chain tensioner BMW 540i 2001 E39 User Guide

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I Cvlinder Head Removal and Installation
4 Install secondary chain tensioner on cylinder head (arrows).
Keep tensioner compressed using BMW special tool 11 3
291 or suitable pin.
< Install exhaust camshaft splined sleeve. Confirm that gap in
sleeve splines aligns with corresponding gap in
camshaft
splines (arrows).
Slide splined shaft onto exhaust camshaft. Be sure that locat-
ing tooth of shaft fits into spline gaps of camshaft and splined
sleeve
(arrows).
- Push splined shaft in further to rotate splined sleeve until the
three threaded holes in primary chain sprocket are centered
in the small slots of the splined sleeve.
4 Place intake and exhaust sprockets in BMW special tool 11 6
180. Position spline gap on intake sprocket (arrow) as shown
and place secondary chain on sprockets.

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113-51
Cylinder Head Removal and Installation
< Pull out exhaust camshaft splined shaft to stop.
- Press down on secondary chain tensioner and remove ten-
sioner lock-down tool.
Preload primary chain:
Tighten adjusting screw on
BMW special tool 11 4 220 to
specified torque.
Tightening torque
Primary chain tensioner preload
0.7 Nrn (6 in-lb)
< Preload exhaust camshaft sprrng plate by pressing on im-
pulse wheel while tightening mounting nuts (arrows) finger
tight.
Install BMW special tool 11 6 150 (VANOS setup bracket) to
front of cylinder head timing case. Install nuts (arrows) finger
tight, then tighten down uniformly until special tool is in full
contact with cylinder head.
CAUTION-
Make sure all gasket material is removed from face of cylin-
der head. Clean sealing
face and keep free of oil. If any for-
eign material is present on the sealing
sudace, the camshait
timina will be incorrect.

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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 I
4 Rotate crankshaft vibration damper to TDC position. Right
head camshaft lobes for number one cylinder should be in
position shown (arrows).
Working at right cylinder head (passengers side) loosen re-
maining
sprocltet fasteners (arrows) on both intake and ex-
haust camshafts approximately
'/? turn.
4 Loosen and remove primary timing chain tensioner (arrow)
from upper timing chain cover on right head.

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11 3-70
Cylinder Head Removal and Installation
- Remove adjustable timing chain tensioner tool from timing
case cover and install primary timing chain tensioner with
new sealing washer.
Tightening torque Chain tensioner cylinder to timing cover
65 Nm (48 ft-lb)
4 Install oil supply lines and mounting nuts (arrows) to both
heads.
Tightening torque
Oil supply line nuts 10 Nm (7.5 ft-lb)
- Remove old gasket from lefl timing cover, and clean gasket
surface.
4 Apply Three Bond 1209 8 sealant to joint between cylinder
head and timing cover (arrows).
Using a new gasket, install lefl timing cover with lower inner
fastener inserted in cover (arrow). Position cover in place
and tighten cover fasteners finger tight.
NOTE-
It is not possible to install lower inner fastener after cover is
in place.

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1 13-75
Cylinder Head Removal and Installation I
4 Loosen and remove primary timing chain tensioner (arrow)
from right cylinder head.
Remove camshaft position sensor (arrow)
chain cover on right cylinder head.
Remove dip
stick tube support fastener. from
upper
Remove upper timing chain cover fasteners
(A) and
cover from right cylinder head. timing
remove

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-8" ."
Cylinder Head Removal and Installation --
Using crankshaft center bolt, rotate engine clockwise from
the
45" before TDC up to TDC position (OIT aligns with cast-
ing mark on cylinder block).
< Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Special tool boss located at the rear of upper engine oil pan.
- Working at right cylinder head (cylinder 5-8) fit primary
sprocltet and chain to camshaft flange.
!
I
4 Press timing chain tensioner rail against timing chain (white
arrow) to check that fastener holes are centered in sprocket
slots (black arrows).
NOTE-
If necessary, remove sprocl Fit sensor gear with mark pointing up (arrow).
Insert bolts and hand tighten.

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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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Cylinder Head Removal and Installation 1
Replace sealing O-ring (arrow) in right cylinder head before
installing upper timing chain cover.
4 Install oil supply lines and mounting nuts on both heads (ar-
rows).
- Using a new gasket, install upper timing chain cover on right
head and tighten cover fasteners finger tight.
4 Remove right cylinder head cover gasket and install spacing
tool
(BMW 11 1 41 1) in place of gasket.
- Install right cylinder head cover fasteners and tighten uni-
formly in
'1, turn steps.
Tightening torque Cylinder head cover fasteners
10 Nm (7.5 ft-lb)
- Tighten right upper timing cover retaining fasteners in two
passes.
I Tightening torque
Upper timing chain cover
10 Nm (7.5 ft-lb)
- Reinstall primary timing chain tensioner with new sealing
washer.
Tightening torque
Chain tensioner to timing cover
65 Nm (48 ft-lb)
- Remove right cylinder head cover and remove special spac-
ingtooi 11 4411.

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/cylinder Head and Valvetrain
Secondary timing chain tensioner locking pin set (6-cylinder)
- 4 Secondary timing chain tensioner locking pin (V-8)
(Tool No. BMW
11 3 310)
4 Adjustable primary timing chain tensioner tool (V-8)
(Tool No. BMW
11 3 390)
4 Camshaft installation tool (V-8)
(Tool No.
BMW 11 3 430)
4 VANOS compressed air fitting
7 (Tool No. BMW 11 3 450)
Adjustable primary timing chain tensioner tool (6-cylinder) (Tool No. BMW
11 4 220)