11 12 105 Removing and installing left cylinder head (M62 up to 9/98)

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

(Cylinder bank 5-8)

Remove left exhaust manifold, refer to 11 62 142 REMOVING AND INSTALLING OR REPLACING BOTH EXHAUST MANIFOLDS ON LEFT (M62 TO 9/98) .

Unfasten drain plug for coolant on left engine block.

Drain and dispose of coolant.

Installation

Replace sealing ring.

Tightening torque, refer to 11 11 5AZ in ENGINE - TIGHTENING TORQUES - 540i .

Bleed cooling system and check for water leaks, refer to 17 00 039 BLEEDING COOLING SYSTEM AND CHECKING FOR WATER LEAKS

Remove both cylinder head covers, refer to 11 12 004 REMOVING AND INSTALLING/SEALING BOTH CYLINDER HEAD COVERS (M62) .

Remove spark plugs, refer to 12 12 011 REPLACING ALL SPARK PLUGS (M60, M62) .

Remove coolant manifold, refer to 11 53 325 REMOVING AND INSTALLING/REPLACING COOLANT MANIFOLD (M62) .

Remove oil lines on left and right of cylinder head.

Fig 1: Removing Oil Lines On Left And Right Of Cylinder Head

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Removal

Removal of cylinder head is described separately from installation. Assembly sequence for removal and installation is different.

Crank engine at central bolt in direction of rotation until the first cylinder is in TDC position.

Unfasten the accessible three screws on exhaust and intake camshafts on cylinder bank 1-4 approx. 1/2 a turn.

Fig 2: Identifying Camshaft Screws

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Fig 3: Unfastening Accessible Three Screws On Exhaust And Intake Camshafts On Cylinder Bank

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Crank engine once enginewise up to TDC position of first cylinder.

Fig 4: Identifying TDC Position Of First Cylinder

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NOTE: When unfastening screw connection on camshaft, brace camshaft on hex head.

CAUTION: Do not damage the cylinder head.
If necessary, machine open-end wrench accordingly.

Fig 5: Unfastening Screw Connection On Camshaft By Bracing Camshaft On Hex Head

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Unfasten remaining three screws on exhaust and intake camshafts on cylinder bank 1-4 approx. 1/2 a turn.

Fig 6: Unfastening Remaining Three Screws On Exhaust And Intake Camshafts On Cylinder Bank

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Remove piston for chain tensioner, refer to 11 31 090 INSTALLING AND REMOVING / REPLACING PISTON FOR CHAIN TENSIONER (M62) .

Remove timing case cover, top left, refer to 11 14 080 REMOVING AND INSTALLING TIMING CASE COVER, TOP LEFT (M62 VANOS FROM 9/98) .

Remove sprocket on left intake camshaft (cylinder bank 5-8).

Secure chain to prevent it from dropping.

Fig 7: Removing Sprocket On Left Intake Camshaft

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Turn engine on central screw counter-enginewise up to 45° before TDC position.

Note markings!

Fig 8: Turning Engine On Central Screw Counter-Enginewise

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Loosen grub screw.

NOTE: Grub screw secures the angle bracket (1) in the cylinder head.

Fig 9: Loosening Grub Screw

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Unfasten guide rail and retaining screw for oil separator.

Removal

Fig 10: Unfastening Guide Rail And Retaining Screw For Oil Separator

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Lift oil separator out of angle bracket.

CAUTION: When lifting the cylinder head, press oil separator outwards.

Fig 11: Lifting Oil Separator Out Of Angle Bracket

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Release cylinder-head bolts in sequence 10... 1.

Lift off cylinder head.

Fig 12: Releasing Cylinder-Head Bolts

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Installation

Installation of cylinder head is described separately from removal. Assembly sequence for removal and installation is different.

Clean sealing faces of cylinder head and engine block, if necessary using wooden scraper to remove gasket debris. Ensure that no gasket debris drops into the oil and coolant ducts.

Threaded bores in engine block must be free of dirt and oil (risk of cracking).

Coat joint between engine block and timing case cover with Drei Bond 1209.

Fig 13: Coating Joint Between Engine Block And Timing Case Cover With Drei Bond

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Check that dowel sleeves are undamaged and correctly located.

Fit new cylinder-head seal.

Fig 14: Fitting New Cylinder-Head Seal

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CAUTION: When fitting cylinder head, press oil separator outwards.

Fig 15: Pressing Oil Separator Outwards

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Fit cylinder head and install new cylinder head screws.

Do not wash off screw coating.

NOTE: Use special tool 00 9 120 as a torsion angle bracket.

