How to Replace timing chain on BMW 520i E60 E61 2003-2005

Special tools

• Camshaft alignment tool 1 – BMW No.11 3 240.
• Camshaft alignment tool 2 – BMW No.11 3 244.
• Camshaft sprockets alignment tool – BMW No.11 6 180.
• Camshaft timing setting tool – BMW No.11 6 150.
• Crankshaft pulley/hub puller (one-piece pulley) – BMW No.11 8 190/200/210.
• Crankshaft pulley/hub puller (two-piece pulley) – BMW No.11 2 150/410.
• Flywheel timing pin – BMW No.11 2 300.
• Timing chain pre-tensioning tool 1 – BMW No.11 4 220.
• Timing chain pre-tensioning tool 2 – BMW No.00 9 250.
• Tensioner locking tool – BMW No.11 3 292.
• VANOS unit checking tool – BMW No.11 3 450.

General precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Removal/installation of timing chain requires:
  • Sump removal, if two-piece crankshaft pulley/damper is fitted.

  NOTE: Refer to Autodata Technical Data for tightening torques.

  NOTE: Refer to Technical Data module for tightening torques.

• Engine at TDC on No.1 cylinder.
• Ensure camshaft lobes are facing [1] .
• Ensure camshaft alignment tool can be fitted [2] .
• If not, adjust camshafts as follows:

  NOTE: Tensioner plunger is spring loaded.

  • Remove tensioner [3] .
  • Pre-load timing chain with tool to 0,7 Nm [4] .
  • Unscrew VANOS unit oil pressure pipe.
  • Connect compressed air (2-8 bar) to VANOS unit. Use special tool.
  • Turn crankshaft two turns until camshaft lobes face each other [1] .
• Insert flywheel timing pin [5] .
• Ensure camshaft alignment tool can be refitted [2] .
• Remove VANOS unit [6] .

  NOTE: Screws behind sealing caps have LH threads [7] .

• Remove timing chain pre-tensioning tool [4] .
• Depress secondary tensioner and lock with tool [8] .
• Remove inlet and exhaust camshaft sprockets [9] & [10] complete with secondary chain.
• Remove secondary tensioner [11] .
• Remove exhaust camshaft sprocket and chain [12] .
• Install sprockets with chains as follows:
  • Fit exhaust camshaft sprocket with chain. Ensure arrow on sprocket aligned with upper edge of cylinder head [13] .
  • Install chain pre-tensioning tool [4] .
  • Screw in adjusting screw until in contact with guide rail (DO NOT tighten screw). If necessary, realign camshaft sprocket [13] .
  • Install secondary tensioner [11] .
  • Fit toothed sleeve [14] and toothed shaft with pin [15] to exhaust camshaft sprocket. Ensure tooth gaps aligned towards each other [16] .
  • Push in toothed shaft until threaded holes positioned in centre of slots [17] .
  • Align camshaft sprockets with secondary chain in position as shown [18] . Use special tool.
  • During installation of camshaft sprockets, ensure tooth gaps on inlet side aligned towards each other [19] .

  NOTE: Camshafts can be turned without valves contacting pistons when crankshaft is set at 30° BTDC on No.1 cylinder.

• Fit toothed shaft with pin to inlet camshaft sprocket. Push in toothed shaft until only 1 mm of spline is visible [20] .
• Install washers and nuts [21] . DO NOT tighten.
• Install plate spring with mark ‘F’ visible [22] and sensor gear [23] to exhaust camshaft.
• Ensure arrow on sensor gear aligned with upper edge of cylinder head [23] . DO NOT tighten nuts.
• Pull out toothed shaft on exhaust side as far as stop.
• Install and release secondary tensioner [8] .
• Pre-load timing chain with tool to 0,7 Nm [4] .
• Slightly pre-load plate spring by pressing on sensor gear [23] . Tighten nuts fingertight.
• Set camshaft timing with tool as follows:

  NOTE: Remove gasket before fitting special tool [24] . Tool No.11 6 150.

  • Tighten screws and nuts in two stages (in sequence shown) [24] :
  • First stage: 5 Nm.
  • Second stage: ‘A’ – 20 Nm. ‘B’, ‘C’ – 10 Nm.
• Install timing chain tensioner [3] .
• Remove alignment tools and turn crankshaft two turns.
• Check engine at TDC on No.1 cylinder. Use special tools.
• Remove camshaft timing setting tool [24] . Tool No.11 6 150.
• Install VANOS unit [6] .

  NOTE: Screws behind sealing caps have LH threads [7] .

• Engine with one-piece crankshaft pulley/damper [25] .
• Engine with two-piece crankshaft pulley/damper [26] .

NOTE: Crankshaft pulley centre bolt MUST only be used once.