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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 01-31-2011, 06:34 PM
Kelley71 Kelley71 is offline
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Mein Auto: 2000 E39 540IA Sport
M62TU Head gasket/ Timing guides journal

Does anyone have any tricks for removing the heads on a 540i.

I have everything unbolted. I twas told I could remove with the exhaust manifolds in place but I am having trouble wrestling this out because the timing rails are in the way to get the angle correct.

Any tips would be appreciated. There is not much room to remove exhaust manifold bolts.

Thanks in advance.

Last edited by Kelley71; 02-08-2011 at 02:08 PM. Reason: title more suited
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  #2  
Old 01-31-2011, 07:02 PM
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bluebee bluebee is offline
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I looked in the the VERY best of E39 Links and only saw related M54 links:
- Replacing the M54 head gasket (1) & M54 cam shaft (1)

So, when you find a good link let us know which were best so we can add them to the best links thread for future users.
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  #3  
Old 01-31-2011, 07:15 PM
Kelley71 Kelley71 is offline
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I will let everyone know. This has been a job! I am almost to the halfway point.

I am replacing both head gaskets while I have the motor tore down.

I have to buy a tool to hold the crank. I am going to replace the rails while I have it down.

The problem is this car SPECIAL TOOLS you to death.
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  #4  
Old 02-01-2011, 08:49 AM
wyowolf wyowolf is online now
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according to ALLDATA the Ex will have to come off. You will also need the tools to retime it all, but you already know that... also looks like you have to support the Engine to remove the exhausts... strange.. but thats what the book says.
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  #5  
Old 02-01-2011, 05:34 PM
Kelley71 Kelley71 is offline
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Well, I got the heads off today.

The passenger side head came off with the exhaust manifold on very easily.

The driver side head, well that with swivel sockets and 2x4's to help adjust the head to get to bolts, I got the exhaust manifold off. Will be a PITA to put back on.

Tomorrow morning they will go the the machine shop.

I posted some photos of the block. The motor had a lot of sludge. The previous owner said he changed the oil when the computer told him to with only synthetic oil. Yuck!!
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  #6  
Old 02-01-2011, 07:55 PM
JBono333 JBono333 is offline
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Bluebee,

You are the man when it comes to snarffing up these threads. Tanks for all the help you geiv the members

JBono333
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  #7  
Old 02-01-2011, 09:42 PM
edjack edjack is offline
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Disgusting! The PO s/b horsewhipped!
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Last edited by edjack; 02-01-2011 at 09:43 PM.
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  #8  
Old 02-02-2011, 09:58 AM
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bluebee bluebee is offline
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Quote:
Originally Posted by edjack View Post
Disgusting! The PO s/b horsewhipped!
Help me here.

I see an open engine.

I don't see what Edjack is referring to as (presumably) neglect.

So that I may learn, what specifically in the pictures below is that neglect.


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  #9  
Old 02-02-2011, 10:21 AM
Mark@EAC Mark@EAC is offline
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you've been here long enough that you have had to have seen ketchup's sludge thread yes? That is what they are talking about, oil sludge built up in the engine.
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  #10  
Old 02-02-2011, 11:58 AM
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bluebee bluebee is offline
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Quote:
Originally Posted by Mark@EACTuning View Post
ketchup's sludge thread yes?
I put this in the bestlinks thread long ago:
- Why sludge in the oil cap is an indication of a failing CCV (aka PCV)

But, the pictures look nothing like the sludge there:

I thought, in the pictures, there was a "mechanical" problem shown.

Is it just the 'brown sludge' from a failed CCV that is what is being referred to as potential neglect?
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  #11  
Old 02-02-2011, 12:45 PM
Mark@EAC Mark@EAC is offline
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well I suppose then it's all in the eye of the beholder. I can see the sludge build up plain as day in the OP's pics.
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  #12  
Old 02-02-2011, 04:31 PM
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bluebee bluebee is offline
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Quote:
Originally Posted by Mark@EACTuning View Post
I can see the sludge build up plain as day .
I guess I need to look closer!
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  #13  
Old 02-02-2011, 05:21 PM
Kelley71 Kelley71 is offline
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Well today it was 19 degrees in Houston with the wind blowing at 25 mph.

