Engines: Removal & Installation BMW 5 series E39

Removal

1. Remove transmission. Remove engine splash guard. Disconnect battery cables, and remove battery. Remove battery tray.
2. Remove generator air intake duct. Disconnect wiring at air mass sensor. Remove air cleaner/airflow sensor assembly. Remove side rivets, and pull out radiator cooling fan cowl.
3. Using Pulley Holder (11-5-030) and 32-mm Wrench (11-5-040), turn cooling fan nut clockwise to remove cooling fan. Drain engine coolant. Plug is located on exhaust manifold side of engine block.
4. Disconnect radiator hoses, coolant level switch and transmission oil cooler lines (if equipped) from radiator. Remove trim next to radiator. Disconnect A/C temperature switch from side of radiator. Remove clips and radiator.
5. Disconnect coolant hoses from heater control valve and heater at engine compartment firewall. Remove nut, spacer and throttle cable cover. Disconnect throttle cable, and pull out cable together with rubber retainer.
6. Disconnect vacuum hose from power brake booster. Remove oil filler cap 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.
7. Detach hose at cylinder head breather vent. Disconnect wiring at air temperature sensor. Disconnect wiring, vacuum hoses and fuel lines at throttle body. Disconnect throttle valve switch. Disconnect vacuum hose from idle speed control valve (on manifold).
8. Disconnect hoses from fuel lines at engine carrier. Remove intake manifold from cylinder head. Disconnect wiring from temperature gauge, temperature sensor, oil pressure switch and idle speed control valve.
9. Disconnect wiring from cylinder identifying sensor and DME pulse sensor. Detach connector, for oxygen sensor, from holder. Disconnect wiring from starter and generator. Remove bolts and wiring harness duct. Set wiring harness aside.
10. Note serpentine belt routing. Insert socket into drive belt tensioner bolt. Compress tensioner by slowly rotating socket clockwise, and remove drive belt.
11. Remove bolts and power steering pump from engine. DO NOT disconnect power steering lines. Remove bolts and power steering pump oil supply tank. Hang power steering pump and oil tank aside.
12. Insert socket into A/C compressor drive belt tensioner. Compress tensioner by slowly rotating socket clockwise, and remove A/C compressor drive belt. Remove A/C compressor. DO NOT disconnect refrigerant lines.
13. Attach Engine Lifting Device (11-0-020) to engine lift points. Remove ground strap and right engine mount. Remove left engine mount nut. Remove engine from vehicle.

Installation

1. To install, reverse removal procedure. Ensure serpentine belt is correctly routed and properly seated in grooves. Turn 32-mm Wrench (11-5-040) counterclockwise, and tighten cooling fan nut to 22 ft. lbs. (30 N.m). NOTE: Tighten cooling fan nut to 29 ft. lbs. (40 N.m) if using a conventional 32-mm open end wrench.
2. Fill and bleed cooling system. To do so, add coolant to expansion tank and fill to level mark. Place A/C-heater control on WARM setting to ensure heater valve is open. Start and run engine at fast idle speed. Open bleed screw on expansion tank and continue to add coolant to expansion tank as coolant level drops. Tighten bleed screw as soon as coolant is free of air bubbles.

1. Remove engine splash guard. Disconnect negative battery cable.
2. Remove air cleaner/air mass sensor assembly. Drain engine coolant. Disconnect coolant hoses from heater control valve and heater at engine compartment firewall.
3. Remove generator air intake duct. Remove grille from fresh air intake duct, below wiper arms. Remove screws and electrical lead along fresh air intake duct. Remove right holder, left screw and fresh air intake duct.
4. Remove nut, spacer and throttle cable cover. On all models, disconnect throttle cable, and pull out cable together with rubber retainer. Disconnect vacuum hose from power brake booster.
5. Remove oil filler cap, screw caps, screws and engine covers. see scheme 1 If necessary, pull forward on cover and swing it out over oil filler neck. 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.
6. Detach hose at cylinder head breather vent. Disconnect wiring at air temperature sensor. Disconnect wiring, vacuum hoses and fuel lines at throttle body.
7. Disconnect vacuum hose from idle speed control valve (on manifold). Disconnect hoses from fuel lines at engine carrier. Remove intake manifold from cylinder head. (Scheme 2)

To install, reverse removal procedure. Ensure no parts fall into intake ports. Replace oval intake manifold gasket. Fill and bleed cooling system.

