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Tim's Auto Repair
Tim's Auto Repair, Mechanic
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Experience:  Have owned a repair shop for 25 yrs.
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Remove and replace head gasket on 2000 BMW 528i

Customer Question

remove and replace head gasket on 2000 BMW 528i
Submitted: 4 years ago.
Category: Car
Expert:  Tim's Auto Repair replied 4 years ago.

hi

please print

thanks

 

Removal & Installation

 

The components of the cylinder head and the mating surface of the cylinder head and engine block are machined within very precise tolerances. The components must be thoroughly cleaned, inspected and if necessary properly lubricated upon installation. Refer to the Engine Reconditioning information in this section for additional information.


WARNING A camshaft removal tool should be used when removing the camshafts from the M42 engine and all E36 6-cylinder engines. Failure to use the proper tool or its equivalent could result in camshaft breakage.

NOTE Both a camshaft and a crankshaft alignment tool are necessary when reinstalling the camshafts onto the cylinder head of BMW M42 engines and all E36 model engines.

WARNING The cylinder head bolts used on E36 6-cylinder engines with a cast iron block are a different length and torque specification than those used on E36 6-cylinder engines with a cast aluminum block and must not be interchanged!
E36 6-Cylinder Engines

  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Before proceeding with the cylinder head removal be sure the engine has cooled sufficiently.
  4. Raise and safely support the vehicle.
  5. Remove the lower engine splash shield.
  6. Disconnect the exhaust manifolds from the exhaust pipes.
  7. Drain the engine coolant from the radiator and the engine block into a sealable container. The engine block drain plug is located on the right side of the block near the rear exhaust manifold, just below the exhaust ports for cylinder numbers four and five.
  8. Remove the rear hood seal, then remove the fasteners securing the sealed plastic housing for the engine wiring harness from the passenger compartment fresh air intake shroud.
  9. Remove the fasteners securing the fresh air intake shroud to the fire wall, and remove the shroud.
  10. If equipped, remove the plastic trim covers from the top of the engine.
  11. Disconnect the Mass Air Flow (MAF) sensor and remove intake manifold air duct along with the air filter housing assembly.
  12. Remove the throttle cable from the throttle body linkage, disconnect the coolant hoses, the Throttle Position (TP) sensor electrical connector, the throttle body mounting fasteners, and remove the throttle body assembly. Cover the opening of the intake manifold to prevent any debris from entering.
  13. Remove the intake manifold support bracket fasteners from the intake manifold and loosen the support bracket fasteners on the engine block.
  14. Disconnect the fuel feed and return lines and make note of their location for reassembly.
  15. Disconnect the vacuum hoses from the intake manifold, and loosen the clamps for the idle speed stabilizer underneath the manifold, and disconnect the hoses.
  16. Remove the intake manifold intake port fasteners and carefully lift the manifold away from the engine. Cover the intake ports to ensure that no debris enters the ports.
  17. Remove the ground cable at the front of the cylinder head, then remove the two radiator hoses from the thermostat housing, and remove the housing.
  18. Remove the exhaust manifolds.
  19. Remove the wire connectors for the ignition coils and cylinder head sensors and remove the coils, then remove the cylinder head cover.
  20. Rotate the engine in the direction of rotation to Top Dead Center (TDC) for cylinder number one. Cylinder number one will be at TDC when the intake and exhaust camshaft peaks for cylinder number one face each other
  21. Lock the engine in the TDC position by placing the crankshaft alignment tool No. 11 2 300 through the machined hole in the engine block, just below the starter motor located on the left lower portion of the engine block. Slide the alignment tool through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  22. The camshafts are held in the TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  23. Remove the valve cover mounting studs.
  24. Remove the two hex plugs at the front of the cylinder head to access the exhaust camshaft sprocket mounting bolts, then loosen the exhaust cam sprocket bolts two turns.
  25. Press down on the secondary cam chain tensioner between the two camshaft sprockets and install tool No. 11-3-292 or equivalent through the back side of the tensioner housing to hold the tensioner down. A similar sized and suitably hardened drill bit can be substituted for tool No. 11 3 292.
  26. If equipped with the hydraulic variable camshaft control system (VANOS)
    1. Remove the fasteners from the front of the cylinder head securing VANOS unit to the cylinder head.
    2. Disconnect the hydraulic lines and sensor connectors from the VANOS unit.
    3. On VANOS equipped engines with a spring plate installed on the intake camshaft, place sprocket tool No. 11 5 490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket clockwise to allow the helical gear of the VANOS unit to be released from the intake camshaft and to allow the VANOS unit to be pulled away from the front of the cylinder head. On models without a spring plate, the VANOS unit can be removed without the use of the special tool.
    4. If tool No. 11 5 490 or equivalent is not available, move the camshaft sprockets to release the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the intake cam sprocket to rotate both cam sprockets clockwise, while alternately pulling on the VANOS unit to release it. This procedure may need to be repeated several times to fully release the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.

  27. Remove the intake and exhaust camshaft sprockets, the hydraulic cam chain tensioner, and the cam chain guide.
  28. From the side of the right front area of the engine, remove the cap nut for the cam chain tensioner for the cam chain that runs between the crankshaft and the exhaust camshaft sprocket. Use care when removing the tensioner cap nut as the cam tensioner spring applies pressure to the cap nut.
  29. Remove the exhaust cam tensioner, and then release the sprocket from the cam chain.
  30. Attach a wire tie or mechanic's wire to the cam chain and temporarily secure the chain fully extended.
  31. Remove the crankshaft alignment tool from the engine and flywheel locking the engine in the TDC position.
  32. While holding the crankshaft to exhaust camshaft cam chain, rotate the engine 30° counterclockwise to avoid damaging the valves during cylinder head removal and reinstallation.
  33. With the attached wire tie or mechanic's wire secured to the cam chain, carefully lower the chain downward making sure there is enough exposed wire to retrieve the chain for reinstallation.
  34. Remove the fasteners located in a recessed area near the front of the camshafts securing the front of the cylinder head to the engine block.
  35. In the reverse order of the tightening sequence, using a proper sized Torx® bit or tool No. 11 2 250, loosen the cylinder head mounting bolts in three steps as follows:

    Step 1: 90° Step 2: 90° Step 3: Completely remove the bolt
  36. With all of the cylinder head bolts removed, verify that all electrical connectors and fluid lines have been removed and lift the cylinder head off the engine block.



NOTE It is not recommended to machine the cylinder head surface of the S52 engine. If machining the cylinder head of an M52 engine, a 0.012 inch (0.3mm) thicker head gasket is available for reassembly.

 

FIG : Cylinder head mounting bolt tightening sequence-E36 models with 6-cylinder engines

image

To install:

  1. Thoroughly clean the deck surface of the engine cylinder block and the cylinder head surface.
  2. If the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before mounting the cylinder head on the engine to allow the lifters to compress fully as follows:

    At room temperature: Wait 4 minutes Temperatures down to 50° F (10° C): Wait 11 minutes Temperatures lower than 50° F (10° C): Wait 30 minutes



NOTE This is to prevent contact between the valves and the piston tops.

  1. The engine may not be cranked under the same condition for a period of:

    Room temperature: 10 minutes Temperatures down to 50° F (10° C): 30 minutes Temperatures below 50° F (10° C): 75 minutes
  2. Check the cylinder head for warpage and pressure test for coolant leakage.



WARNING Use care to not drop any pieces of gasket or debris into the oil or coolant passages.

  1. Inspect the condition and location of the head locating dowel sleeves.
  2. Apply a bead of an elastic non-drying gasket sealant such as Drei Bond® 1209 to the seam at the top of the area where the front timing cover and the engine block meet.
  3. Place a new head gasket on the engine block over the locating dowels.
  4. Carefully place the cylinder head onto the engine block making sure the dowel sleeves are properly aligned and be sure that the head sits flat on the engine block.



WARNING The cylinder head bolts may not be reused.

NOTE The bolts are a different length and have a different torque specification for aluminum engine blocks than those for the cast iron engine blocks.

  1. Install and torque the new cylinder head bolts in three steps, following the illustrated tightening sequence.
  2. On cast iron engine blocks:
    1. Wash the bolts in a cleaning solvent.
    2. Apply a light coating of oil to the head and threads of the bolts.
    3. Torque the M10 x 95mm bolts for cast iron engine blocks using the tightening sequence as follows:

      Step 1: 22.l ft. lbs. (30 Nm) Step 2: 90° Step 3: 90°

  3. On cast aluminum engine blocks:
    1. DO NOT remove the coating on the head bolts or wash them.
    2. Apply a light coating of oil to the head and threads of the bolts.
    3. Torque the M10 x 110mm bolts for cast aluminum engine blocks using the tightening sequence as follows:

      Step 1: 29.5 ft. lbs. (40 Nm). Step 2: 90°. Step 3: 90°.

  4. Install the fasteners located in the recessed area near the front of the camshafts securing the front of the cylinder head to the engine block and torque to 96 inch lbs. (10 Nm).
  5. With the attached wire secured to the crankshaft cam chain, carefully raise the chain upward and apply a light tension to the chain, then while holding the chain, carefully rotate the engine clockwise to TDC on cylinder number one.
  6. Lock the engine in the TDC position by placing the crankshaft positioning tool No. 11 2 300 through the machined hole in the engine block, just below the starter motor located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  7. Hold the camshafts TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  8. Position the crankshaft cam chain over the exhaust cam chain sprocket and install the sprocket on the exhaust cam such that the slotted holes are centered with the fastener bores in the camshaft.
  9. Install the hydraulic cam chain tensioner, and the cam chain guide, then the intake and exhaust camshaft sprockets along with the cam chain and remove the tool used to hold the hydraulic cam chain tensioner collapsed.
  10. Install the crankshaft cam chain tensioner assembly, spring and cap nut.
  11. Apply gasket sealant to the upper corners of the cylinder head where the cover plate or the VANOS housing mounts and install a new gasket.
  12. On models equipped with VANOS ;
    1. Press the helical gear of the VANOS assembly toward the housing and install the VANOS assembly. On engines with a spring plate installed on the intake camshaft, place tool No. 11-5-490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket counterclockwise to allow the helical gear of the VANOS unit to thread into the intake camshaft and to allow the VANOS unit to be pulled into the front of the cylinder head.
    2. If tool No. 11-5-490 or equivalent is not available, move the camshaft sprockets to install the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the exhaust cam sprocket to rotate both cam sprockets counterclockwise, while alternately pressing on the VANOS unit to install it. This procedure may need to be repeated several times to fully install the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.
    3. NOTE Make sure when assembling the VANOS unit is able to rest on the front of the cylinder head without being forced or without binding. If the VANOS unit does not fully seat it may be necessary to reposition the camshaft sprockets such that the slots in the camshaft sprockets allow enough movement of the sprockets for the helical gear of the VANOS assembly to be fully seated during assembly.
      1. Tighten the VANOS unit fastener and then torque the camshaft sprocket bolts of both the intake and exhaust cams to 16 ft. lbs. (22 Nm).