So I dropped off the heads at

David's Automotive Machine Shop in Houston, TX. They do great work. I have been using them for a long time.

I ordered all my parts. Spent the rest of the day CLEANING parts in the shop.

I need to get the Jesus bolt out. If anyone in the Houston area has a counter hold tool or anyone has an idea building one. Let me know.

When it warms I will drop the pan, break the Jesus bolt and clean the rest of what I can on the motor getting the sludge out.
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  #14  
Old 02-04-2011, 06:48 AM
Kelley71 Kelley71 is offline
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Yesterday was the fight with the Jesus bolt and I lost. I made a tool holding 2 bolts and I broke a piece of the hub away.

My father and I are making a good tool now.

See photos below. We are almost finished. We just have to attach something to hold now.

This tool will be top class.
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  #15  
Old 02-05-2011, 01:04 PM
Kelley71 Kelley71 is offline
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My new tool worked awesome. I have to go to work now though....

Question??

I removed the lower pan, all 8 bolts to drop lower timing cover. Removed Power steering. All front cover bolts that I could find and this lower cover WILL NOT BUDGE...


Any suggestions?
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  #16  
Old 02-05-2011, 07:52 PM
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bluebee bluebee is offline
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Just a quick question ... what's a "jesus bolt"?
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  #17  
Old 02-05-2011, 10:05 PM
repcapale repcapale is offline
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That bolt in that picture with the big wrench on it. Good name. Jesus bolt.
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  #18  
Old 02-05-2011, 11:45 PM
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first540i first540i is offline
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did you remove the water pump for the lower timing cover?
theres another bolt in there
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  #19  
Old 02-06-2011, 03:25 AM
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Jason5driver Jason5driver is offline
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Wow!
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  #20  
Old 02-06-2011, 08:10 AM
Kelley71 Kelley71 is offline
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Yesterday we finished building the counter hold tool. I will say my tool kicks BMW's A**. My father is a genius when it comes to manufacturing. We welded a steel plate and machined out so a one inch breakover bar will fit. I rested the breakover bar again the frame and the Jesus bolt (center crankshaft pully bolt) broke loose easily. This tool you can do it alone.

I dropped the lower pan. Found the retaining clip to one of my cam to cam tensioners. I removed the 8 bolts under the front of the upper pan.
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Last edited by Kelley71; 02-06-2011 at 08:42 PM.
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  #21  
Old 02-06-2011, 08:38 PM
Kelley71 Kelley71 is offline
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Today I removed the guide rails (glad I did now), cleaned the surfaces, installed new valley pan and cover, and finished the deck of the motor.

Now I am waiting on my heads, Vanos tools, and will have my valve covers powder coated.

Tomorrow I will change motor mounts.

See photos, thanks for all the insight from all you guys!
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Last edited by Kelley71; 02-06-2011 at 08:42 PM.
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  #22  
Old 02-08-2011, 02:06 PM
Kelley71 Kelley71 is offline
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Update,

Exhaust valve guides needed to be replaced on both heads. This set me back a day because no one in Houston stocked the guides.

Everything is clean awaiting reassembly.

A head gasket / timing guide job while working two jobs was more than I expected but a great sense of accomplishment when this thing is done.

Changed motor mounts today. Driver side was definitely shot .
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  #23  
Old 02-08-2011, 03:16 PM
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bluebee bluebee is offline
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Originally Posted by Kelley71 View Post
Everything is clean awaiting reassembly
I'm jealous!
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  #24  
Old 02-08-2011, 03:32 PM
jamesthebikeguy jamesthebikeguy is offline
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Ugh, that engine sludge is like no other in their eh?

Would dropping a can of sea-foam in the oil loosen any of that up you think?

Sea-foam worked wonders on the egr, and ccv on my old Mazdaspeed3
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  #25  
Old 02-09-2011, 10:01 PM
Kelley71 Kelley71 is offline
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Today I spent the day waiting for UPS and Fedex. No one stocked valve guides so my head will be ready at 10:00 am CST.

But my valve cover were finished being powder coated.

I was told the valve covers must be baked at 400 to release any gases before powder coating. BMW uses epoxy to fill in any imperfections and powder coating has to be bare metal. But for 95 dollars my valve covers look great.

Tomorrow weather permitting I can reassemble the top half until I get my timing tools.
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