timing chain BMW 540i 2001 E39 Owner's Manual

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Cylinder Head Removal and Installation
4 While maintaining tension on timing chain, rotate crankshaft
at vibration damper from
30" before TDC in direction of rota-
tion (clockwise) until number
1 cylinder is at TDC position
with line between the
OIT (arrow) on front pulley lined up
with boss on lower timing chain cover.

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1 13-46
Cylinder Head Removal and Installation
Double
VANOS Timing
Chain Components
1. Impulse wheel mounting nut
2. Exhaust camshaft impulse
wheel
3. Spring plate, exhaust
4. Thrust spacer (T
= 3.5 mm)
5. Splined shaft
6. Torx screw
7. Exhaust camshaft secondary
sprocket
8. Secondary timing chain
9. Splined sleeve
10. Primary sprocket
11. Threaded locating stud
12. Secondary chain tensioner
13. Secondary chain lower guide
14. Sprocket mounting nut
15. Spring plate, intake
16. Splined shaft
17. lntakecamshaft sprocket
18. Locating stud
19. Thrust spacer
20. Intake camshaft impulse wheel
Double VANOS timing chain components,
installing,
M52 TU and M54 engines -
4 Slide impulse wheel on intake camshaft, aligning boss with
raised portion on camshaft
(arrow).

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Cylinder Head Removal - an-]
Fit thrust spacer (A) to intake camshaft (B) and tighten down
with threaded locating studs. Place longer threaded end of
studs into camshaft
(arrows).
Tightening torque
Impulse
wheel studs to intake camshaft) 20 Nm (15 ft-lb)
Fit primary sprocket to primary timing chain and install on ex-
haust camshaft so that pointer on sprocket
(arrow) lines up
with cylinder head sealing surface.
4 Insert BMW special tool 11 4 220 into timing chain tensioner
bore and bring center spindle into contact with tensioning rail.
Tighten until slack is removed, but do not pretension timing
chain.
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the tensioner.
- Rechecic arrow on primary sprocket is aligned with upper
edge of cylinder head. Reposition sprocket if necessary.
Insert and tighten down threaded locating studs
(arrows) in
end of exhaust camshaft. Note installed position of studs.
Tightening torques Exhaust camshaft locating stud
20 Nm (15 ft-lb)

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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
Secure camshaft sprockets and impulse wheels:
Tighten mounting screws
(A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Tighten mounting nuts
(8) on exhaust and intake sprocket
assemblies to approx.
5 Nm (44 in-lb).
Torque down mounting screws (A) and nuts (B) to final
specifications.
Tightening torques
sprocket assembly to camshaft
initial torque
5 Nm (44 in-lb)
Sprocket assembly
wheel to camshaft
M7 torx screws (A) 20 Nm (15 ft-lb)
M6 mounting nuts (5) 10 Nm (8 ft-lb)
- Remove crankshaft locking tool from transmission bell hous-
ing so that crankshaft is no longer secured in
TDC position.
- Remove camshaft locking tools from cylinder head.
4 Turn engine over twice in direction of rotation until cylinder 1
intake and exhaust camshaft lobes (arrows) face each other.
- Secure crankshaft in TDC position with BMW special tool 11
2 300.
4 Place BMW special tool set 11 3 240 over camshafts and
measure clearances.
CAUTION-
- If the exhaust side of the tool (A) is not flush with tlie head,
camshaft timing is incorrect Reset camshaft timing as de-
scribed in
117 Camshaft Timing Chain.
* Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft tim-
ing is set correctly, the intake side of special tool
11 3
240 (6) may be up to 1 mm (0.04 in.) above the surface
of the cylinder head. This is normal. Reassemble en-
gine.
Othe~lise, reset camshaft timing as described in
11 7 Camshaft Timing Chain.
- Remove BMW special tool 11 6 150 from front of cylinder
head.

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Cylinder Head Removal and Installation /
< Clean contact edges of cylinder head face and VANOS unit
and apply a thin coat of permanently elastic Three Bond
1209 8 or equivalent to suriaces.
CAUTION-
Check locating dowel (A) and dowel sleeve (B) at top of
cylinder head for damage or incorrect installation.
Make sure all gasket material is removed from face of
cylinder head. Clean sealing face and keep free of oil.
If any foreign material is present on the sealing surface,
the camshaft timing will be incorrect.
- Install new steel gasket to front of cylinder head and install
VANOS unit.
NOTE -
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in
11 7 Camshaft Tim-
ing Chain.
- Reinstall engine lifting eye.
Tightening torque
VANOS unit to cylinder head
M6 nut
M7 nut
lo Nm (89 in-lb)
14 Nrn (10 it-lb)
- Reconnect electrical harness connectors to camshaft posi-
tion sensors and VANOS solenoid valves.
4 Insert and tighten down VANOS hydraulic piston set screws
in splined shafts on
intake and exhaust camshafts.
CAUJION-
Set screws have left hand tliread. Tighten counterclockwise.
Tightening torque
Hydraulic piston
to splined shaft 10 Nm (89 in-lb)
< Replace sealing caps inside VANOS unit with short needle
nose pliers.

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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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1 13-64
Cylinder Head Removal and Installation
< Remove upper timing chain cover fasteners (A) and cover
from left cylinder head.
4 Remove fasteners from intake camshaft sprocket (arrows)
on left cylinder head.
- Remove primary timing chain sprocket and suspend timing
chain using mechanics wire to prevent chain from dropping
into lower housing.
Turn crankshaft counterclockwise until
45" mark on crank-
shaft is aligned with boss on front timing chain cover
(arrow).

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11 3-69
Cylinder Head Removal and Installation
4 Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Boss for special tool 11 3 200 located at rear of engine oil
pan.
4 Working at left cylinder head (driver's side) fit primary sprock-
et and chain to camshaft flange, centering threaded bores.
Insert bolts (arrows) and hand tighten.
?-I I 4 Install BMW special tool 11 3 390 into right timing case cover.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
I - Tighten sprocket retaining bolts in the following order:
All bolts on left cylinder head exhaust camshaft
3 accessible bolts on right cylinder head exhaust camshaft
All bolts on left cylinder head
intake camshaft
3 accessible bolts on right cylinder head intake camshaft r"".."..7n
Tightening torques
Sprocltet bolts to camshait 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 right cylinder head cam-
shafts. Tighten remaining bolts.
Tightening torques Sprocket bolts to camshaft flange 15 Nm
(11 ft-lb)