Fig 16: Using Special Tool 00 9 120 As A Torsion Angle Bracket

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Tighten down cylinder head screws in sequence 1... 10.

Tightening torque, refer to 11 12 8AZ in ENGINE - TIGHTENING TORQUES - 540i .

Fig 17: Tightening Down Cylinder Head Screws

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Ensure that oil return pipe is correctly seated in oil separator.

Fig 18: Identifying Position Of Oil Return Pipe

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Check sealing ring in angle section, replace if necessary.

Press oil separator into angle section.

Tighten guide rail and retaining screw for oil separator.

Fig 19: Tightening Guide Rail And Retaining Screw For Oil Separator

Courtesy of BMW OF NORTH AMERICA, INC.

Replace grub screw.

Insert grub screw only until it makes contact with angle section (1) without play; do not tighten down.

NOTE: Grub screw secures the angle bracket (1) in the cylinder head.

Fig 20: Identifying Grub Screw Location

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Align camshafts with open-end wrench.

CAUTION: Do not damage the cylinder head.

Fig 21: Aligning Camshafts With Open-End Wrench

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Fit special tool 11 2 445 / 441 to camshafts on cylinder bank 1-4.

Fig 22: Fitting Special Tool

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NOTE: In TDC position of first cylinder, marker bores of camshafts point upwards.

Fig 23: Identifying Marker Bores Of Camshafts

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Fit special tool 11 2 446 / 442 to camshafts on cylinder bank 5-8.

Fig 24: Fitting Special Tool

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NOTE: In TDC position of first cylinder, marker bores of camshafts point upwards.

Fig 25: Identifying Marker Bores Of Camshafts

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Align all camshafts with open-end wrench in such a way that special tools 11 2 445 / 441 / 446 / 442 fit on cylinder heads with no gaps.

CAUTION: Do not damage the cylinder head.

Fig 26: Aligning Camshafts With Open-End Wrench

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Fit special tool 11 2 443 to special tool 11 2 445 / 441 and secure with special tool 11 2 444 using the spark plug thread.

Fig 27: Fitting Special Tool

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Fit special tool 11 2 443 to special tool 11 2 446 / 442 and secure with special tool 11 2 444 using the spark plug thread.

Fig 28: Fitting Special Tool

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Crank engine from the 45° before TDC position in direction of rotation up to TDC position.

Secure crankshaft in TDC position with special tool 11 2 300.

CAUTION: Remove special tool 11 2 300 before starting engine.

Fig 29: Securing Crankshaft In TDC Position With Special Tool

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Fit sprocket with chain to intake camshaft on cylinder bank 5-8 with long bores aligned centrally.

Fit screws with no clearance.

Fig 30: Locating Screws With No Clearance

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Install special tool 11 3 390 in right timing case cover.

Fig 31: Installing Special Tool In Right Timing Case Cover

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Tighten bow cover by turning the adjusting screw on the special tool 11 3 390 with special tool 00 9 250 to 0.7 Nm.

NOTE: If installation tolerance is unfavorable, attach special tool 00 9 250 from underside.

Fig 32: Tightening Bow Cover By Turning Adjusting Screw

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Tighten sprockets in the following order:

All screws on exhaust camshaft, left
Three screws on exhaust camshaft, right
All screws on inlet camshaft, left
Three screws on inlet camshaft, right

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES - 540i .

Remove special tools 11 2 444 / 443 / 441 / 445.

Fig 33: Removing Special Tools 11 2 444 / 443 / 441 / 445

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Remove special tools 11 2 44 / 443 / 442 / 446.

Fig 34: Removing Special Tools 11 2 44 / 443 / 442 / 446

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Remove special tool 11 2 300.

Turn over engine once.

Tighten down remaining three screws on exhaust and intake camshafts on cylinder bank 1-4 firmly.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES - 540i .

Fig 35: Identifying Three Screws On Exhaust And Intake Camshafts

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Install oil lines on left and right of cylinder head.

Fig 36: Installing Oil Lines On Left And Right Of Cylinder Head

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Loosen special tool 11 3 390 and remove.

Install chain tensioning piston, refer to 11 31 090 INSTALLING AND REMOVING / REPLACING PISTON FOR CHAIN TENSIONER (M62) .

Install timing case cover, top left, refer to 11 14 080 REMOVING AND INSTALLING TIMING CASE COVER, TOP LEFT (M62 VANOS FROM 9/98) .

Assemble engine.

Fig 37: Loosening & Removing Special Tool 11 3 390

Courtesy of BMW OF NORTH AMERICA, INC.