Timing chain cover BMW 540i 2000 E39 Workshop Manual

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Engine-General
This section covers system descriptions and general informa-
tion on engines and engine management systems. Also cov-
ered is basic engine troubleshooting.
For specific repair procedures, refer to the appropriate repair
group:
110 Engine Removal and Installation
0 113 Cylinder Head Removal and Installation
116 Cylinder Head and Valvetrain
0 117 Camshaft Timing Chain
119 Lubrication System
120 Ignition System
130 Fuel Injection
0 170 Radiator and Cooling System
E39 models are fitted with a variant of either an inline 6-cylin-
der or a
V-8 engine. See Table a.
Table a. Engine specifications

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11 3-2
Cylinder Head Removal and Installation
This group covers cylinder head removal and installation as
well as cylinder
headlvalve diagnostic procedures.
In the procedures in this repair group, engines are referred to
by engine code. If necessary, see
100 Engine-General for
engine code and application information.
The information given in this repair group assumes that the
engine is installed in the engine bay. On the
6-cylinder en-
gines, the VANOS control unit must be removed in orderto re-
move the cylinder head from the engine block. On
M52TU
and M54 engines, camshafts must be removed from the cylin-
der head before the head is removed.
The cylinder head removal and installation procedures for the
M62 V-8 are also included, butthe proceduresforthe M62TU
V-8 with VANOS are not provided.
For cylinder head and valvetrain reconditioning information,
see
116 Cylinder Head and Valvetrain.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
If a head gasket problem is suspected, a compression test or
leak-down test will usually detect the fault See Diagnostic
Testing later
in this group.
Special tools
Special BMW service tools are required to properly remove
and install the cylinder head on engines covered by this man-
ual. The special tools are used to time the valvetrain to the
crankshaft, and to remove the VANOS control unit, the cam-
shafts and the
Tom (El2) head bolts. Read the entire proce-
dure through before beginning the job.

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- - , -. I Cylinder Head Removal and lnstallatio~
4 Remove oil baffle cover from above intake camshaft.
4 Unscrew and remove three cylinder head cover studs (ar-
rows)
at rear of cylinder head.
Set engine to approximate top dead center
(TDC) by turning
crankshaft bolt in direction of rotation (clocltwise when
viewed from front of engine) until camshaft lobes for cylinder
1 face each other (dotted lines) and arrows on camshaft
sprocltets face up.
- Set engine to TDC by aligning "OIP mark of vibration damp-
er with boss cast on lower timing chain cover.
< Lock cranltshaft at TDC:
Remove sealing plug from bore on lower left side of engine
block below starter. Secure crankshaft in
TDC position with
BMW special tool 11 2 300.

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113-16
Cylinder Head Removal and Installation
- Remove secondary timing chain and sprockets:
Remove mounting nuts from front of intake camshaft
sprocket. Remove and label shim.
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
ening or tightening sprocket mounting fasteners.
Remove mounting nuts from front of exhaust camshaft
sprocket and remove and label thrust washer.
NOTE-
Where applicable, make note of thrust washerpositions. The
thicker
(0.4 mm) washer is mounted outermost.
- Remove secondary sprockets together with camshaft tim-
ing chain from front of camshafts.
CAUTION-
The camshafts must be locledin the TDCposition using the
special service tool as described earlier: The arrows on the
sprockets should not be used to accurately set the engine to
TDC. The tool holds the camshafts parallel to each other and
NOTE-
Do not remove the sprocl parts are being replaced. Wire tie each sprocket to the chain
to
Iceep the sproclefs timed to each other:
CAUTIOI\C
The crankshaft must not be allowed to rotate once the cam-
shaft timing chain is removed. The pistons can
contact the
valves.
Unscrew timing chain guide and remove.
Lift off primary sprocket with chain.
Secure chain with wire to prevent chain from dropping into
lower timing cover.
Unscrew timing case cover to cylinder head bolts (arrows).
NOTE-
Photo shows timing chain guide in place; it should first be re-
moved as described previously.
Remove crankshaft locking tool
(BMW special tool 11 2 300).
Using the crankshaft vibration damper bolt, turn engine op-
posite of normal direction of rotation (counterclocltwise as
viewed from the front) approximately 30". This prevents ac-
cidental contact between valves and pistons during installa-
tion.