      1. Remove the crankshaft TDC alignment tool No. 113240 or equivalent from the engine, and remove the camshaft TDC positioning tool No. 11 3 240 or equivalent from the valve cover mating surface at the back of the cylinder head.


      WARNING If the camshafts have been removed and reinstalled, a waiting period dependent on the ambient temperature is necessary before rotating the crankshaft to allow the lifters to fully compress.
      1. The engine may not be cranked under these conditions for a period of:

        Room temperature: 10 minutes Temperatures down to 50° F (10° C): 30 minutes Temperatures below 50° F (10° C): 75 minutes


      NOTE This is to prevent contact between the valves and the piston tops.
      1. Once the waiting period has expired, slowly and carefully rotate the engine clockwise four complete revolutions bringing cylinder number one to TDC. If the engine binds for any reason stop immediately to evaluate and rectify the cause of the binding.
      2. With cylinder number one at TDC slide the camshaft TDC positioning tool No. 11-3-240 or equivalent over the ends of the cams and onto the valve cover mating surface. If the tool slides over the cams and is flush with the mating surface, the camshafts are properly timed. If the tool does not slide easily over the ends of the cams, or if the tool is not flush with the valve cover mating surface, the camshaft timing must be repeated until the tool fits squarely.
      3. The balance of installation is the reverse of the removal procedure.
      4. Top off the engine cooling system and bleed as necessary.


      NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
      1. Change the engine oil and filter.
      2. Check and top off all fluid levels as necessary.
      3. Connect the negative battery cable, start the engine and check for any leaks.

      M20 Engine
      1. Disconnect the negative battery cable. Make sure the engine is cool. Disconnect the exhaust pipes at the manifold and at the transmission clamp. Remove the drain plug at the bottom of the radiator and drain the coolant. Drain the engine oil.
      2. Disconnect the accelerator and cruise control cables. If the vehicle has automatic transmission, disconnect the throttle cable that goes to the transmission.
      3. Working at the front of the block, disconnect the upper radiator hose, the bypass water hose, and several smaller water hoses. Remove the diagnosis plug located at the front corner of the manifold. Remove the bracket located just underneath. Disconnect the fuel line and drain the contents into a metal container for safe disposal.
      4. Working on the air cleaner/airflow sensor, disconnect the vacuum hoses, labeling them if necessary. Disconnect all electrical connectors and unclip and remove the wiring harness. There is a relay located in an L-shaped box near the strut tower. Disconnect and remove it. Unclamp and remove the air hose. Remove the mounting nuts and remove the assembly.
      5. Disconnect the hose at the coolant overflow tank. Disconnect the idle speed positioner vacuum hose and then remove the positioner from the manifold.
      6. If equipped with 4-wheel drive, disconnect the vacuum hose from the servo mounted on the manifold.
      7. Place a drain pan underneath and then disconnect the water connections at the front of the intake manifold. Detach the electrical connector.
      8. Disconnect the heater water hoses. Press down on the vent tube collar and install the special tool or a similar device to retain the collar in the unlocked position. Disconnect the vent tube and inspect its O-ring seal, replacing it, if necessary.
      9. Unbolt the dipstick tube at the manifold. Remove the fuel hose bracket at the cylinder head. Make sure the engine is cold. Then, place a metal container under the connection and disconnect the fuel hose at the connection.
      10. Disconnect the high tension lead from the coil. Disconnect and remove the coolant expansion tank.
      11. If equipped with 4-wheel drive, disconnect the intake manifold vacuum hose leading the servo that engages 4-wheel drive.
      12. Detach the fuel injector connectors from all 6 injectors, as well as the 2 additional electrical connectors to sensors on the head. Disconnect the oil pressure sending unit connector. Then, unfasten the carriers and remove this wiring harness toward the left side of the vehicle.
      13. Disconnect the coil high tension wire and disconnect the high tension wires at the plugs. Then, disconnect the tube in which the wires run at the camshaft cover. Disconnect the PCV hose. Then, remove the retaining nuts and remove the camshaft cover.
      14. Turn the crankshaft so the TDC line is aligned on the indicator and the valves of No. 6 cylinder are in overlapping, slightly open position.
      15. Remove the distributor cap. Then, unscrew and remove the rotor. Unscrew and remove the adapter just underneath the rotor. Remove the cover underneath the adapter. Check its O-ring and replace it, if necessary.
      16. Remove the distributor mounting bolts and the protective cover.
      17. These engines are equipped on a rubber drive and timing belt. Remove the belt covers. To loosen belt tension, loosen the tension roller bracket pivot bolt and adjusting slot bolt. Push the roller and bracket away from the belt to release the tension, hold the bracket in this position, and tighten the adjusting slot bolt to retain the bracket it this position.
      18. Remove the timing belt.


      NOTE Make sure to avoid rotating both the engine and camshaft from this point onward
      1. Remove the cylinder head mounting bolts in three steps using the exact reverse order of the tightening sequence. Then, remove the cylinder head.
      2. FIG : To release the vent tube on the M20 engine, the collar must be held down with Tool No. 11 1 290 or equivalent

        image

      3. FIG : Cylinder head bolt torque sequencer-M20 engine

        image

      4. To install:

        1. Clean both cylinder head and block sealing surfaces thoroughly with a hardwood scraper. Inspect the surfaces for flatness.
        2. Install the cylinder head using a new gasket. Check that all passages line up with the gasket holes. Make sure all the bolt cavities are thoroughly cleaned and free of debris. Make sure to keep oil out of all the bolt cavities otherwise cracking may occur and/or the cylinder head torque will be inaccurate.
        3. The cylinder head must be installed using new Torx® head fasteners. Before installing the cylinder head bolts, carefully wash and oil them.



        NOTE New Torx® head fasteners are required for cylinder head installation. Neither the Torx® head or the hex head fasteners can be reused.

        1. Tighten the Torx® head cylinder head-to-engine block bolts as follows:
          1. Step 1: 22 ft. lbs. (30 Nm) following the cylinder head tightening sequence
          2. Step 2: Tighten 90° following the tightening sequence
          3. Step 3: Tighten and additional 90° following the tightening sequence



        NOTE With the No. 1 piston at Top Dead Center (TDC) of the compression stroke, make sure to align the timing marks when installing the timing belt. The crankshaft sprocket mark must point at the notch in the flange of the front engine cover. The camshaft sprocket arrow must point at the alignment mark on the cylinder head. BMW recommends that the timing belt be replaced every time the cylinder head is removed and/or the belt is disturbed. Make sure the belt is properly tensioned.

        1. Check and adjust the valves as necessary.
        2. Complete the installation by reversing all removal procedures making sure of the following.
        3. Change the engine oil and filter.
        4. Top off the cooling system with the proper mixture of coolant and bleed as necessary.
        5. Use new gaskets for the exhaust system connections, and coat the studs with an anti-seizing compound.
        6. Install the connectors for the DME reference mark and speed signals such that the gray plug goes to the socket with a ring underneath.
        7. Check and top off all fluid levels.
        8. Connect the negative battery cable and check for normal operation.


        M42 Engine

        1. Disconnect the negative battery cable.
        2. Remove the intake manifold and the exhaust manifold as outlined in this section.
        3. Remove the ignition coil cover and pull off the spark plug connectors.
        4. Remove the complete ignition leads. Remove the cylinder head cover.
        5. Disconnect the coolant hoses and remove the position sensor.
        6. Remove the thermostat housing and thermostat. Unscrew the upper timing case cover.
        7. Rotate the engine clockwise until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the camshaft sprockets should be facing up.
        8. Remove the chain tensioner. Remove the upper chain guide, chain guide bolt on the right side and the sprockets.
        9. Remove the cylinder head bolts in three steps in the opposite order of the tightening sequence.
        10. Remove the cylinder head. Clean the sealing surfaces on the cylinder head and the crankcase.
        11. FIG : Cylinder head bolt tightening sequence-M42 engine

          image

        12. To install:

          1. Clean the new head bolts and the bores of the cylinder block. Do not allow oil or contaminants to fill the bores. Use a 0.012 inch (0.3mm) thicker head gasket if the head was machined.
          2. Before installing the cylinder head;
            1. Make sure the camshafts are positioned in the cylinder head such that the camshaft is in the Top Dead Center (TDC) position for the compression stroke for cylinder number 1. In this position, the tips of the camshaft lobes for cylinder number 1 are pointing toward one another and the alignment tool No. 11 3 240 or its equivalent can be placed into position.
            2. Install a new head gasket in the proper orientation as marked on the gasket. Check the condition of the guide dowels in the cylinder deck.
            3. Install new seals into the top of the front timing case.
            4. On M42 engines produced since 9.92, make sure the check valve with the rubber lined spacing sleeve for the oil supply to the cylinder head is properly installed into the engine block.



          WARNING An improperly installed check valve will cause mechanical damage to the cylinder head.

          NOTE New cylinder head bolts must be installed, they cannot be reused.

          1. Thoroughly wash the new cylinder head bolts and lubricate them with fresh engine oil.
          2. Place the cylinder head onto the engine block and torque the cylinder head bolts in three steps following the illustrated tightening sequence as follows:
            1. Step 1: 22 ft. lbs. (30 Nm)
            2. Step 2: 90°
            3. Step 3: 90°



          NOTE During cylinder head or camshaft installation a waiting period is necessary before the camshaft timing chain can be installed to allow the hydraulic lash adjusters to bleed down and prevent the valves from contacting the pistons.

          1. If the camshafts were removed and installed while the cylinder head was removed, or if the camshafts are to be installed after the cylinder head is installed, a waiting period is necessary before the camshaft timing can be performed to allow the hydraulic lash adjusters to bleed down and prevent the valves from contacting the pistons.