Scheme 2

Removal & Installation

Remove exhaust manifold flange bolts. Remove exhaust manifold. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS .

1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-49329-S14671528922001091300000) under REMOVAL & INSTALLATION. Remove thermostat housing. Disconnect wiring from ignition coils, and remove coils.
2. Remove cylinder head cover. Remove pulse sensor from side of cylinder head. Detach wiring harness duct above thermostat housing opening. Remove upper timing case cover and front engine lifting eye.
3. 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 face up. Use TDC Aligning Plug (11-2-300) to hold crankshaft in TDC position.
4. Install Camshaft Locating Fixture (11-3-240) to cylinder head. see scheme 25or (Scheme 3). Press down on upper chain tensioner and hold in place using Holding Spring (11-3-290). (Scheme 4)
5. Remove oil line connector and electrical connector from Variable Camshaft Control (VANOS). (Scheme 17) Remove upper timing chain cover with VANOS assembly. (Scheme 5)
6. Remove camshaft sprocket nuts (intake) and bolts (exhaust). Remove intake sprocket thrust washer. Remove upper camshaft sprockets and upper timing chain.
7. Remove upper chain tensioner. Remove chain guide directly below front end of camshaft. Remove lower timing chain tensioner plug, spring and piston. Remove lower chain sprocket from exhaust camshaft and tie up lower timing chain.
8. Remove 2 bolts directly below front end of camshaft. Use E12 Torx Bit (11-2-250) to loosen cylinder head bolts in several steps, starting from outside bolts and working toward inside (center) bolts. Remove cylinder head.

Note. Some cylinder head washers are staked into position.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Ensure cylinder head dowels are installed and not damaged. Remove oil from head bolt threaded holes in cylinder block. Lubricate threads of NEW head bolts. NOTE: A.012" (0.3 mm) thicker cylinder head gasket is available for machined cylinder heads.
2. Install cylinder head gasket. Wait for hydraulic cam followers to compress. See «VALVE TRAIN SERVICING PRECAUTIONS»(ref-49329-S37527673062001091300000). Install cylinder head. NOTE: When installing a new cylinder head, also use NEW washers, but DO NOT stake them into place.
3. Tighten NEW, lightly oiled cylinder head bolts to 24 ft. lbs. (33 N.m) in sequence. (Scheme 6) Use Torque Angle Gauge (11-2-110), E12 Torx Bit (11-2-250) and Guide Sleeve (11-2-113) to tighten head bolts to 90 degrees. Tighten cylinder head bolts to 90 degrees once again.
4. Ensure camshafts are aligned with Camshaft Locating Fixture (11-3-240). see scheme 25or (Scheme 3). Install lower timing chain on sprocket and install on exhaust camshaft.
5. Ensure arrow on exhaust camshaft sprocket is up and tapped holes are at left side of slots in sprocket. Finger tighten bolts.
6. Install Chain Adjusting Screw (11-3-390) to side of cylinder head. (Scheme 7) Tighten screw finger tight. Tapped holes in camshaft should now be centered in sprocket slots.
7. Install chain guide and upper chain tensioner. Install intake pulse sensing wheel (if removed). Install thrust washer bolts to intake camshaft. DO NOT mix bolts for cylinder head cover and sprockets. (Scheme 8)and (Scheme 9).
8. Install upper timing chain and sprockets to camshafts. Ensure that tapped camshaft holes are centered in sprocket slots. (Scheme 10) Install intake camshaft thrust washer and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49329-S42284370282001091300000).
9. Install thrust washer on exhaust camshaft and tighten bolts finger tight. Turn both sprockets clockwise as far as possible. (Scheme 11) Push splined gear of VANOS housing as far as stop. (Scheme 12)
10. Apply Sealant (3-Bond 1209) to top corners of cylinder head. Install, but DO NOT tighten, upper timing chain cover and VANOS assembly. (Scheme 13)
11. Turn VANOS splined shaft to engage splines on camshaft. Turn upper timing chain/sprockets counterclockwise until camshaft sprocket meshes with VANOS splined shaft. Push VANOS splined shaft into camshaft sprocket splines. (Scheme 14), (Scheme 15) and (Scheme 16).
12. Tighten upper timing chain cover and VANOS assembly nuts. Remove the Holding Spring (11-3-290) from upper chain tensioner. (Scheme 4) Tighten Chain Adjusting Screw (11-3-390) to 10 ft. lbs. (13 N.m). Tighten exhaust camshaft sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49329-S42284370282001091300000).
13. Remove Chain Adjusting Screw (11-3-390). (Scheme 7) Install timing chain tensioner with groove in piston perpendicular to tensioner rail. Remove TDC Aligning Plug (11-2-300) and Camshaft Locating Fixture (11-3-240) from engine.
14. Install VANOS Air Hose Adapter (11-3-450) to oil fitting and Jumper Harness (12-6-410) to the VANOS solenoid connector. (Scheme 17) Apply 28-110 psi (2.0-8.0 kg/cm 2 ) of air pressure to hose adapter.
15. Connect positive lead of jumper harness to positive terminal of battery and ground lead to negative terminal of battery. Using a vernier caliper, measure distance camshaft moves. (Scheme 18)
16. Camshaft sprocket should move.33-.49" (8.5-12.5 mm). If not, check VANOS assembly. Remove VANOS testing tools. Connect VANOS oil fitting and electrical connector. Ensure cylinder head cover gasket is correctly seated at rear of cylinder head. To complete installation, reverse removal procedure.

