BMW 3 Series Service Manual (E39)

Cylinder Head Removal and Installation/

4 Remove top engine cover by releasing quick release fasteners (arrows) by pressing down.

NOTE-

Earlier models may have an engine cover with pry off caps and fasteners Inplace of quick release fasteners.

4 Remove left and right interior ventilation ducts (left side -shown):

Release locking tabs (A) or locking strap (early models, not shown).

Release spring lock (B).

*Rotate duct inward (arrow) to remove.

Disconnect electrical harness from hood light switch (C). Release locking clip and remove ventilation housing cover

(D).

-Lift out housing from inner fender.

Removal of right side ventilation housing is similar.

4 Air filter housing assembly, removing:

Disconnect electrical harness connectors from mass air flow sensor (A) and temperature sensor (B).

Loosen hose clamp (C).

Remove filter housing mounting fastener (arrow) and remove filter housing with mass air flow sensor.

Cylinder Head Removal and Installation

Pry out ignition coil cover trim caps, remove fasteners and covers from lefl and right sides.

<Disconnect throttle cables from throttle shafl (A) and remove cables from support bracket (B).

<Disconnect cable from jump start post (arrow) on left cylinder head cover.

< Disconnect the following electrical harness connectors: Knock sensors (A).

Thermostat (6).

Throttle position sensor and idle valve (C).

Camshaft position sensor (D).

Ignition coils (E).

< Remove mounting nuts (arrows) from wiring harness ducts.

4 Release fuel injector connectors by releasing spring clip (arrow) on each injector.

Lift up and remove electrical ducts and set to one side

113-60

Cylinder Head Removal and Installation

Label and disconnect fuel lines from fuel rail by pressing locking sleeves (arrows) in to release lines.

NOTE-

BMW uses three styles of fuel line connections; a single use clamp; a locking fitting that uses special tool 16 1 050 to release; and a quick release sleeve (arrow) that disconnects the line when depressed.

Working at rear of intake manifold, disconnect crankcase ventilation valve from pipe by prying up on lock (A) and sliding tube forward (B) .

113-61

Cylinder Head Removal and installationI

Remove intake manifold fasteners (A).

Carefully lift intake manifoldoff engine while checkingthat all hoses and harnesses have been disconnected.

Left cylinder head, removing, M62 engine

-Remove intake manifold as described earlier

-Remove left side exhaust manifold. See 180 Exhaust System.

-Drain engine coolant, then remove viscous clutch cooling fan. See 170 Radiator and Cooling System.

WARNING-

Use extreme caution when draininganddisposfngof eng~ne coolant. Coolantispoisonousandlethalto humansandpets. Pets are attractedto coolant because of its sweet smelland taste. Seek med~calattentionimmediatelyifcoolant isingested.

4 Remove coolant manifold mounting fasteners and carefully remove manifold.

NOTE-

Engine shown removed from engine bay

4 Remove ignition coil fasteners and coils (noting location of ground strap).

- Remove spark plugs.

. . - --

[Cylinder~ e a Removald and Installation

4 Remove cylinder head cover fasteners (arrows) and remove covers from left and right cylinder heads.

4 Remove oil distribution tubes from camshaft bearing caps from left and right cylinder heads.

4 Using crankshaft center bolt, turn crankshaft clockwise until number one cylinder (passenger side front cylinder) is in TDC overlap position (arrow).

NOJE-

Number one cylinder is at valve overlap when both the intake and exhaust valves are starting to open (camshaft lobes facing down).

4 Working at right cylinder head, loosen three accessible camshaft sprocltet fasteners (arrows) on both intakeand exhaust camshafts approximately 'I2turn.

To prevent valve to piston contact when looseningcamshaft sprocket fasteners, counterholdcamshaft with 27mm openend wrench. If necessary, grind outerside of wrenchjaws to prevent damaging cylinder head.

. - - -

Cylinder Head Removal and Installation I

4 Rotate crankshaft vibration damper to TDC position. Right head camshaft lobes for number one cylinder should be in position shown (arrows).

Working at right cylinder head (passengers side) loosen remaining sprocltet fasteners (arrows) on both intake and exhaust camshafts approximately '/?turn.

4 Loosen and remove primary timing chain tensioner (arrow) from upper timing chain cover on right head.

113-64

Cylinder Head Removal and Installation

<Remove upper timing chain cover fasteners (A) and cover from left cylinder head.

4 Remove fasteners from intake camshaft sprocket (arrows) on left cylinder head.

-Remove primary timing chain sprocket and suspend timing chain using mechanics wire to prevent chain from dropping into lower housing.

Turn crankshaft counterclockwise until 45" mark on crankshaft is aligned with boss on front timing chain cover (arrow).

. . - --

I Cylinder Head Removal and Installation

-Evaluate cylinder head as described in 116 Cylinder head and valvetrain.

Left cylinder head, installing, M62 engine

-Clean cylinder head and block sealing surfaces of gasket debris, making sure no debris drops into coolant or oil passages.

-Clean cylinder head bolt holes and check condition of threads.

<Check cylinder head locator sleeves (arrows) for damage.

If the cylinder headhas been machined, a special0.3 mm thicker gasket shouldbe installed. The thickergasketisavailable through an authorizedBMW dealer andshouldbe markedaccordingly.

-Place new cylinder head gasket over locating sleeve on block.

The word "OBEN" or "TOP" (arrow) printed on the gasket, must face up.

Set lefl side cylinder head in position on cylinder block while pressing oil separator outward.

CAUJION-

Male sure the crankshaft, which hadbeen rotatedapproximately45" opposite the direction of engine rotation from TDC, isstillin thatpositionbeforeinstallingthe cylinderhead. All pistonsmust be out of TDCposition to prevent valvelpiston contact.

-Install new cylinder head bolts and washers finger tight. Be sure not to remove coating from new cylinder head bolts.

4 Tighten cylinder head bolts in correct sequence (1-10) to stage 1 torque values.