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Cylinder Head Removal -- and lnstallati~i
4 Cylinder head bolt loosening sequence.
- Using BMW special tool 11 2 250 or an equivalent tool, loos-
en cylinder head bolts in sequence. Discard head bolts.
- Separate the cylinder head from the block and remove head.
Evaluate head as described in
116 Cylinder Head and Val-
vetrain.
Cylinder head, installing, M52 engine
If the camshafts were removed and installed while the cylin-
der head was off, a minimum waiting time is required after in-
stalling the camshafts. When the camshafts are removed, the
hydraulic lifters can expand. This expansion can cause in-
creased valve lift when the camshafts are bolted down, result-
ing in open valves.
Camshaft installation waiting times
68" F (20" C) and higher 4 minutes
50.68' F (1 0-20" C) 11 minutes
32-50' F (0-1 0" C) 30 minutes
- Clean cylinder head and gasket surfaces of cylinder block
and all timing chain covers.
CAUTION-
Do not use a metal scraper or wire brush to clean the alumi-
num cylinder head orpistons. If necessary, use a hard wood-
en orplastic scraper. Also available are abrasive discs to be
used in conjunction with an electric drill. Be sure to use the
correct disc for the type of metal being cleaned.
- Remove all debris and fluids from bolt holes and clean with a
thread chaser.
- Check gasket surface of cylinder head and cylinder block for
warpage using a straight edge.
NOTE-
If the cylinder head has been machined, a special 0.3 mm
thicker gasket should be installed. The thicker
gasket is avail-
able from an authorized
BMW dealer.

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I Cylinder Head Removal and Installation
4 Check that two locating dowels are correctly positioned in
block and are not damaged.
- Apply permanently elastic sealing compound Three Bond
1209 8 to joints where cylinder block joins timing case cover.
- Place new cylinder head gasket on cylinder block.
NOTE-
The word "OBEN" or 'TOP': printed on the gasket, should
face up. The cylinder head
gasket will fit correctly in only one
orientation.
- With camshafts locked in TDC oosition with BMW soecial
tools as described during cylinder head removal,
seicylinder
head in position, guiding primary chain through cylinder head
opening.
NOTE-
* The camshafts must be locl(ed in the TDC position at the
rear of the cylinder head with
BMW special tool I1 3 240
before installing the cylinder head.
Make sure the
cranksha% which had been rotated approx-
imately
30" opposite the direction of engine rotation, is still
in that position before lowering the cylinder head into posi-
tion.
- Lightly lubricate new cylinder head bolts. Loosely install bolts
and their washers, then thread them in until they are finger
tight.
NOTE-
. Torx-type cylinder head bolts should not be reused. They
are stretch-type bolts and must always be replaced when-
ever loosened.
Check that all washers for the cylinder head bolts are in
place before installing the bolts. Some of the washers may
be
stalced to the cylinder head.
CAUTIOI\C
Cylinder head bolts for a cast iron engine block are different
length and require different tightening torque than bolts for an
aluminum cylinder bloclc engines
(95 rnm versus 110 rnm
bolts).
- Install cylinder head-to-lower timing chain cover bolts finger
tight.
< Tighten cylinder head bolts in correct sequence to initial
torque value.

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I Cylinder Head Removal and Installation I
< Use BMW tool 11 2 110 or torque angle gauge to tighten cyl-
inder head bolts in sequence to stage
2 and 3.
Tightening torques
Cylinder head to cast iron
bloclc
Staoe 1
staie 2
Stage 3
Cyllnder head to aiumlnum block
Stage
1 40 Nm (30 it-lb)
Stage 2 +90°
Staoe 3 -80"
- Tighten cylinder head-to-lower timing chain cover bolts.
Tightening torques
cylinderhead to lower timing chain cover 10 Nm (89 in-lb)
- Inspect secondary chain guide rail and tensioner rail for
grooves caused by chain contact. Replace any part that is
worn.
NOTE-
Inspect timing chain sprocl(ets. Sprockets that have worn
or missing teeth should be replaced.
* If any of the sprockets are being replaced due to wear, the
chain should also be replaced.
If the crankshaft sproclet requir?s replacement, the oil
pump drive sprocket and chain must be removed as de-
scribed under
119 Lubrication System.
The procedure outlined below assumes that the camshafts
and the
cranl(shaft are locledin the TDCposition with special
4 Mount primary timing chain sprocltet to primary chain so that
arrow on sprocket faces up. Mount sprocket to camshaft so
that tapped holes in camshaft are on left side of elongated
holes in sprocltet
Install BMW special tool
1 I 4 220 into primary timing chain
tensioner sleeve. Thread center spindle in finger tight
until
slack is removed from chain.