Scheme 17

Scheme 18

1. Install Flywheel Holder (11-2-170) to hold flywheel in place. If necessary, remove 6 bolts and vibration damper. Remove bolt, washer and vibration damper hub.
2. Remove crankshaft front seal. (Scheme 19) To install, reverse removal procedure. Use Seal Installer (11-3-280), hub bolt and washer to press in new seal.

Scheme 19

1. Remove timing chain and sprockets from cylinder head. See «CYLINDER HEAD»(ref-49329-S28616138062001091300000) under REMOVAL & INSTALLATION. Remove lower timing case cover. (Scheme 19) Fold down tensioner rail, and lift out timing chain.
2. Remove retainers and timing chain guide. Remove chain tensioner for oil pump timing chain. To install, reverse removal procedure.

1. Check centering sleeves on mounting bolts for bearing caps No. 2 and 7. Install camshaft so intake and exhaust valve camshaft lobes for cylinder No. 1 face each other. Install bearing plate complete with hydraulic cam followers. Install camshaft bearing caps.
2. Install fixture, and tighten fixture bolts to 17 ft. lbs. (23 N.m). Apply a load on bearing caps by turning eccentric shaft on fixture. Tighten bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49329-S42284370282001091300000) . Slowly release load, and remove fixture. Wait for hydraulic cam followers to compress. See «VALVE TRAIN SERVICING PRECAUTIONS»(ref-49329-S37527673062001091300000) .
3. Install exhaust camshaft timing chain sprocket with arrow pointing up and slots aligned with bolt holes at leftmost position. Ensure pulse sensor wheel is installed on intake camshaft.
4. Install camshaft sprockets and timing chain. See «CYLINDER HEAD»(ref-49329-S28616138062001091300000) under REMOVAL & INSTALLATION. Install and adjust VANOS assembly. See «CYLINDER HEAD»(ref-49329-S28616138062001091300000) under REMOVAL & INSTALLATION.
5. Install timing chain tensioner with groove in piston perpendicular to tensioner rail. Ensure cylinder head cover gasket is correctly seated at rear of cylinder head. To complete installation, reverse removal procedure.

1. Remove transmission. Use Flywheel Holder (11-2-170) to hold flywheel in place. If necessary, remove 6 bolts and clutch pressure plate. Remove flywheel. Remove crankshaft rear cover and seal.
2. With crankshaft cover removed, use Seal Installer (11-1-260) to install crankshaft rear seal. Place Sleeve (11-2-213) over crankshaft. Lubricate crankshaft rear seal, and slide cover into place. To complete installation, reverse removal procedure.

Note. Using Crankshaft Ball Bearing Installer (11-2-030) and Drift (00-5-000), install transmission shaft pilot bearing in crankshaft (if necessary).

Hold water pump pulley on drive belt and remove bolts. Remove drive belt and pump pulley. Remove water pump bolts. Use 2 metric (6 mm) bolts in water pump threaded holes to press water pump out. To install, reverse removal procedure. Lightly lubricate "O" ring, and install water pump.

1. Drain engine oil. Disconnect wiring from oxygen sensor. Detach wiring from holder at transmission crossmember.
2. Remove bolts and exhaust pipes from exhaust manifold. On vehicles with automatic transmission, remove crossmember for center of gravity suspension.
3. Remove bolts, and detach exhaust pipe from transmission holder. Detach rubber rings from exhaust pipes. Remove rearmost bolts and lower exhaust assembly downward.
4. On all models, release hinge at hood, and prop hood open past center position. Remove air cleaner/air mass sensor assembly.
5. Remove generator air intake duct. Remove rivets, and pull out radiator cooling fan cowl. Using Pulley Holder (11-5-030) and 32-mm Wrench (11-5-040), turn cooling fan nut clockwise to remove cooling fan. Remove clips at top of radiator.
6. Remove grille from fresh air intake duct. Remove electrical lead along fresh air intake duct. Remove right holder and fresh air intake duct.
7. Remove guide tube for engine oil dipstick. Note serpentine belt routing. Insert socket into drive belt tensioner bolt. Compress tensioner by slowly rotating socket clockwise, and remove drive belt.
8. Remove bolts and power steering pump from engine. DO NOT disconnect power steering lines. Remove bolts and power steering pump oil supply tank. Hang power steering pump and oil tank aside.
9. Insert socket into A/C compressor drive belt tensioner bolt. Compress tensioner by slowly rotating socket clockwise, and remove A/C compressor drive belt. Remove A/C compressor. DO NOT disconnect refrigerant lines.
10. Remove ground strap and right engine mount nut. Remove left engine mount nut. Loosen lower nuts on right/left engine mount. Attach Engine Holding Hoop (00-0-200) and Sling (00-0-204) to engine carrier. Raise engine as far as possible. Ensure wiring harness, ducts and hoses are not stretched or pinched.
11. On all models, remove oil pan bolts. Lower oil pan. Turn sprocket nut clockwise, and pull oil pump sprocket off splines. Remove bolts and oil strainer. Remove bolts and oil pump. Remove oil pan by pulling it rearward.

1. To install, reverse removal procedure. Use Elastic Sealing Compound (3 Bond 1027B) to fill joints between oil pan and front timing case and rear cover.
2. Tighten oil pump sprocket nut counterclockwise. Nut uses left-hand threads. Ensure serpentine belt is correctly routed and properly seated in grooves. Turn 32-mm Wrench (11-5-040) counterclockwise, and tighten cooling fan nut to 22 ft. lbs. (30 N.m).

Note. Tighten cooling fan nut to 29 ft. lbs. (40 N.m) if using a conventional 32-mm open-end wrench.

Removal & Disassembly

1. Remove oil pan. See «OIL PAN»(ref-49329-S10828349902001091300000) under REMOVAL & INSTALLATION. Turn oil pump sprocket nut clockwise to remove nut. Nut uses left-hand threads.
2. Carefully remove sprocket and chain. Remove oil pump. Locate oil pressure relief valve on oil pump housing. Lightly press down on oil pressure relief valve spring, and remove snap ring.
3. Remove oil pressure relief valve components. Remove oil pump pick-up tube. Remove pump shaft/rotor assembly. see scheme 24

Reassembly & Installation

To reassemble oil pump, reverse disassembly procedure. A gasket is used between oil pump housing and pick-up tube. Tighten oil pump sprocket nut counterclockwise.