          The waiting period varies depending on the work environment's ambient air temperature. The waiting period is as follows:



          Above 68°F (20°C): 4 minutes 50-67°F (10-19.4°C): 11 minutes 32-49°F (0-9.4°C): 30 minutes

          1. Once the proper waiting period has been observed, install the camshaft alignment Tool No. 11 3 240 or its equivalent. This positions the camshafts at Top Dead Center (TDC) on the firing stroke for cylinder number 1, and the arrows on the camshaft sprockets should be facing up. If the camshaft sprockets were removed, install the sprockets with the arrows pointing up and torque to 10-12 ft. lbs. (13-17 Nm).
          2. Pull upward and support the timing chain by hand and slowly rotate the crankshaft clockwise until cylinder number 1 is at (TDC).
          3. Secure the engine at TDC by installing Tool No. 11 2 300 or its equivalent through the machined hole in the engine block, and into the flywheel. The machined hole in the engine block is located just below the starter motor, and is sealed with a removable plug.
          4. Install the timing chain, timing guide bolt on the right side and the upper chain guide.
          5. If not installing a new tensioner piston, knock the outer sleeve of the tensioner piston so the piston is released from the sleeve. Assemble the tensioner with the spring, the piston and the snaprings in position. Place in a vice and press together until both snaprings engage. If the piston starts to extend, the procedure must be done again. The compressed tensioner length should be 2.697 inches (68.5mm).
          6. Install the tensioner into its bore and tighten the plug to 17-19 ft. lbs. (23-27 Nm). Push the tensioner rail against the tensioner to release the tensioner piston.
          7. Remove the camshaft and crankshaft alignment tools. Install the front timing upper cover using new gaskets filling the seam gaps with a suitable non hardening sealer. Press down on the cover to align it with a the cylinder head. Install the bolts and torque to 53-62 inch lbs. (8-10 Nm) for M6 bolts and 15-17 ft. lbs. (20-22 Nm) for M8 bolts.
          8. Install the thermostat housing using a new gasket and torque to 53-62 inch lbs. (8-10 Nm).



          NOTE Make sure the vent hole on the thermostat faces up.

          1. Install the camshaft position sensor.
          2. The balance of installation is in reverse order of removal noting the following.
          3. Fill and bleed the cooling system with the proper mixture of coolant.
          4. Change the engine oil and filter.
          5. Check and top off all fluid levels.
          6. Connect the negative battery cable and check for normal operation.


          M44 1.9L Engines

          1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
          2. Drain the cooling system.
          3. Relieve the fuel system pressure.
          4. Remove or disconnect the following:

            Negative battery cable Fuel feed and return lines Intake manifold Ignition coil cover and remove the spark plug connectors All the fasteners securing the brackets for the ignition coil wire harness, then move the harness aside to access the cylinder head cover Cylinder head cover Coolant hoses and temperature sensor Thermostat housing and thermostat Upper timing case cover
          5. Rotate the engine in the direction of the rotation until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the cam sprocket should face up.
          6. Remove or disconnect the following:

            Chain tensioner, the upper chain guide, the chain guide bolt on the right side and the camshaft sprockets Cylinder head bolts in the reverse order of the tightening sequence (from the outside to the inside) in at least 3 steps Cylinder head
          7. FIG : Cylinder head torque sequence-M44B19 1.9L engine

            image

          8. Install the cylinder head with a new gasket and bolts. Tighten the bolts in sequence as follows:

            Step 1: 22 ft. lbs. (30 Nm) Step 2: +90 degrees Step 3: +90 degrees
          9. The balance of installation is the reverse of the removal procedure.
          10. Fill the cooling system.
          11. Start the engine and check for leaks.
            NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
Expert:  Tim's Auto Repair replied 4 years ago.

hi

please print

thanks

 

Removal & Installation

 

The components of the cylinder head and the mating surface of the cylinder head and engine block are machined within very precise tolerances. The components must be thoroughly cleaned, inspected and if necessary properly lubricated upon installation. Refer to the Engine Reconditioning information in this section for additional information.


WARNING A camshaft removal tool should be used when removing the camshafts from the M42 engine and all E36 6-cylinder engines. Failure to use the proper tool or its equivalent could result in camshaft breakage.

NOTE Both a camshaft and a crankshaft alignment tool are necessary when reinstalling the camshafts onto the cylinder head of BMW M42 engines and all E36 model engines.

WARNING The cylinder head bolts used on E36 6-cylinder engines with a cast iron block are a different length and torque specification than those used on E36 6-cylinder engines with a cast aluminum block and must not be interchanged!
E36 6-Cylinder Engines

  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Before proceeding with the cylinder head removal be sure the engine has cooled sufficiently.
  4. Raise and safely support the vehicle.
  5. Remove the lower engine splash shield.
  6. Disconnect the exhaust manifolds from the exhaust pipes.
  7. Drain the engine coolant from the radiator and the engine block into a sealable container. The engine block drain plug is located on the right side of the block near the rear exhaust manifold, just below the exhaust ports for cylinder numbers four and five.
  8. Remove the rear hood seal, then remove the fasteners securing the sealed plastic housing for the engine wiring harness from the passenger compartment fresh air intake shroud.
  9. Remove the fasteners securing the fresh air intake shroud to the fire wall, and remove the shroud.
  10. If equipped, remove the plastic trim covers from the top of the engine.
  11. Disconnect the Mass Air Flow (MAF) sensor and remove intake manifold air duct along with the air filter housing assembly.
  12. Remove the throttle cable from the throttle body linkage, disconnect the coolant hoses, the Throttle Position (TP) sensor electrical connector, the throttle body mounting fasteners, and remove the throttle body assembly. Cover the opening of the intake manifold to prevent any debris from entering.
  13. Remove the intake manifold support bracket fasteners from the intake manifold and loosen the support bracket fasteners on the engine block.
  14. Disconnect the fuel feed and return lines and make note of their location for reassembly.
  15. Disconnect the vacuum hoses from the intake manifold, and loosen the clamps for the idle speed stabilizer underneath the manifold, and disconnect the hoses.
  16. Remove the intake manifold intake port fasteners and carefully lift the manifold away from the engine. Cover the intake ports to ensure that no debris enters the ports.
  17. Remove the ground cable at the front of the cylinder head, then remove the two radiator hoses from the thermostat housing, and remove the housing.
  18. Remove the exhaust manifolds.
  19. Remove the wire connectors for the ignition coils and cylinder head sensors and remove the coils, then remove the cylinder head cover.
  20. Rotate the engine in the direction of rotation to Top Dead Center (TDC) for cylinder number one. Cylinder number one will be at TDC when the intake and exhaust camshaft peaks for cylinder number one face each other
  21. Lock the engine in the TDC position by placing the crankshaft alignment tool No. 11 2 300 through the machined hole in the engine block, just below the starter motor located on the left lower portion of the engine block. Slide the alignment tool through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  22. The camshafts are held in the TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  23. Remove the valve cover mounting studs.
  24. Remove the two hex plugs at the front of the cylinder head to access the exhaust camshaft sprocket mounting bolts, then loosen the exhaust cam sprocket bolts two turns.
  25. Press down on the secondary cam chain tensioner between the two camshaft sprockets and install tool No. 11-3-292 or equivalent through the back side of the tensioner housing to hold the tensioner down. A similar sized and suitably hardened drill bit can be substituted for tool No. 11 3 292.
  26. If equipped with the hydraulic variable camshaft control system (VANOS)
    1. Remove the fasteners from the front of the cylinder head securing VANOS unit to the cylinder head.
    2. Disconnect the hydraulic lines and sensor connectors from the VANOS unit.
    3. On VANOS equipped engines with a spring plate installed on the intake camshaft, place sprocket tool No. 11 5 490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket clockwise to allow the helical gear of the VANOS unit to be released from the intake camshaft and to allow the VANOS unit to be pulled away from the front of the cylinder head. On models without a spring plate, the VANOS unit can be removed without the use of the special tool.
    4. If tool No. 11 5 490 or equivalent is not available, move the camshaft sprockets to release the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the intake cam sprocket to rotate both cam sprockets clockwise, while alternately pulling on the VANOS unit to release it. This procedure may need to be repeated several times to fully release the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.

  27. Remove the intake and exhaust camshaft sprockets, the hydraulic cam chain tensioner, and the cam chain guide.
  28. From the side of the right front area of the engine, remove the cap nut for the cam chain tensioner for the cam chain that runs between the crankshaft and the exhaust camshaft sprocket. Use care when removing the tensioner cap nut as the cam tensioner spring applies pressure to the cap nut.
  29. Remove the exhaust cam tensioner, and then release the sprocket from the cam chain.
  30. Attach a wire tie or mechanic's wire to the cam chain and temporarily secure the chain fully extended.
  31. Remove the crankshaft alignment tool from the engine and flywheel locking the engine in the TDC position.
  32. While holding the crankshaft to exhaust camshaft cam chain, rotate the engine 30° counterclockwise to avoid damaging the valves during cylinder head removal and reinstallation.
  33. With the attached wire tie or mechanic's wire secured to the cam chain, carefully lower the chain downward making sure there is enough exposed wire to retrieve the chain for reinstallation.
  34. Remove the fasteners located in a recessed area near the front of the camshafts securing the front of the cylinder head to the engine block.
  35. In the reverse order of the tightening sequence, using a proper sized Torx® bit or tool No. 11 2 250, loosen the cylinder head mounting bolts in three steps as follows:

    Step 1: 90° Step 2: 90° Step 3: Completely remove the bolt
  36. With all of the cylinder head bolts removed, verify that all electrical connectors and fluid lines have been removed and lift the cylinder head off the engine block.



NOTE It is not recommended to machine the cylinder head surface of the S52 engine. If machining the cylinder head of an M52 engine, a 0.012 inch (0.3mm) thicker head gasket is available for reassembly.

 

FIG : Cylinder head mounting bolt tightening sequence-E36 models with 6-cylinder engines

image

To install:

  1. Thoroughly clean the deck surface of the engine cylinder block and the cylinder head surface.
  2. If the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before mounting the cylinder head on the engine to allow the lifters to compress fully as follows:

    At room temperature: Wait 4 minutes Temperatures down to 50° F (10° C): Wait 11 minutes Temperatures lower than 50° F (10° C): Wait 30 minutes



NOTE This is to prevent contact between the valves and the piston tops.

  1. The engine may not be cranked under the same condition for a period of:

    Room temperature: 10 minutes Temperatures down to 50° F (10° C): 30 minutes Temperatures below 50° F (10° C): 75 minutes
  2. Check the cylinder head for warpage and pressure test for coolant leakage.



WARNING Use care to not drop any pieces of gasket or debris into the oil or coolant passages.

  1. Inspect the condition and location of the head locating dowel sleeves.
  2. Apply a bead of an elastic non-drying gasket sealant such as Drei Bond® 1209 to the seam at the top of the area where the front timing cover and the engine block meet.
  3. Place a new head gasket on the engine block over the locating dowels.
  4. Carefully place the cylinder head onto the engine block making sure the dowel sleeves are properly aligned and be sure that the head sits flat on the engine block.



WARNING The cylinder head bolts may not be reused.

NOTE The bolts are a different length and have a different torque specification for aluminum engine blocks than those for the cast iron engine blocks.

  1. Install and torque the new cylinder head bolts in three steps, following the illustrated tightening sequence.
  2. On cast iron engine blocks:
    1. Wash the bolts in a cleaning solvent.
    2. Apply a light coating of oil to the head and threads of the bolts.
    3. Torque the M10 x 95mm bolts for cast iron engine blocks using the tightening sequence as follows:

      Step 1: 22.l ft. lbs. (30 Nm) Step 2: 90° Step 3: 90°

  3. On cast aluminum engine blocks:
    1. DO NOT remove the coating on the head bolts or wash them.
    2. Apply a light coating of oil to the head and threads of the bolts.
    3. Torque the M10 x 110mm bolts for cast aluminum engine blocks using the tightening sequence as follows:

      Step 1: 29.5 ft. lbs. (40 Nm). Step 2: 90°. Step 3: 90°.

