOS repair
information for the following engines:
M52 (Single VANOS 6-cylinder engine)
M52
TU and M54 (Double VANOS engines)
M62 (Non VANOS
V-8 engine)
NOTE-
The M62 TU V-8 engine with VANOS Variable Camshaft
Timing repair information is not included.
NOTE-
See 100 Engine General for engine code and application
information.
Worn timing chains and sprocltets can lead to noisy operation
and erratic valve timing. Afaulty tensionercan also cause tim-
ing chain noises.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
113 Cylinder Head Removal and Installation
119 Lubrication System
121 Ignition System
170 Radiator and Cooling System
Special tools
Special BMW service tools are needed to perform the service
and repairs procedures covered in this repair group. Many of
these tools are expensive and only available through an au-
thorized BMW dealer. Be sure to read each procedure thor-
oughly before starting a job to determine which special tools
will be necessary.
In addition, Double VANOS system diagnosis can only be
carried out by using BMW specific electronic scan tools, such
as BMW
DISplus, MoDiC or equivalent.
4 Torque wrench wl flex extension
(Tool No. BMW 00
9 250)

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Camshaft Timina chain1
- Remove viscous clutch cooling fan. See 170 Radiator and
Cooling
System.
CA UTlOEIC
The radiator cooling fan nut (32mm wrench) has left- hand
threads.
.
< Remove engine trim covers:
Pry out plastic trim caps (arrows).
. Remove cover fasteners and covers.
4 Remove ignition coils:
0 Disconnect ignition coil electrical harness connectors
Remove
coil mounting fasteners and remove coils.
Remove spark plugs.
NOTE-
Make note of ignition coil ground strap locations.
Disconnect VANOS electrical harness connector
(A) and oil
line fitting
(B) from VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
- Disconnect cranltcase breather by squeezing at arrows,
- Remove cylinder cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas.
kets should be reinstalled in their original positions. Make
note of their arrangement during removal.

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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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Camshaft Timing Chain
4 Disconnect VANOS electrical harness connector (A) and oil
line fitting
(B) from VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
Disconnect cranltcase breather by squeezing at arrows.
- Remove cylinder cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators andgas-
lets should be reinstalled in their original positions. Make
note of their arrangement during removal.
4 Remove oil baffle cover from intake camshaft

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-
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.

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Camshaft Timing Chain Timing chains, removing
(M52 engine)
Camshaft timing chain removal on M52 engines requires en-
gine oil pan removal.
Special
BMW sewice tools are needed for timing chain re-
moval and installation procedures. The special tools assure
propertiming of thevalvetrain. Precise marks to
setthe timing
on the camshafts are not provided for reassembly. Read the
procedures through before beginning the job.
NOTE-
If the camshafts are not properly timed, the pistons can con-
tact the valves.
- Remove VANOS control unit. See VANOS control unit, re-
moving (M52 engine).
- Remove radiator cooling fan and shroud. See 170 Radiator
and Cooling System.
- Drain cooling system. See 170 Radiator and Cooling Sys-
tem.
- Remove coolant hoses from thermostat housing and remove
thermostat housing from front of cylinder head.
- Loosen bolts for coolant pump pulley.
- Remove drive belts for alternator and AIC compressor. See
020 Maintenance.
- Remove coolant pump pulley.
Remove drive belt tensioner mounting bolts (arrows) and re-
move tensioner from front of engine.
- Remove engine speed sensor from lower timing chain cover.

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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.