How to Replace timing chain on BMW 525D E60 E61 2004-2007

Special tools

• Camshaft alignment/locking tool – BMW No.11 6 320.
• Crankshaft pulley turning tool – BMW No.11 6 480.
• Flywheel locking tool 1 – BMW No.11 8 182/11 8 183.
• Flywheel locking tool 2 – BMW No.11 8 010.
• Flywheel timing pin – BMW No.11 2 300.
• Timing chain tensioner locking pins – BMW No.11 3 340.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• 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:
  • Engine removal.
  • Cylinder head removal.
  • Sump removal.

NOTE: Refer to Autodata Technical Data for tightening sequence and torques.

NOTE: Refer to Technical Data module for tightening torques.

• Engine at TDC on No.1 cylinder.
• Insert flywheel timing pin [1] .
• Ensure camshaft lobes are positioned as shown [2] & [3] .
• Install camshaft alignment/locking tool on inlet camshaft [4] .
• Ensure camshaft alignment/locking tool abuts cylinder head.
  • Remove camshaft alignment/locking tool.
• Install camshaft alignment/locking tool on exhaust camshaft [5] .
• Ensure camshaft alignment/locking tool abuts cylinder head.
• If not, adjust camshafts as follows:
  • Ensure inlet camshaft lobe positioned as shown [2] .
  • Hold camshafts with spanner on hexagon [6] .
  • Slacken camshaft sprocket bolts [7] & [8] .
  • Ensure camshaft sprockets turn freely but do not tilt.
  • If necessary, adjust position of inlet camshaft.
  • Install camshaft alignment/locking tool on inlet camshaft [4] .
  • Ensure camshaft alignment/locking tool abuts cylinder head.
  • Hold inlet camshaft with spanner on hexagon [6] .
  • Tighten inlet camshaft sprocket bolt [8] . Tightening torque: 20 Nm + 50°.

  NOTE: Camshaft sprocket bolt MUST only be used once.

  • Remove camshaft alignment/locking tool.
  • Ensure exhaust camshaft lobe positioned as shown [3] .
  • If necessary, adjust position of exhaust camshaft.
  • Install camshaft alignment/locking tool on exhaust camshaft [5] .
  • