BMW 3 Series Service Manual (E39)

110-19

Engine Removal and Installation

M62 engine, remove ASC throttle body.

- Disconnect ASC actuator cable (arrow).

.Remove mounting fasteners and remove throttle body.

On front of left side cylinder head, disconnect electrical harness connector (A), and removeand plugfuel tank vent valve vacuum line (0) .

Raise car and support in a safe manner.

CAUTION-

Male sure the car is stable and well supportedat aN times. Usea professionalautomotivelifiorjackstands designedfor

I the ouroose. A floor jack is not adequate support.

Working- beneath car:

Remove engine splash shield.

Remove right and left heat shield from front suspension subframe.

Working underneath engine compartment, disconnect ground cable on right side engine mount (arrow).

--

<lnstall engine lifting device (BMW 11 0 000 or equivalent) to front and rear engine supports and raise engine until it's weight is supported. Detach engine mounts.

aWatch carefully for hoses and electrical wires that might snag.

-installation is reverse of removal:

Replace all gaskets, O-rings and seals.

V-8 engine mounts have two sets of mounting holes. E39 cars use front most mounting holes.

*On cars with automatic transmission, use new O-rings at ATF cooler lines.

Use new alignment sleeves when installing transmission.

Be sure engine drive belts properly engage pulley grooves. When installing belt, preload tensioner to stop (toward belt), then tighten tensioner clamping nut.

lnstall front exhaust pipes using new gasltets and copper paste and new mounting hardware. See 180 Exhaust System.

Change engine oil and filter. Check all other fluid levels as described in 020 Maintenance.

Refill and bleed cooling system as described in 170 Radiator and Cooling System.

CAUTION-

Do not interchangeknoclc sensor harness connectors. Serious engine damage may result

113-2

Cylinder Head Removal and Installation

This group covers cylinder head removal and installation as well as cylinder headlvalve diagnostic procedures.

Inthe procedures in this repair group, engines are referred to by engine code. If necessary, see 100 Engine-General for engine code and application information.

The information given in this repair group assumes that the engine is installed in the engine bay. On the 6-cylinder en- gines, the VANOS control unit must be removed in orderto remove the cylinder head from the engine block. On M52TU and M54 engines, camshafts must be removed from the cylinder head before the head is removed.

The cylinder head removal and installation procedures for the

M62 V-8 are also included, butthe proceduresforthe M62TU

V-8 with VANOS are not provided.

For cylinder head and valvetrain reconditioning information, see 116 Cylinder Head and Valvetrain.

For specific repair procedures, refer to the appropriate repair group:

020 Maintenance

116 Cylinder Head and Valvetrain

117 Camshaft Timing Chain

170 Radiator and Cooling System

610 Component locations

NOTE-

I fa headgasket problem issuspected, a compression test or leak-down test will usually detect the fault See Diagnostic Testing later in this group.

Special tools

Special BMW service tools are required to properly remove and install the cylinder head on engines covered by this manual. The special tools are used to time the valvetrain to the crankshaft, and to remove the VANOS control unit, the camshafts and the Tom (El2) head bolts. Read the entire procedure through before beginning the job.

113-4

Cylinder Head Removal and Installation

4 Camshaft locking tools (cyl. 5-8), V-8

(Tool No. BMW 11 2 442111 2 446111 2 443111 2 444)

4 Camshaft loclting tools (cyl. 1-4), V-8

(Tool No. BMW 11 2 445111 2 441111 2 443111 2 444)

4 Timing chain adjustable tension setup tool, V-8 (Tool No. BMW 11 3 390)

Secondary timing chain tensioner loclting pin, V-8 (Tool No. BMW 11 3 310)

4 Hydraulic lifter securing plugs (Tool No. BMW 11 3 250)

< Camshaft bearing cap tensioner (6-cylinder) for camshaft removal and installation

(Tool No. BMW 11 3 260111 3 270)

4 Secondary timing chain tensioner loclt set (Tool No. BMW 11 3 291111 3 292)

113-5

Cylinder Head Removal and InstallationI

<Fuel line plugs

(Tool No. BMW 13 5 281113 5 282)

4 Fuel line removal tool for quick-disconnect fittings (Tool No. BMW 16 1 050)

<Tensioning bracket (V-8) (Tool No. BMW 11 7 380)

Compressed air fitting for testing VANOS operation ((Tool No. BMW 11 3 450)

<Upper timing cover installation tool set, V-8 (Tool No. BMW 11 1 410)

Cylinder compression, checking

A compressiongauge is needed to make a compression test. For accurate test, the battery and starter must be capable of cranking the engine at least 300 rpm, and the engine should be at normal operating temperature.

NOTE-

Performinga compression test may cause a fault to set in the ECMand may illuminate the Malfunction Indicator Light (MIL). The light can only be turned out using either BMW special service scan tools or an equivalent aftermarketscan tool. Disconnecting the battery will not erase the fault memory or turn out the light. See OBD On-Board Diagnostics.

113-6

Cylinder Head Removal and Installation

-Disable ignition system by removing DME main relay. See 610 Component Locations for relay location.

.WARNING-

The ignition system produces high voltages that can be fatal. Avoid contact with exposed terminals and use exfreme caution when working on a car with the ignition switched on or the engine running.

Do not touch or disconnect ignition components while the engine is running or being cranked by the starter.

Failure to remove the DME main relay or attempting to disabie the fuel andignition systems by other methods may result in damaoe to the enoine control module (ECM).

- - Remove plastic cylinder head cover(s)

,.,. .*,,.,,&-I - Remove coil grounding straps.

-Remove coils.

-Remove spark plugs from all cylinders.

NOTE-

Check the spark plugs for oil deposits that may indicate poor cylinder sealing, then set them aside in order. Used spark plugs should be reinstalled in the same cylinder from which they were removed.

4 Install compression gauge in first cylinder spark plug hole, tight enough to form a good seal.

-With parking brake set, transmission in PARK or NEUTRAL, and accelerator pedal pressed to floor, crank engine with starter. Record highest value indicated by gauge.

NOTE-

*The compression gauge reading should increase with each compression stroke and reach near its maximum reading in about 4-6 strokes.

All cylinders should reach maximum compression in the same number of strolces. If a cylinder needs significantly more strokes to reach maximum compression, there is a problem.