  4. Install the fasteners located in the recessed area near the front of the camshafts securing the front of the cylinder head to the engine block and torque to 96 inch lbs. (10 Nm).
  5. With the attached wire secured to the crankshaft cam chain, carefully raise the chain upward and apply a light tension to the chain, then while holding the chain, carefully rotate the engine clockwise to TDC on cylinder number one.
  6. Lock the engine in the TDC position by placing the crankshaft positioning tool No. 11 2 300 through the machined hole in the engine block, just below the starter motor located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  7. Hold the camshafts TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  8. Position the crankshaft cam chain over the exhaust cam chain sprocket and install the sprocket on the exhaust cam such that the slotted holes are centered with the fastener bores in the camshaft.
  9. Install the hydraulic cam chain tensioner, and the cam chain guide, then the intake and exhaust camshaft sprockets along with the cam chain and remove the tool used to hold the hydraulic cam chain tensioner collapsed.
  10. Install the crankshaft cam chain tensioner assembly, spring and cap nut.
  11. Apply gasket sealant to the upper corners of the cylinder head where the cover plate or the VANOS housing mounts and install a new gasket.
  12. On models equipped with VANOS ;
    1. Press the helical gear of the VANOS assembly toward the housing and install the VANOS assembly. On engines with a spring plate installed on the intake camshaft, place tool No. 11-5-490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket counterclockwise to allow the helical gear of the VANOS unit to thread into the intake camshaft and to allow the VANOS unit to be pulled into the front of the cylinder head.
    2. If tool No. 11-5-490 or equivalent is not available, move the camshaft sprockets to install the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the exhaust cam sprocket to rotate both cam sprockets counterclockwise, while alternately pressing on the VANOS unit to install it. This procedure may need to be repeated several times to fully install the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.
    3. NOTE Make sure when assembling the VANOS unit is able to rest on the front of the cylinder head without being forced or without binding. If the VANOS unit does not fully seat it may be necessary to reposition the camshaft sprockets such that the slots in the camshaft sprockets allow enough movement of the sprockets for the helical gear of the VANOS assembly to be fully seated during assembly.
      1. Tighten the VANOS unit fastener and then torque the camshaft sprocket bolts of both the intake and exhaust cams to 16 ft. lbs. (22 Nm).

      1. Remove the crankshaft TDC alignment tool No. 113240 or equivalent from the engine, and remove the camshaft TDC positioning tool No. 11 3 240 or equivalent from the valve cover mating surface at the back of the cylinder head.


      WARNING If the camshafts have been removed and reinstalled, a waiting period dependent on the ambient temperature is necessary before rotating the crankshaft to allow the lifters to fully compress.
      1. The engine may not be cranked under these conditions for a period of:

        Room temperature: 10 minutes Temperatures down to 50° F (10° C): 30 minutes Temperatures below 50° F (10° C): 75 minutes


      NOTE This is to prevent contact between the valves and the piston tops.
      1. Once the waiting period has expired, slowly and carefully rotate the engine clockwise four complete revolutions bringing cylinder number one to TDC. If the engine binds for any reason stop immediately to evaluate and rectify the cause of the binding.
      2. With cylinder number one at TDC slide the camshaft TDC positioning tool No. 11-3-240 or equivalent over the ends of the cams and onto the valve cover mating surface. If the tool slides over the cams and is flush with the mating surface, the camshafts are properly timed. If the tool does not slide easily over the ends of the cams, or if the tool is not flush with the valve cover mating surface, the camshaft timing must be repeated until the tool fits squarely.
      3. The balance of installation is the reverse of the removal procedure.
      4. Top off the engine cooling system and bleed as necessary.


      NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
      1. Change the engine oil and filter.
      2. Check and top off all fluid levels as necessary.
      3. Connect the negative battery cable, start the engine and check for any leaks.

      M20 Engine
      1. Disconnect the negative battery cable. Make sure the engine is cool. Disconnect the exhaust pipes at the manifold and at the transmission clamp. Remove the drain plug at the bottom of the radiator and drain the coolant. Drain the engine oil.
      2. Disconnect the accelerator and cruise control cables. If the vehicle has automatic transmission, disconnect the throttle cable that goes to the transmission.
      3. Working at the front of the block, disconnect the upper radiator hose, the bypass water hose, and several smaller water hoses. Remove the diagnosis plug located at the front corner of the manifold. Remove the bracket located just underneath. Disconnect the fuel line and drain the contents into a metal container for safe disposal.
      4. Working on the air cleaner/airflow sensor, disconnect the vacuum hoses, labeling them if necessary. Disconnect all electrical connectors and unclip and remove the wiring harness. There is a relay located in an L-shaped box near the strut tower. Disconnect and remove it. Unclamp and remove the air hose. Remove the mounting nuts and remove the assembly.
      5. Disconnect the hose at the coolant overflow tank. Disconnect the idle speed positioner vacuum hose and then remove the positioner from the manifold.
      6. If equipped with 4-wheel drive, disconnect the vacuum hose from the servo mounted on the manifold.
      7. Place a drain pan underneath and then disconnect the water connections at the front of the intake manifold. Detach the electrical connector.
      8. Disconnect the heater water hoses. Press down on the vent tube collar and install the special tool or a similar device to retain the collar in the unlocked position. Disconnect the vent tube and inspect its O-ring seal, replacing it, if necessary.
      9. Unbolt the dipstick tube at the manifold. Remove the fuel hose bracket at the cylinder head. Make sure the engine is cold. Then, place a metal container under the connection and disconnect the fuel hose at the connection.
      10. Disconnect the high tension lead from the coil. Disconnect and remove the coolant expansion tank.
      11. If equipped with 4-wheel drive, disconnect the intake manifold vacuum hose leading the servo that engages 4-wheel drive.
      12. Detach the fuel injector connectors from all 6 injectors, as well as the 2 additional electrical connectors to sensors on the head. Disconnect the oil pressure sending unit connector. Then, unfasten the carriers and remove this wiring harness toward the left side of the vehicle.
      13. Disconnect the coil high tension wire and disconnect the high tension wires at the plugs. Then, disconnect the tube in which the wires run at the camshaft cover. Disconnect the PCV hose. Then, remove the retaining nuts and remove the camshaft cover.
      14. Turn the crankshaft so the TDC line is aligned on the indicator and the valves of No. 6 cylinder are in overlapping, slightly open position.
      15. Remove the distributor cap. Then, unscrew and remove the rotor. Unscrew and remove the adapter just underneath the rotor. Remove the cover underneath the adapter. Check its O-ring and replace it, if necessary.
      16. Remove the distributor mounting bolts and the protective cover.
      17. These engines are equipped on a rubber drive and timing belt. Remove the belt covers. To loosen belt tension, loosen the tension roller bracket pivot bolt and adjusting slot bolt. Push the roller and bracket away from the belt to release the tension, hold the bracket in this position, and tighten the adjusting slot bolt to retain the bracket it this position.
      18. Remove the timing belt.


      NOTE Make sure to avoid rotating both the engine and camshaft from this point onward
      1. Remove the cylinder head mounting bolts in three steps using the exact reverse order of the tightening sequence. Then, remove the cylinder head.
      2. FIG : To release the vent tube on the M20 engine, the collar must be held down with Tool No. 11 1 290 or equivalent

        image

      3. FIG : Cylinder head bolt torque sequencer-M20 engine

        image

      4. To install:

        1. Clean both cylinder head and block sealing surfaces thoroughly with a hardwood scraper. Inspect the surfaces for flatness.
        2. Install the cylinder head using a new gasket. Check that all passages line up with the gasket holes. Make sure all the bolt cavities are thoroughly cleaned and free of debris. Make sure to keep oil out of all the bolt cavities otherwise cracking may occur and/or the cylinder head torque will be inaccurate.
        3. The cylinder head must be installed using new Torx® head fasteners. Before installing the cylinder head bolts, carefully wash and oil them.



        NOTE New Torx® head fasteners are required for cylinder head installation. Neither the Torx® head or the hex head fasteners can be reused.

        1. Tighten the Torx® head cylinder head-to-engine block bolts as follows:
          1. Step 1: 22 ft. lbs. (30 Nm) following the cylinder head tightening sequence
          2. Step 2: Tighten 90° following the tightening sequence
          3. Step 3: Tighten and additional 90° following the tightening sequence



        NOTE With the No. 1 piston at Top Dead Center (TDC) of the compression stroke, make sure to align the timing marks when installing the timing belt. The crankshaft sprocket mark must point at the notch in the flange of the front engine cover. The camshaft sprocket arrow must point at the alignment mark on the cylinder head. BMW recommends that the timing belt be replaced every time the cylinder head is removed and/or the belt is disturbed. Make sure the belt is properly tensioned.

        1. Check and adjust the valves as necessary.
        2. Complete the installation by reversing all removal procedures making sure of the following.
        3. Change the engine oil and filter.
        4. Top off the cooling system with the proper mixture of coolant and bleed as necessary.
        5. Use new gaskets for the exhaust system connections, and coat the studs with an anti-seizing compound.
        6. Install the connectors for the DME reference mark and speed signals such that the gray plug goes to the socket with a ring underneath.
        7. Check and top off all fluid levels.
        8. Connect the negative battery cable and check for normal operation.


        M42 Engine

        1. Disconnect the negative battery cable.
        2. Remove the intake manifold and the exhaust manifold as outlined in this section.
        3. Remove the ignition coil cover and pull off the spark plug connectors.
        4. Remove the complete ignition leads. Remove the cylinder head cover.
        5. Disconnect the coolant hoses and remove the position sensor.
        6. Remove the thermostat housing and thermostat. Unscrew the upper timing case cover.
        7. Rotate the engine clockwise until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the camshaft sprockets should be facing up.
        8. Remove the chain tensioner. Remove the upper chain guide, chain guide bolt on the right side and the sprockets.
        9. Remove the cylinder head bolts in three steps in the opposite order of the tightening sequence.
        10. Remove the cylinder head. Clean the sealing surfaces on the cylinder head and the crankcase.
        11. FIG : Cylinder head bolt tightening sequence-M42 engine

          image

        12. To install:

          1. Clean the new head bolts and the bores of the cylinder block. Do not allow oil or contaminants to fill the bores. Use a 0.012 inch (0.3mm) thicker head gasket if the head was machined.
          2. Before installing the cylinder head;
            1. Make sure the camshafts are positioned in the cylinder head such that the camshaft is in the Top Dead Center (TDC) position for the compression stroke for cylinder number 1. In this position, the tips of the camshaft lobes for cylinder number 1 are pointing toward one another and the alignment tool No. 11 3 240 or its equivalent can be placed into position.
            2. Install a new head gasket in the proper orientation as marked on the gasket. Check the condition of the guide dowels in the cylinder deck.
            3. Install new seals into the top of the front timing case.
            4. On M42 engines produced since 9.92, make sure the check valve with the rubber lined spacing sleeve for the oil supply to the cylinder head is properly installed into the engine block.