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- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Install intake camshaft cover and 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
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in 020 Mainte-
nance.
If necessary, adjust accelerator cable.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl

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. - -- -
Cylinder Head Removal and Installation --
Remove bolts (arrows) holding timing chain cover to cylinder
head. (Photo shows camshafts and camshaft bearing caps in
place).
4 Using BMW special tool 11 2 250 or equivalent, loosen cylin-
der head bolts in several stages, in sequence shown. Discard
head bolts.
NOJE-
BMW special tool 11 2 250 is a thin-walled Torx El2 socket
with an extended reach. The cylinder head bolts are re-
cessed into the head below the
camshaft towers with little
working space.
- Lift off cylinder head. Refer to 116 Cylinder Head and Val-
vetrain for cylinder head reconditioning information.
Cylinder head, installing, M52 TU and M54
engines
Clean cylinder head and gasket surfaces of cylinder bloclc
and all timing chain covers.
CAUTION- Remove foreign matter and liquid from bolt holes. Trapped oil
or coolant in bolt holes can cause damage to
blocl~,
CAUJION-
Do not use a metal scraper or wire brush to clean the alumi-
num cylinder head or pistons. If necessary, use a hard wood-
en orplastic scraper. Also available are abrasive discs to be
used in conjunction with an electric drill. Be sure to use the
correct disc for the type of metal being cleaned.
Evaluate cylinder head as shown in
116 Cylinder Head and
Valvetrain.
NOTE- If the cylinder head has been machined, a special 0.3
mm
(0.01 1 in.) thicker gasket should be installed. The thicker
gasket is available from an authorized
BMW dealer and
should be marked accordingly
Cylinder head and valve specifications are covered in 116
Cylinder Head and Valvetrain.

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11 3-40
I Cylinder Head Removal and Installation
Lubricate camshafts, camshaft carriers, bearing caps, hy-
draulic lifters, friction washers, splined shafts and spline hubs
with assembly lubricant before installation.
4 Check that two cylinder head aligning sleeves (arrows) are
correctly positioned in block and are not damaged.
- Apply elastic sealing compound Three Bond 1209 8 to cor-
ner joints on cylinder block to timing chain cover.
- Place new cylinder head gasket on cylinder block.
NOTE-
The word "OBEN" or "TOP printed on the gasket, should
face up. The cylinder headgaslet will fit correctly in only one
orientation.
- Set cylinder head in position, guiding primary chain through
cylinder head opening.
CAUJION-
Make sure the crankshaft, which had been rotated approxi-
mately 30" opposite the direction of engine rotation from
TDC, is still in thatposition before lowering the cylinder head
into position. All pistons must be out of TDC position to pre-
vent
valve/piston interference when the camshafts are in-
stalled.
- Lightly lubricate new cylinder head bolts and washers with
oil. Install bolts and washers finger tight. Install cylinder head
to lower timing chain cover bolts finger tight.
NOJE-
Cylinder head bolts should not be reused. They are
stretch-type bolts and must be replaced whenever loos-
ened.
* Aluminum cylinder blocls use different length cylinder
head bolts and torque values than cast iron blocks.
Check that all washers for
Nle head bolts are in place be-
fore installing the bolts. Some of the washers may be
staked to the cylinder head.
I 12 10 4 2 6 8 141 Tighten cylinder head bolts in correct sequence (1-14)
CA U TIOW-
The bolts should be tightened in three stages as listed below
The final stages require the use of a BMW special tool
11 2
110 or a suitable protractor to tighten the bolts to a specified
torque angle.