Engines: Other BMW 5 series E39

FUEL PRESSURE RELEASE

Fuel system pressure release procedure is not available at time of publication. Disconnect negative terminal of fuel pump connector, under left rear side of vehicle. It may also be possible to remove fuel pump relay, start engine and run engine until fuel pressure drops (engine stalls).

Fuel pump relay is located on right rear corner of engine compartment, next to DME control unit and DME master relay.

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Note. Remove transmission before removing engine. For vehicles with automatic transmissions, see TRANSMISSION REMOVAL & INSTALLATION - A/T article in AUTOMATIC TRANS SERVICE section or TRANSMISSION REMOVAL & INSTALLATION - M/T article in MANUAL TRANS SERVICE section.

Scheme 20

CAMSHAFT

Note. Intake or exhaust camshaft may be replaced with engine installed in vehicle.

Scheme 21

Scheme 22

1. Release hinge at hood, and prop hood open past center position. On all models, remove side rivets, and pull out radiator cooling fan cowl. Using 32-mm Wrench (11-5-040) and Pulley Holder (11-5-030), turn cooling fan nut clockwise to remove cooling fan.
2. Remove grille from fresh air intake duct, below wiper arms. Remove screws and electrical lead along fresh air intake duct. Remove right holder and fresh air intake duct.
3. On all models, remove oil filler cap, screw caps, screws and engine covers. Remove ignition coil ground strap from timing case cover. Remove ignition coil cover plate. Disconnect wiring from ignition coils, and remove plate together with wiring. Remove ignition coils.
4. Detach hose at cylinder head breather vent. Remove cylinder head cover. Remove pulse sensor from side of timing case cover. Remove wiring harness duct located directly above thermostat housing.
5. Remove engine lift bracket and upper timing case cover. Pull off camshaft cover. With cylinder No. 1 coming up on TDC, turn crankshaft in normal direction of rotation until cylinder No. 1 intake and exhaust cam lobes face each other. Arrows on sprockets should face up. NOTE: If camshaft position has to be turned so much that valves on 1st and 6th cylinders are moved, first turn crankshaft 30 degrees in normal direction of rotation past TDC. This will keep valves from contacting pistons. After aligning camshafts, turn crankshaft back to TDC position.
6. Remove valve cover mounting studs. Use Camshaft Locating Fixture (11-3-240) to align and hold camshafts. (Scheme 25)or see scheme 3. Camshafts may be turned using a 27-mm open end wrench. Use TDC Aligning Plug (11-2-300) to hold crankshaft in TDC position.
7. Remove timing chain tensioner from side of timing case cover. Press down on upper chain tensioner and hold in place using Spring Holder (11-3-290). see scheme 6 Remove timing chain sprockets and timing chain. (Scheme 21) See CYLINDER HEAD under REMOVAL & INSTALLATION.
8. Prepare Camshaft Fixture (11-3-260) and Adapter (11-3-270). (Scheme 22) Remove spark plugs from cylinder head. Mount and bolt fixture in spark plug holes. Tighten fixture bolts to 17 ft. lbs. (23 N.m). CAUTION: Camshaft may be damaged during removal/installation if fixture is not used. In addition, valves may be bent by contacting tops of pistons.
9. Load bearing caps by turning eccentric shaft on fixture. Remove bearing cap bolts. Slowly release load from bearing caps, and remove fixture. Lift out bearing caps and camshafts.
10. Hold hydraulic cam followers with an assistant or using Suction Cups (11-3-250). Lift out bearing plate complete with hydraulic cam followers. Inspect bearing surfaces of hydraulic cam followers for wear.

Note. Camshafts, camshaft bearing caps and camshaft bearing plates (journals) are marked with "A" for EXHAUST and "E" for INTAKE. Camshafts, camshaft bearing caps and camshaft bearing plates (journals) are marked with AD for EXHAUST and ED for INTAKE. Intake camshaft also has a notch cut into camshaft sprocket mounting flange.

Valves & Valve Springs

1. Remove cylinder head and camshaft. Remove valve springs, spring retainers and valve stem oil seals.
2. Determine valve seat depth by inserting valve in corresponding valve guide, measuring protrusion from valve stem to valve guide, and noting distance.
3. Machine valve seat. See VALVE SEATS. Insert same valve again, and measure protrusion from valve stem to valve guide, noting distance. Difference between two readings is amount of machining.

Valve Stem Oil Seals

Pull off valve stem oil seal. To install oil seals, place Assembly Sleeve (11-1-380) over valve stem. Lubricate valve stem oil seal, and install. Using Assembly Mandrel (11-1-200), press valve stem oil seal against stop.

Valve Guides

1. Insert a new valve in valve guide to be checked. End of valve stem must be flush with valve guide. Place dial indicator tip on side of valve head. Tilt valve from side-to-side to measure valve guide wear. Maximum tilt is 0.020" (0.50 mm).
2. If necessary, ream valve guide, and install a replacement valve with an oversize stem diameter of 0.004" (0.10 mm) or 0.008" (0.20 mm). Press reamer guide (cone) on valve seat, and ream out valve guide from combustion chamber side. Ream guide only once. Machine valve seat after reaming valve guide.

Valve Seats

1. Machine valve seats using Valve Seat Lathe (00-3-520) and Valve Seat Reseating Set (00-3-580), following instructions supplied with tools. After machining valve seat angle, produce valve seat diameter "B" and valve seat width "D" by machining correction angles "D" and "E" and countersinking "C". see scheme 22 See «VALVE SEAT CORRECTION ANGLES»(ref-49329-S35815670522001091300000) table.
2. If more than 0.008" (0.20 mm) is machined off valve seat, install a valve with a thicker valve head. See «OVERSIZE VALVES AVAILABLE»(ref-49329-S27146584932001091300000) table to determine available oversize valves.