          WARNING An improperly installed check valve will cause mechanical damage to the cylinder head.

          NOTE New cylinder head bolts must be installed, they cannot be reused.

          1. Thoroughly wash the new cylinder head bolts and lubricate them with fresh engine oil.
          2. Place the cylinder head onto the engine block and torque the cylinder head bolts in three steps following the illustrated tightening sequence as follows:
            1. Step 1: 22 ft. lbs. (30 Nm)
            2. Step 2: 90°
            3. Step 3: 90°



          NOTE During cylinder head or camshaft installation a waiting period is necessary before the camshaft timing chain can be installed to allow the hydraulic lash adjusters to bleed down and prevent the valves from contacting the pistons.

          1. If the camshafts were removed and installed while the cylinder head was removed, or if the camshafts are to be installed after the cylinder head is installed, a waiting period is necessary before the camshaft timing can be performed to allow the hydraulic lash adjusters to bleed down and prevent the valves from contacting the pistons.

          The waiting period varies depending on the work environment's ambient air temperature. The waiting period is as follows:



          Above 68°F (20°C): 4 minutes 50-67°F (10-19.4°C): 11 minutes 32-49°F (0-9.4°C): 30 minutes

          1. Once the proper waiting period has been observed, install the camshaft alignment Tool No. 11 3 240 or its equivalent. This positions the camshafts at Top Dead Center (TDC) on the firing stroke for cylinder number 1, and the arrows on the camshaft sprockets should be facing up. If the camshaft sprockets were removed, install the sprockets with the arrows pointing up and torque to 10-12 ft. lbs. (13-17 Nm).
          2. Pull upward and support the timing chain by hand and slowly rotate the crankshaft clockwise until cylinder number 1 is at (TDC).
          3. Secure the engine at TDC by installing Tool No. 11 2 300 or its equivalent through the machined hole in the engine block, and into the flywheel. The machined hole in the engine block is located just below the starter motor, and is sealed with a removable plug.
          4. Install the timing chain, timing guide bolt on the right side and the upper chain guide.
          5. If not installing a new tensioner piston, knock the outer sleeve of the tensioner piston so the piston is released from the sleeve. Assemble the tensioner with the spring, the piston and the snaprings in position. Place in a vice and press together until both snaprings engage. If the piston starts to extend, the procedure must be done again. The compressed tensioner length should be 2.697 inches (68.5mm).
          6. Install the tensioner into its bore and tighten the plug to 17-19 ft. lbs. (23-27 Nm). Push the tensioner rail against the tensioner to release the tensioner piston.
          7. Remove the camshaft and crankshaft alignment tools. Install the front timing upper cover using new gaskets filling the seam gaps with a suitable non hardening sealer. Press down on the cover to align it with a the cylinder head. Install the bolts and torque to 53-62 inch lbs. (8-10 Nm) for M6 bolts and 15-17 ft. lbs. (20-22 Nm) for M8 bolts.
          8. Install the thermostat housing using a new gasket and torque to 53-62 inch lbs. (8-10 Nm).



          NOTE Make sure the vent hole on the thermostat faces up.

          1. Install the camshaft position sensor.
          2. The balance of installation is in reverse order of removal noting the following.
          3. Fill and bleed the cooling system with the proper mixture of coolant.
          4. Change the engine oil and filter.
          5. Check and top off all fluid levels.
          6. Connect the negative battery cable and check for normal operation.


          M44 1.9L Engines

          1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
          2. Drain the cooling system.
          3. Relieve the fuel system pressure.
          4. Remove or disconnect the following:

            Negative battery cable Fuel feed and return lines Intake manifold Ignition coil cover and remove the spark plug connectors All the fasteners securing the brackets for the ignition coil wire harness, then move the harness aside to access the cylinder head cover Cylinder head cover Coolant hoses and temperature sensor Thermostat housing and thermostat Upper timing case cover
          5. Rotate the engine in the direction of the rotation until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the cam sprocket should face up.
          6. Remove or disconnect the following:

            Chain tensioner, the upper chain guide, the chain guide bolt on the right side and the camshaft sprockets Cylinder head bolts in the reverse order of the tightening sequence (from the outside to the inside) in at least 3 steps Cylinder head
          7. FIG : Cylinder head torque sequence-M44B19 1.9L engine

            image

          8. Install the cylinder head with a new gasket and bolts. Tighten the bolts in sequence as follows:

            Step 1: 22 ft. lbs. (30 Nm) Step 2: +90 degrees Step 3: +90 degrees
          9. The balance of installation is the reverse of the removal procedure.
          10. Fill the cooling system.
          11. Start the engine and check for leaks.
            NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
Expert:  Tim's Auto Repair replied 4 years ago.

hi

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thanks

 

Removal & Installation

 

The components of the cylinder head and the mating surface of the cylinder head and engine block are machined within very precise tolerances. The components must be thoroughly cleaned, inspected and if necessary properly lubricated upon installation. Refer to the Engine Reconditioning information in this section for additional information.


WARNING A camshaft removal tool should be used when removing the camshafts from the M42 engine and all E36 6-cylinder engines. Failure to use the proper tool or its equivalent could result in camshaft breakage.

NOTE Both a camshaft and a crankshaft alignment tool are necessary when reinstalling the camshafts onto the cylinder head of BMW M42 engines and all E36 model engines.

WARNING The cylinder head bolts used on E36 6-cylinder engines with a cast iron block are a different length and torque specification than those used on E36 6-cylinder engines with a cast aluminum block and must not be interchanged!
E36 6-Cylinder Engines

  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Before proceeding with the cylinder head removal be sure the engine has cooled sufficiently.
  4. Raise and safely support the vehicle.
  5. Remove the lower engine splash shield.
  6. Disconnect the exhaust manifolds from the exhaust pipes.
  7. Drain the engine coolant from the radiator and the engine block into a sealable container. The engine block drain plug is located on the right side of the block near the rear exhaust manifold, just below the exhaust ports for cylinder numbers four and five.
  8. Remove the rear hood seal, then remove the fasteners securing the sealed plastic housing for the engine wiring harness from the passenger compartment fresh air intake shroud.
  9. Remove the fasteners securing the fresh air intake shroud to the fire wall, and remove the shroud.
  10. If equipped, remove the plastic trim covers from the top of the engine.
  11. Disconnect the Mass Air Flow (MAF) sensor and remove intake manifold air duct along with the air filter housing assembly.
  12. Remove the throttle cable from the throttle body linkage, disconnect the coolant hoses, the Throttle Position (TP) sensor electrical connector, the throttle body mounting fasteners, and remove the throttle body assembly. Cover the opening of the intake manifold to prevent any debris from entering.
  13. Remove the intake manifold support bracket fasteners from the intake manifold and loosen the support bracket fasteners on the engine block.
  14. Disconnect the fuel feed and return lines and make note of their location for reassembly.
  15. Disconnect the vacuum hoses from the intake manifold, and loosen the clamps for the idle speed stabilizer underneath the manifold, and disconnect the hoses.
  16. Remove the intake manifold intake port fasteners and carefully lift the manifold away from the engine. Cover the intake ports to ensure that no debris enters the ports.
  17. Remove the ground cable at the front of the cylinder head, then remove the two radiator hoses from the thermostat housing, and remove the housing.
  18. Remove the exhaust manifolds.
  19. Remove the wire connectors for the ignition coils and cylinder head sensors and remove the coils, then remove the cylinder head cover.
  20. Rotate the engine in the direction of rotation to Top Dead Center (TDC) for cylinder number one. Cylinder number one will be at TDC when the intake and exhaust camshaft peaks for cylinder number one face each other
  21. Lock the engine in the TDC position by placing the crankshaft alignment tool No. 11 2 300 through the machined hole in the engine block, just below the starter motor located on the left lower portion of the engine block. Slide the alignment tool through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  22. The camshafts are held in the TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  23. Remove the valve cover mounting studs.
  24. Remove the two hex plugs at the front of the cylinder head to access the exhaust camshaft sprocket mounting bolts, then loosen the exhaust cam sprocket bolts two turns.
  25. Press down on the secondary cam chain tensioner between the two camshaft sprockets and install tool No. 11-3-292 or equivalent through the back side of the tensioner housing to hold the tensioner down. A similar sized and suitably hardened drill bit can be substituted for tool No. 11 3 292.
  26. If equipped with the hydraulic variable camshaft control system (VANOS)
    1. Remove the fasteners from the front of the cylinder head securing VANOS unit to the cylinder head.
    2. Disconnect the hydraulic lines and sensor connectors from the VANOS unit.
    3. On VANOS equipped engines with a spring plate installed on the intake camshaft, place sprocket tool No. 11 5 490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket clockwise to allow the helical gear of the VANOS unit to be released from the intake camshaft and to allow the VANOS unit to be pulled away from the front of the cylinder head. On models without a spring plate, the VANOS unit can be removed without the use of the special tool.
    4. If tool No. 11 5 490 or equivalent is not available, move the camshaft sprockets to release the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the intake cam sprocket to rotate both cam sprockets clockwise, while alternately pulling on the VANOS unit to release it. This procedure may need to be repeated several times to fully release the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.

  27. Remove the intake and exhaust camshaft sprockets, the hydraulic cam chain tensioner, and the cam chain guide.
  28. From the side of the right front area of the engine, remove the cap nut for the cam chain tensioner for the cam chain that runs between the crankshaft and the exhaust camshaft sprocket. Use care when removing the tensioner cap nut as the cam tensioner spring applies pressure to the cap nut.
  29. Remove the exhaust cam tensioner, and then release the sprocket from the cam chain.
  30. Attach a wire tie or mechanic's wire to the cam chain and temporarily secure the chain fully extended.
  31. Remove the crankshaft alignment tool from the engine and flywheel locking the engine in the TDC position.
  32. While holding the crankshaft to exhaust camshaft cam chain, rotate the engine 30° counterclockwise to avoid damaging the valves during cylinder head removal and reinstallation.
  33. With the attached wire tie or mechanic's wire secured to the cam chain, carefully lower the chain downward making sure there is enough exposed wire to retrieve the chain for reinstallation.
  34. Remove the fasteners located in a recessed area near the front of the camshafts securing the front of the cylinder head to the engine block.
  35. In the reverse order of the tightening sequence, using a proper sized Torx® bit or tool No. 11 2 250, loosen the cylinder head mounting bolts in three steps as follows:

    Step 1: 90° Step 2: 90° Step 3: Completely remove the bolt
  36. With all of the cylinder head bolts removed, verify that all electrical connectors and fluid lines have been removed and lift the cylinder head off the engine block.



