11 12 106 Removing and installing right 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 1-4)

Remove right exhaust manifold, refer to 11 62 143 REMOVING AND INSTALLING OR REPLACING BOTH EXHAUST MANIFOLDS ON RIGHT (M62 TO 9/98) .

Unfasten drain plug for coolant on right engine block.

Drain and dispose of coolant.

Installation

Replace sealing ring.

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

Vent cooling system and check for 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 fan clutch with impeller, refer to 11 52 020 REMOVING AND INSTALLING OR REPLACING FAN COUPLING (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.

Fig 2: Cranking Engine Until First Cylinder Is At TDC

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Unfasten the accessible three screws on exhaust and inlet camshafts on cylinder bank 5 to 8 approx. 1/2 a turn.

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

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

Fig 4: Cranking Engine Once Enginewise Up To 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: Bracing Camshaft On Hex Head

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Unfasten remaining three screws on exhaust and inlet camshafts on cylinder bank 5 to 8 approx. 1/2 a turn.

Fig 6: Unfastening Remaining Three Screws On Exhaust And Inlet Camshafts On Cylinder Bank 5 To 8

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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 right, refer to 11 14 085 REMOVING AND INSTALLING TIMING CASE COVER, TOP RIGHT (M62 VANOS FROM 9/98) .

Remove sprocket on right inlet camshaft (cylinder bank 1 to 4).

Secure chain to prevent it from dropping.

Fig 7: Removing Sprocket On Right Inlet 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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Release cylinder-head bolts in sequence 10... 1.

Lift off cylinder head.

Fig 9: 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 (danger of cracking).

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

Fig 10: Coating Joint Between Engine Block And Timing Case Cover With Drei Bond 1209

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Check that dowel sleeves are undamaged and correctly located.

Fit new cylinder-head seal.

Fig 11: Fitting New Cylinder-Head Seal

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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 12: Installing New Cylinder Head Screws Using Special Tool 00 9 120

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

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

Fig 13: Tightening Down Cylinder Head Screws

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Align camshafts with open-end wrench.

CAUTION: Do not damage the cylinder head.

Fig 14: Aligning Camshafts With Open-End Wrench

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

Fig 15: Fitting Special Tool 11 2 445 / 441 To Camshafts On Cylinder Bank 1 To 4

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

Fig 16: Identifying Marker Bores Of Camshafts

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

Fig 17: Fitting Special Tool 11 2 446 / 442

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

Fig 18: Identifying Marker Bores Of Camshafts

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Align all camshafts with open-end wrench in such a way that special tools 11 2 441 / 445 / 446 / 442 locate firmly against cylinder heads.

CAUTION: Do not damage the cylinder head.

Fig 19: Aligning All 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 20: Fitting Special Tool 11 2 443 To Special Tool 11 2 445 / 441 And Secure With Special Tool 11 2 444

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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 21: Fitting Special Tool 11 2 443 To Special Tool 11 2 446 / 442 And Secure With Special Tool 11 2 444

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

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

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

Fig 22: Holding Crankshaft In TDC Position With Special Tool 11 2 300

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Fit sprocket with chain to inlet camshaft on cylinder bank 1 to 4 with long bores aligned centrally.

Brace sprocket, press bow cover against the timing chain and check the position of the long bores.

If necessary, remove sprocket once again and align position of long bores centrally.

Fig 23: Identifying Sprocket With Chain

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Fit sensor gear with mark on sensor gear in cylinder shaft pointing upwards.

Insert screws and fit flush.

Fig 24: Fitting Sensor Gear With Mark On Sensor Gear

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Attach special tool 11 7 380 to right cylinder head (cylinder bank 1 to 4).

Fig 25: Attaching Special Tool 11 7 380

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Install special tool 11 3 390 in special tool 11 7 380.

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 26: Tightening Bow Cover By Turning The Adjusting Screw

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Tighten sprockets in the following order:

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

Tightening torque, refer to 11 31 4AZ in ENGINE - TIGHTENING TORQUES - 540i .

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

Fig 27: Removing Special Tools 11 2 444 / 443 / 441 / 445

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Remove special tools 11 2 444 / 443 / 442 / 446.

Fig 28: Removing Special Tools 11 2 444 / 443 / 442 / 446

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Remove special tool 11 2 300.

Turn over engine once.

Tighten down remaining three screws in exhaust and intake camshafts on cylinder bank 5-8.

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

Fig 29: Tightening Down Remaining Three Screws In Exhaust And Intake Camshafts

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Install oil lines on left and right of cylinder head.

Fig 30: Installing Oil Lines On Left And Right Of Cylinder Head

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Relieve load on special tool 11 3 390 and remove with special tool 11 7 380.

Install timing case cover, top right, refer to 11 14 085 REMOVING AND INSTALLING TIMING CASE COVER, TOP RIGHT (M62 VANOS FROM 9/98) .

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

Assemble engine.

Fig 31: Removing Special Tool

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