Valve Seat Correction Angles

See VALVE SEATS. See VALVE SEAT CORRECTION ANGLES table.

Cylinder Head Height

1. Check flatness of cylinder head using a 0.0012" (0.03 mm) feeler gauge and straight edge. If necessary, machine cylinder head.
2. Ensure cylinder head height exceeds minimum cylinder head height. See «CYLINDER HEAD»(ref-49329-S20606601022001091300000) table under ENGINE SPECIFICATIONS.

Note. A .012" (0.30 mm) thicker cylinder head gasket is available for machined cylinder heads.

Fitting Pistons

1. Measure piston diameter about 33/64" (13 mm) from lower edge of piston skirt. Set dial indicator to zero using measured piston diameter.
2. Measure cylinder bore diagonally at bottom, middle and top of bore. Piston-to-cylinder wall clearance should be within specification. See «PISTONS, PINS & RINGS»(ref-49329-S21878614592001091300000) table under ENGINE SPECIFICATIONS.

Piston Rings

1. Measure piston ring end gaps. See «PISTONS, PINS & RINGS»(ref-49329-S21878614592001091300000) table under ENGINE SPECIFICATIONS. Install piston rings with word TOP facing up (top of piston crown). (Scheme 23)
2. Position piston ring gaps 120 degrees apart from each other, but DO NOT position gaps above piston pin eye. Measure piston ring side clearances.

Scheme 23

Connecting Rod & Bushing

1. Check connecting rod for parallelism and distortion. If connecting rod replacement is necessary, use only connecting rods of same weight.
2. Piston pin should pass through connecting rod bushing using only thumb pressure. If necessary, replace bushing. Press in bushing with gaps located at 135 degrees or 225 degrees from top.
3. Drill out oil at top of piston using a 0.236" (6 mm) bit, and deburr both edges of hole. Ream out connecting rod bushing to 0.8662-0.8665" (22.0005-22.010 mm).

Rod Bearings

1. Select connecting rod bearing shells matching color code on connecting rod. Use Plastigage to check connecting rod bearing oil clearance.
2. Oil clearance should be 0.0008-0.0022" (0.020-0.055 mm). Install new bearing shells or bearing shells with a different color code to correct oil clearance.

Crankshaft & Main Bearings

1. Main bearing caps are marked for location. Bearing cap No. 6 (thrust bearing) has a shoulder on side of cap. Ensure oil spray jets are installed in oil passages for bearings No. 2, 3, 4, 5, 6 and 7.
2. Use Plastigage to check connecting rod bearing oil clearance. Oil clearance should be 0.0008-0.0022" (0.020-0.055 mm). Install new bearing shells or bearing shells with a different color code to correct oil clearance.
3. Install upper bearing shells having same color code as dot on bearing support in crankcase. Install lower bearing shells having same color code as dot on crankshaft throw. Ensure grooves of bearing shell guide are located on same side.
4. Tighten lubricated main bearing cap bolts to 17 ft. lbs. (23 N.m). Using Torque Angle Gauge (11-2-110), tighten main bearing cap bolts an additional 50-degree torque angle.

Note. Reground crankshafts are marked with one or 2 stripes of paint. One stripe indicates crankshaft is .010" (.25 mm) undersize. 2 stripes indicate crankshaft is .020" (.50 mm) undersize. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Thrust Bearing

Bearing cap No. 6 has a shoulder on side of cap. Ensure thrust bearing and bearing cap No. 6 are installed in same location.

Oil Pressure

Oil pressure should be more than 7 psi (.5 kg/cm 2 ) at idle and 56 psi (4.0 kg/cm 2 ) at 3000 RPM.

Scheme 24

OIL PUMP

Note. A chain tensioner is used on oil pump drive chain. Tensioner is located next to crankshaft sprocket.

VALVE TRAIN SERVICING PRECAUTIONS

Note. Hydraulic cam followers expand when camshaft is removed and require a certain amount of time after installation before they compress.

1. If camshafts will be removed and installed without removing cylinder head from engine, turn crankshaft in normal direction of rotation about 30 degrees from TDC. This will keep valves from hitting pistons.
2. Install camshafts with lobes for cylinder No. 1 facing each other. Use Camshaft Locating Fixture (11-3-240) to align and hold camshafts. (Scheme 25)or see scheme 3. NOTE: Always wait specified time between installation of camshaft and installation of cylinder head. For procedures see «CYLINDER HEAD INSTALLATION WAITING TIMES»(ref-49329-S14429480822001091300000) table. CYLINDER HEAD INSTALLATION WAITING TIMES Temperature °F (°C) Minutes 68 (20) 4 50-68 (10-20) 11 32-50 (0-10) 30
3. Wait recommended time to permit hydraulic cam followers to compress. See «CYLINDER HEAD INSTALLATION WAITING TIMES»(ref-49329-S14429480822001091300000) table. Turn crankshaft back to TDC position.
4. Use TDC Aligning Plug (11-2-300) to hold crankshaft in TDC position. Install timing chain. Remove camshaft and crankshaft holders. Wait for at least 10 minutes before cranking engine. See «ENGINE CRANKING WAITING TIMES»(ref-49329-S39786264092001091300000) table.

Note. Engine may be cranked only after waiting specified time after installation of camshaft and timing chain. For procedures see ENGINE CRANKING WAITING TIMES table.

ENGINE CRANKING WAITING TIMES

Scheme 25