NOTE It is not recommended to machine the cylinder head surface of the S52 engine. If machining the cylinder head of an M52 engine, a 0.012 inch (0.3mm) thicker head gasket is available for reassembly.

 

FIG : Cylinder head mounting bolt tightening sequence-E36 models with 6-cylinder engines

image

To install:

  1. Thoroughly clean the deck surface of the engine cylinder block and the cylinder head surface.
  2. If the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before mounting the cylinder head on the engine to allow the lifters to compress fully as follows:

    At room temperature: Wait 4 minutes Temperatures down to 50° F (10° C): Wait 11 minutes Temperatures lower than 50° F (10° C): Wait 30 minutes



NOTE This is to prevent contact between the valves and the piston tops.

  1. The engine may not be cranked under the same condition for a period of:

    Room temperature: 10 minutes Temperatures down to 50° F (10° C): 30 minutes Temperatures below 50° F (10° C): 75 minutes
  2. Check the cylinder head for warpage and pressure test for coolant leakage.



WARNING Use care to not drop any pieces of gasket or debris into the oil or coolant passages.

  1. Inspect the condition and location of the head locating dowel sleeves.
  2. Apply a bead of an elastic non-drying gasket sealant such as Drei Bond® 1209 to the seam at the top of the area where the front timing cover and the engine block meet.
  3. Place a new head gasket on the engine block over the locating dowels.
  4. Carefully place the cylinder head onto the engine block making sure the dowel sleeves are properly aligned and be sure that the head sits flat on the engine block.



WARNING The cylinder head bolts may not be reused.

NOTE The bolts are a different length and have a different torque specification for aluminum engine blocks than those for the cast iron engine blocks.

  1. Install and torque the new cylinder head bolts in three steps, following the illustrated tightening sequence.
  2. On cast iron engine blocks:
    1. Wash the bolts in a cleaning solvent.
    2. Apply a light coating of oil to the head and threads of the bolts.
    3. Torque the M10 x 95mm bolts for cast iron engine blocks using the tightening sequence as follows:

      Step 1: 22.l ft. lbs. (30 Nm) Step 2: 90° Step 3: 90°

  3. On cast aluminum engine blocks:
    1. DO NOT remove the coating on the head bolts or wash them.
    2. Apply a light coating of oil to the head and threads of the bolts.
    3. Torque the M10 x 110mm bolts for cast aluminum engine blocks using the tightening sequence as follows:

      Step 1: 29.5 ft. lbs. (40 Nm). Step 2: 90°. Step 3: 90°.

  4. Install the fasteners located in the recessed area near the front of the camshafts securing the front of the cylinder head to the engine block and torque to 96 inch lbs. (10 Nm).
  5. With the attached wire secured to the crankshaft cam chain, carefully raise the chain upward and apply a light tension to the chain, then while holding the chain, carefully rotate the engine clockwise to TDC on cylinder number one.
  6. Lock the engine in the TDC position by placing the crankshaft positioning tool No. 11 2 300 through the machined hole in the engine block, just below the starter motor located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  7. Hold the camshafts TDC position by placing tool No. 11 3 240 or equivalent on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts such that two sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  8. Position the crankshaft cam chain over the exhaust cam chain sprocket and install the sprocket on the exhaust cam such that the slotted holes are centered with the fastener bores in the camshaft.
  9. Install the hydraulic cam chain tensioner, and the cam chain guide, then the intake and exhaust camshaft sprockets along with the cam chain and remove the tool used to hold the hydraulic cam chain tensioner collapsed.
  10. Install the crankshaft cam chain tensioner assembly, spring and cap nut.
  11. Apply gasket sealant to the upper corners of the cylinder head where the cover plate or the VANOS housing mounts and install a new gasket.
  12. On models equipped with VANOS ;
    1. Press the helical gear of the VANOS assembly toward the housing and install the VANOS assembly. On engines with a spring plate installed on the intake camshaft, place tool No. 11-5-490 or equivalent onto the exhaust camshaft sprocket and carefully rotate the sprocket counterclockwise to allow the helical gear of the VANOS unit to thread into the intake camshaft and to allow the VANOS unit to be pulled into the front of the cylinder head.
    2. If tool No. 11-5-490 or equivalent is not available, move the camshaft sprockets to install the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the exhaust cam sprocket to rotate both cam sprockets counterclockwise, while alternately pressing on the VANOS unit to install it. This procedure may need to be repeated several times to fully install the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.
    3. NOTE Make sure when assembling the VANOS unit is able to rest on the front of the cylinder head without being forced or without binding. If the VANOS unit does not fully seat it may be necessary to reposition the camshaft sprockets such that the slots in the camshaft sprockets allow enough movement of the sprockets for the helical gear of the VANOS assembly to be fully seated during assembly.
      1. Tighten the VANOS unit fastener and then torque the camshaft sprocket bolts of both the intake and exhaust cams to 16 ft. lbs. (22 Nm).

      1. Remove the crankshaft TDC alignment tool No. 113240 or equivalent from the engine, and remove the camshaft TDC positioning tool No. 11 3 240 or equivalent from the valve cover mating surface at the back of the cylinder head.


      WARNING If the camshafts have been removed and reinstalled, a waiting period dependent on the ambient temperature is necessary before rotating the crankshaft to allow the lifters to fully compress.
      1. The engine may not be cranked under these conditions for a period of:

        Room temperature: 10 minutes Temperatures down to 50° F (10° C): 30 minutes Temperatures below 50° F (10° C): 75 minutes


      NOTE This is to prevent contact between the valves and the piston tops.
      1. Once the waiting period has expired, slowly and carefully rotate the engine clockwise four complete revolutions bringing cylinder number one to TDC. If the engine binds for any reason stop immediately to evaluate and rectify the cause of the binding.
      2. With cylinder number one at TDC slide the camshaft TDC positioning tool No. 11-3-240 or equivalent over the ends of the cams and onto the valve cover mating surface. If the tool slides over the cams and is flush with the mating surface, the camshafts are properly timed. If the tool does not slide easily over the ends of the cams, or if the tool is not flush with the valve cover mating surface, the camshaft timing must be repeated until the tool fits squarely.
      3. The balance of installation is the reverse of the removal procedure.
      4. Top off the engine cooling system and bleed as necessary.


      NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
      1. Change the engine oil and filter.
      2. Check and top off all fluid levels as necessary.
      3. Connect the negative battery cable, start the engine and check for any leaks.

      M20 Engine
      1. Disconnect the negative battery cable. Make sure the engine is cool. Disconnect the exhaust pipes at the manifold and at the transmission clamp. Remove the drain plug at the bottom of the radiator and drain the coolant. Drain the engine oil.
      2. Disconnect the accelerator and cruise control cables. If the vehicle has automatic transmission, disconnect the throttle cable that goes to the transmission.
      3. Working at the front of the block, disconnect the upper radiator hose, the bypass water hose, and several smaller water hoses. Remove the diagnosis plug located at the front corner of the manifold. Remove the bracket located just underneath. Disconnect the fuel line and drain the contents into a metal container for safe disposal.
      4. Working on the air cleaner/airflow sensor, disconnect the vacuum hoses, labeling them if necessary. Disconnect all electrical connectors and unclip and remove the wiring harness. There is a relay located in an L-shaped box near the strut tower. Disconnect and remove it. Unclamp and remove the air hose. Remove the mounting nuts and remove the assembly.
      5. Disconnect the hose at the coolant overflow tank. Disconnect the idle speed positioner vacuum hose and then remove the positioner from the manifold.
      6. If equipped with 4-wheel drive, disconnect the vacuum hose from the servo mounted on the manifold.
      7. Place a drain pan underneath and then disconnect the water connections at the front of the intake manifold. Detach the electrical connector.
      8. Disconnect the heater water hoses. Press down on the vent tube collar and install the special tool or a similar device to retain the collar in the unlocked position. Disconnect the vent tube and inspect its O-ring seal, replacing it, if necessary.
      9. Unbolt the dipstick tube at the manifold. Remove the fuel hose bracket at the cylinder head. Make sure the engine is cold. Then, place a metal container under the connection and disconnect the fuel hose at the connection.
      10. Disconnect the high tension lead from the coil. Disconnect and remove the coolant expansion tank.
      11. If equipped with 4-wheel drive, disconnect the intake manifold vacuum hose leading the servo that engages 4-wheel drive.
      12. Detach the fuel injector connectors from all 6 injectors, as well as the 2 additional electrical connectors to sensors on the head. Disconnect the oil pressure sending unit connector. Then, unfasten the carriers and remove this wiring harness toward the left side of the vehicle.
      13. Disconnect the coil high tension wire and disconnect the high tension wires at the plugs. Then, disconnect the tube in which the wires run at the camshaft cover. Disconnect the PCV hose. Then, remove the retaining nuts and remove the camshaft cover.
      14. Turn the crankshaft so the TDC line is aligned on the indicator and the valves of No. 6 cylinder are in overlapping, slightly open position.
      15. Remove the distributor cap. Then, unscrew and remove the rotor. Unscrew and remove the adapter just underneath the rotor. Remove the cover underneath the adapter. Check its O-ring and replace it, if necessary.
      16. Remove the distributor mounting bolts and the protective cover.
      17. These engines are equipped on a rubber drive and timing belt. Remove the belt covers. To loosen belt tension, loosen the tension roller bracket pivot bolt and adjusting slot bolt. Push the roller and bracket away from the belt to release the tension, hold the bracket in this position, and tighten the adjusting slot bolt to retain the bracket it this position.
      18. Remove the timing belt.


      NOTE Make sure to avoid rotating both the engine and camshaft from this point onward
      1. Remove the cylinder head mounting bolts in three steps using the exact reverse order of the tightening sequence. Then, remove the cylinder head.
      2. FIG : To release the vent tube on the M20 engine, the collar must be held down with Tool No. 11 1 290 or equivalent

        image

      3. FIG : Cylinder head bolt torque sequencer-M20 engine

        image

      4. To install:

        1. Clean both cylinder head and block sealing surfaces thoroughly with a hardwood scraper. Inspect the surfaces for flatness.
        2. Install the cylinder head using a new gasket. Check that all passages line up with the gasket holes. Make sure all the bolt cavities are thoroughly cleaned and free of debris. Make sure to keep oil out of all the bolt cavities otherwise cracking may occur and/or the cylinder head torque will be inaccurate.
        3. The cylinder head must be installed using new Torx® head fasteners. Before installing the cylinder head bolts, carefully wash and oil them.



        NOTE New Torx® head fasteners are required for cylinder head installation. Neither the Torx® head or the hex head fasteners can be reused.

        1. Tighten the Torx® head cylinder head-to-engine block bolts as follows:
          1. Step 1: 22 ft. lbs. (30 Nm) following the cylinder head tightening sequence
          2. Step 2: Tighten 90° following the tightening sequence
          3. Step 3: Tighten and additional 90° following the tightening sequence



        NOTE With the No. 1 piston at Top Dead Center (TDC) of the compression stroke, make sure to align the timing marks when installing the timing belt. The crankshaft sprocket mark must point at the notch in the flange of the front engine cover. The camshaft sprocket arrow must point at the alignment mark on the cylinder head. BMW recommends that the timing belt be replaced every time the cylinder head is removed and/or the belt is disturbed. Make sure the belt is properly tensioned.

        1. Check and adjust the valves as necessary.
        2. Complete the installation by reversing all removal procedures making sure of the following.
        3. Change the engine oil and filter.
        4. Top off the cooling system with the proper mixture of coolant and bleed as necessary.
        5. Use new gaskets for the exhaust system connections, and coat the studs with an anti-seizing compound.
        6. Install the connectors for the DME reference mark and speed signals such that the gray plug goes to the socket with a ring underneath.
        7. Check and top off all fluid levels.
        8. Connect the negative battery cable and check for normal operation.


        M42 Engine

        1. Disconnect the negative battery cable.
        2. Remove the intake manifold and the exhaust manifold as outlined in this section.
        3. Remove the ignition coil cover and pull off the spark plug connectors.
        4. Remove the complete ignition leads. Remove the cylinder head cover.
        5. Disconnect the coolant hoses and remove the position sensor.
        6. Remove the thermostat housing and thermostat. Unscrew the upper timing case cover.
        7. Rotate the engine clockwise until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the camshaft sprockets should be facing up.
        8. Remove the chain tensioner. Remove the upper chain guide, chain guide bolt on the right side and the sprockets.
        9. Remove the cylinder head bolts in three steps in the opposite order of the tightening sequence.
        10. Remove the cylinder head. Clean the sealing surfaces on the cylinder head and the crankcase.
        11. FIG : Cylinder head bolt tightening sequence-M42 engine

          image

        12. To install:

          1. Clean the new head bolts and the bores of the cylinder block. Do not allow oil or contaminants to fill the bores. Use a 0.012 inch (0.3mm) thicker head gasket if the head was machined.
          2. Before installing the cylinder head;
            1. Make sure the camshafts are positioned in the cylinder head such that the camshaft is in the Top Dead Center (TDC) position for the compression stroke for cylinder number 1. In this position, the tips of the camshaft lobes for cylinder number 1 are pointing toward one another and the alignment tool No. 11 3 240 or its equivalent can be placed into position.
            2. Install a new head gasket in the proper orientation as marked on the gasket. Check the condition of the guide dowels in the cylinder deck.
            3. Install new seals into the top of the front timing case.
            4. On M42 engines produced since 9.92, make sure the check valve with the rubber lined spacing sleeve for the oil supply to the cylinder head is properly installed into the engine block.



          WARNING An improperly installed check valve will cause mechanical damage to the cylinder head.

          NOTE New cylinder head bolts must be installed, they cannot be reused.

          1. Thoroughly wash the new cylinder head bolts and lubricate them with fresh engine oil.
          2. Place the cylinder head onto the engine block and torque the cylinder head bolts in three steps following the illustrated tightening sequence as follows:
            1. Step 1: 22 ft. lbs. (30 Nm)
            2. Step 2: 90°
            3. Step 3: 90°



          NOTE During cylinder head or camshaft installation a waiting period is necessary before the camshaft timing chain can be installed to allow the hydraulic lash adjusters to bleed down and prevent the valves from contacting the pistons.

          1. If the camshafts were removed and installed while the cylinder head was removed, or if the camshafts are to be installed after the cylinder head is installed, a waiting period is necessary before the camshaft timing can be performed to allow the hydraulic lash adjusters to bleed down and prevent the valves from contacting the pistons.

          The waiting period varies depending on the work environment's ambient air temperature. The waiting period is as follows:



          Above 68°F (20°C): 4 minutes 50-67°F (10-19.4°C): 11 minutes 32-49°F (0-9.4°C): 30 minutes

          1. Once the proper waiting period has been observed, install the camshaft alignment Tool No. 11 3 240 or its equivalent. This positions the camshafts at Top Dead Center (TDC) on the firing stroke for cylinder number 1, and the arrows on the camshaft sprockets should be facing up. If the camshaft sprockets were removed, install the sprockets with the arrows pointing up and torque to 10-12 ft. lbs. (13-17 Nm).
          2. Pull upward and support the timing chain by hand and slowly rotate the crankshaft clockwise until cylinder number 1 is at (TDC).
          3. Secure the engine at TDC by installing Tool No. 11 2 300 or its equivalent through the machined hole in the engine block, and into the flywheel. The machined hole in the engine block is located just below the starter motor, and is sealed with a removable plug.
          4. Install the timing chain, timing guide bolt on the right side and the upper chain guide.
          5. If not installing a new tensioner piston, knock the outer sleeve of the tensioner piston so the piston is released from the sleeve. Assemble the tensioner with the spring, the piston and the snaprings in position. Place in a vice and press together until both snaprings engage. If the piston starts to extend, the procedure must be done again. The compressed tensioner length should be 2.697 inches (68.5mm).
          6. Install the tensioner into its bore and tighten the plug to 17-19 ft. lbs. (23-27 Nm). Push the tensioner rail against the tensioner to release the tensioner piston.
          7. Remove the camshaft and crankshaft alignment tools. Install the front timing upper cover using new gaskets filling the seam gaps with a suitable non hardening sealer. Press down on the cover to align it with a the cylinder head. Install the bolts and torque to 53-62 inch lbs. (8-10 Nm) for M6 bolts and 15-17 ft. lbs. (20-22 Nm) for M8 bolts.
          8. Install the thermostat housing using a new gasket and torque to 53-62 inch lbs. (8-10 Nm).



          NOTE Make sure the vent hole on the thermostat faces up.

          1. Install the camshaft position sensor.
          2. The balance of installation is in reverse order of removal noting the following.
          3. Fill and bleed the cooling system with the proper mixture of coolant.
          4. Change the engine oil and filter.
          5. Check and top off all fluid levels.
          6. Connect the negative battery cable and check for normal operation.


          M44 1.9L Engines

          1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
          2. Drain the cooling system.
          3. Relieve the fuel system pressure.
          4. Remove or disconnect the following:

            Negative battery cable Fuel feed and return lines Intake manifold Ignition coil cover and remove the spark plug connectors All the fasteners securing the brackets for the ignition coil wire harness, then move the harness aside to access the cylinder head cover Cylinder head cover Coolant hoses and temperature sensor Thermostat housing and thermostat Upper timing case cover
          5. Rotate the engine in the direction of the rotation until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the cam sprocket should face up.
          6. Remove or disconnect the following:

            Chain tensioner, the upper chain guide, the chain guide bolt on the right side and the camshaft sprockets Cylinder head bolts in the reverse order of the tightening sequence (from the outside to the inside) in at least 3 steps Cylinder head
          7. FIG : Cylinder head torque sequence-M44B19 1.9L engine

            image

          8. Install the cylinder head with a new gasket and bolts. Tighten the bolts in sequence as follows:

            Step 1: 22 ft. lbs. (30 Nm) Step 2: +90 degrees Step 3: +90 degrees
          9. The balance of installation is the reverse of the removal procedure.
          10. Fill the cooling system.
          11. Start the engine and check for leaks.
            NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
Customer: replied 4 years ago.
So there is no misunderstanding, this car is a 2000 528i, e39 series, with, I believe, am m5? motor! Your responce refers to e36, which is a 3 series.
Expert:  Tim's Auto Repair replied 4 years ago.

the straight 6 is your engine

thanks

Customer: replied 4 years ago.

That's correct. But as I'm sure you know, most BMW engines were straight 6's! As I understand it this motor is the m52B28. I am particularly interested in any issues with removal and replacement of the head gasket as it relates to that motor!? Thanks, Glenn

Expert:  Tim's Auto Repair replied 4 years ago.

ok..sorry for the delay..storm here

 

this is the m52 engine

thanks

 

 

M50/M52/S50 Engines

  1. If engine is not already removed from the vehicle, disconnect the negative battery cable and drain the engine coolant. Remove the intake manifold and throttle valve. Disconnect the exhaust pipes and the oxygen sensor wire. Remove the exhaust manifolds. Remove the thermostat housing and engine lifting eye.
  2. Pull off the connectors for the ignition coils and remove the coils. Unscrew the cylinder heads cover and remove. Remove the sender from the head and the electrical lead duct.
  3. Remove the upper timing case cover and the camshaft cover. Crank the engine in the direction of rotation so the intake and exhaust camshaft peaks for cylinder No. 1 face each other. Hold the camshafts in place with tool 11 3 240 or equivalent. With the camshafts in this alignment, the arrows on the sprockets will be facing up. Remove the valve cover mounting studs. Lock the flywheel in place to prevent movement of the crankshaft.
  4. Unscrew the chain tensioner and carefully remove. There is a spring contained within the tensioner and may eject if care is not taken.
  5. Press down on the upper chain tensioner and lock it into place using tool 11 3 290 or equivalent. Unscrew the transfer timing chain sprockets and pull the 2 off together with the chain. Remove the upper chain tensioner and the lower chain guide. Pull off the main timing chain sprocket along with the chain. Use a bent piece of wire to hold the chain from falling down into the engine. Do not rotate the engine after this point or the valve timing will be disturbed when the engine is reassembled.
  6. Unscrew the bolts on the head at the ends of the cams. Using a proper sized Torx® bit or tool 11 2 250, loosen the cylinder head bolts in several steps. Use an outside to inside pattern to prevent warpage. On production heads the bolt washers are locked into place while on replacement heads the washers are loose. Keep track of the bolt washers.

 

To install:

  1. If the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before mounting the cylinder head on the engine. At room temperature wait 4 minutes to allow the lifters to compress fully. At temperatures down to 50°F (10°C) wait 11 minutes. At temperatures lower than 50°F (10°C) wait 30 minutes. This is to prevent contact between the valves and the piston tops. The engine may not be cranked under the same condition for a period of 10 minutes at room temperature; 30 minutes for temperatures down to 50°F (10°C); 75 minutes for temperatures below 50°F (10°C).
  2. Clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or dirt into the oil or coolant passages. Check the condition of the head locating dowel sleeves.
  3. Place a new head gasket on the engine block over the locating dowels and gently place the head on the engine. Align the head with the dowel sleeves and check that the head sits flat on the engine.
  4. Cylinder head bolts may only be used once. Lightly oil the threads of the new cylinder head bolts. Check that the head bolt washers are in place and install the bolts. Torque the head bolts in 3 steps; Step 1 to 24 ft. lbs. (33 Nm), Step 2 and 3 to 93 degree torque angle. Torque the center bolts first and go out in a diagonal pattern.
  5. Align main timing chain and sprocket on the can so the arrow faces up. The bolt holes in the camshaft should be on the left sides of the sprocket slots. This will allow the tensioner to take up the slack in the chain and rotate the gear to the counterclockwise position.
  6. The balance of installation is the reverse of the removal procedure.
  7. Connect the negative battery cable, start the engine and check for any leaks.


M52 2.5L, 2.8L, And S52 3.2L Engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable Lower engine splash shield Exhaust manifolds from the exhaust pipes Rear hood seal, then remove the fasteners securing the sealed plastic housing for the engine wiring harness from the passenger compartment fresh air intake shroud Fresh air intake shroud If equipped, plastic trim covers from the top of the engine MAF sensor and remove intake manifold air duct along with the air filter housing assembly Throttle cable from the throttle body linkage, coolant hoses, the TP sensor electrical connector, the throttle body mounting fasteners, and remove the throttle body assembly Intake manifold support bracket fasteners from the intake manifold and loosen the support bracket fasteners on the engine block Fuel feed and return lines Vacuum hoses from the intake manifold, and loosen the clamps for the idle speed stabilizer underneath the manifold, and disconnect the hoses Intake manifold intake port fasteners and carefully lift the manifold away from the engine Ground cable at the front of the cylinder head, then remove the 2 radiator hoses from the thermostat housing, and remove the housing Exhaust manifolds Wire connectors for the ignition coils and cylinder head sensors and remove the coils, then remove the cylinder head cover
  5. Rotate the engine in the direction of rotation to TDC for cylinder number one. Cylinder number 1 will be at TDC when the intake and exhaust camshaft peaks for cylinder number 1 face each other
  6. Lock the engine in the TDC position by placing the holding dowel tool No. 11-2-300 through the machined hole in the engine block, just inside of the transmission bell housing mounting tab located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  7. The camshafts are held in the TDC position by placing tool No. 11-3-240 on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts. Secure the camshafts so that 2 sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  8. Remove or disconnect the following:

    Valve cover mounting studs The 2 hex plugs at the front of the cylinder head to access the exhaust camshaft sprocket mounting bolts, then loosen the exhaust cam sprocket bolts 2 turns
  9. Press down on the secondary cam chain tensioner between the 2 camshaft sprockets and install tool No. 11-3-292 through the back side of the tensioner housing to hold the tensioner down. A similar sized and suitably hardened drill bit can be substituted for tool No. 11-3-292.
  10. Remove the fasteners from the front of the cylinder head securing the hydraulic variable camshaft control (VANOS) unit to the cylinder head, and inspect to make sure any hydraulic or sensor connectors have been removed or disconnected.
  11. On engines with a spring plate installed on the intake camshaft, place tool No. 11-5-490, onto the exhaust camshaft sprocket. Carefully rotate the sprocket clockwise to allow the helical gear of the VANOS unit to release the intake camshaft and to allow the VANOS unit to be pulled away from the front of the cylinder head.
  12. If tool No. 11-5-490 is not available, move the camshaft sprockets to release the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the intake cam sprocket to rotate both cam sprockets clockwise, while alternately pulling on the VANOS unit to release it. This procedure may need to be repeated several times to fully release the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.
  13. With the VANOS assembly removed, remove the intake and exhaust camshaft sprockets, the hydraulic cam chain tensioner, and the cam chain guide.
  14. From the side of the right front area of the engine, remove the cap nut for the cam chain tensioner for the cam chain that runs between the crankshaft and the exhaust camshaft sprocket. Use care when removing the tensioner cap nut as the cam tensioner spring applies pressure to the cap nut.
  15. Remove the exhaust cam tensioner, and then release the sprocket from the cam chain.
  16. Attach a wire tie or mechanic-s wire to the cam chain and temporarily secure the chain fully extended.
  17. Remove the dowel from the engine and flywheel locking the engine in the TDC position.
  18. While holding the crankshaft to exhaust camshaft cam chain, rotate the engine 30 degrees counterclockwise to avoid damaging the valves during cylinder head removal and reinstallation.
  19. With the attached wire tie or mechanic-s wire secured to the cam chain, and carefully lower the chain downward making sure there is enough exposed wire to retrieve the chain for reinstallation.
  20. Remove the fasteners located in a recessed area near the front of the camshafts securing the front of the cylinder head to the engine block.
  21. In the reverse order of the tightening sequence, using a proper sized Torx® bit or tool No. 11-2-250, loosen the cylinder head mounting bolts in 3 steps as follows:

    Step 1: 90 degrees Step 2: 90 degrees Step 3: Completely remove the bolt
  22. With all of the cylinder head bolts removed, verify that all electrical connectors and fluid lines have been removed and lift the cylinder head off the engine block.
    NOTE It is not recommended to mill the cylinder head surface of the S52 engine. If milling the cylinder head of an M52 engine, a thicker head gasket is available for reassembly.

 

To install:

FIG : Cylinder head torque sequence-M52 2.5L, 2.8L, S52 3.2L engines

image

  • Thoroughly clean the deck surface of the engine cylinder block.
  • If the camshafts have been removed and reinstalled a waiting period dependent on the ambient temperature is necessary before mounting the cylinder head on the engine. At room temperature wait 4 minutes to allow the lifters to compress fully. At temperatures down to 50°F (10°C), wait 11 minutes. At temperatures lower than 50°F (10°C) wait 30 minutes. This is to prevent contact between the valves and the piston tops. The engine may not be cranked under the same condition for a period of 10 minutes at room temperature; 30 minutes for temperatures down to 50°F (10°C); 75 minutes for temperatures below 50°F (10°C).
  • Make sure the cylinder head has been checked for warpage and coolant leakage.
  • Do not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves.
  • Place a new head gasket on the engine block over the locating dowels and gently place the head on the engine with the dowel sleeves properly aligned and check that the head sits flat on the engine.
    NOTE The cylinder head bolts may not be reused. The bolts are a different length and have a different torque specification for aluminum engine blocks than those for the cast iron engine blocks.
  • Install and torque the new cylinder head bolts in 3 steps following the tightening sequence.
  • On cast iron engine blocks, wash the bolts in a cleaning solvent, then apply oil to the threads of the bolts and torque in sequence as follows:

    Step 1: 22.l ft. lbs. (30 Nm) Step 2: 90 degrees Step 3: 90 degrees
  • On aluminum engine blocks do not remove the coating on the head bolts, apply oil to the threads and torque in sequence as follows:

    Step 1: 29.5 ft. lbs. (40 Nm) Step 2: 90 degrees Step 3: 90 degrees
  • Install the fasteners located in the recessed area near the front of the camshafts securing the front of the cylinder head to the engine block and torque to 96 inch lbs. (10 Nm).
  • With the attached wire secured to the crankshaft cam chain, carefully raise the chain upward and apply a light tension to the chain, then while holding the chain, carefully rotate the engine clockwise to TDC on cylinder number one.
  • Lock the engine in the TDC position by placing the holding dowel tool No. 11-2-300 through the machined hole in the engine block, just inside of the transmission bell housing mounting tab located on the left lower portion of the engine block. Slide the locating dowel through the machined hole in the block and into the machined hole in the flywheel to prevent movement of the crankshaft.
  • Hold the camshafts in the TDC position by placing tool No. 11-3-240, on the valve cover mating surface at the back of the cylinder head and onto the squared ends of the camshafts, securing the camshafts so that 2 sides of the squared ends are parallel with the cam cover gasket mating surface. With the camshafts in this position, the arrows on the sprockets will be facing up.
  • Position the crankshaft cam chain over the exhaust cam chain sprocket and install the sprocket on the exhaust cam such that the slotted holes are centered with the fastener bores in the camshaft.
  • Install the hydraulic cam chain tensioner, and the cam chain guide, then the intake and exhaust camshaft sprockets along with the cam chain and remove the tool used to hold the hydraulic cam chain tensioner collapsed.
  • Install the crankshaft cam chain tensioner assembly, spring and cap nut.
  • Apply sealant to the upper corners of the cylinder head where the VANOS housing mounts and install a new VANOS housing gasket.
  • Press the helical gear of the VANOS assembly toward the housing and install the VANOS assembly. To do so on engines with a spring plate installed on the intake camshaft, place tool No. 11-5-490 onto the exhaust camshaft sprocket. Carefully rotate the sprocket counterclockwise to allow the helical gear of the VANOS unit to thread into the intake camshaft and to allow the VANOS unit to be pulled into the front of the cylinder head.
  • If tool No. 11-5-490 is not available, move the camshaft sprockets to install the VANOS by using a suitable drift and soft faced mallet and lightly tapping on a sprocket tooth of the exhaust cam sprocket to rotate both cam sprockets counterclockwise, while alternately pressing on the VANOS unit to install it. This procedure may need to be repeated several times to fully install the VANOS unit, and must be performed very carefully, in such a manner to not distort or damage the teeth of the cam sprocket.
    NOTE Make sure when assembling the VANOS unit is able to rest on the front of the cylinder head without being forced or without binding. If the VANOS unit does not fully seat it may be necessary to reposition the camshaft sprockets such that the slots in the camshaft sprockets allow enough movement of the sprockets for the helical gear of the VANOS assembly to be fully seated during assembly.
  • Tighten the VANOS unit fastener and then torque the camshaft sprocket bolts of both the intake and exhaust cams to 16 ft. lbs. (22 Nm).
  • Remove the crankshaft TDC holding dowel tool No. 11-3-240 from the engine, and remove the camshaft TDC positioning tool No. 11-3-240 from the valve cover mating surface at the back of the cylinder head.
  • Slowly and carefully rotate the engine clockwise 4 complete revolutions bringing cylinder number 1 to TDC. If the engine binds for any reason stop immediately to evaluate and rectify the cause of the binding.
  • With cylinder number 1 at TDC slide the camshaft TDC positioning tool No. 11-3-240 over the ends of the cams and onto the valve cover mating surface. If the tool slides over the cams and is flush with the mating surface, the camshafts are properly timed. If the tool does not slide easily over the ends of the cams, or if the tool is not flush with the valve cover mating surface, the camshaft timing must be repeated until the tool fits squarely.
  • The balance of installation is the reverse of the removal procedure.
  • Top off the engine cooling system and bleed as necessary.
    NOTE It may be necessary to bleed the cooling system a second time after the engine has been started.
  • Change the engine oil and filter.
  • Connect the negative battery cable, start the engine and check for any leaks.
  • Tim's Auto Repair, Mechanic
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    Customer: replied 4 years ago.
    Thank you!
    Expert:  Tim's Auto Repair replied 4 years ago.

    you are welcome

    thanks for using justanswer

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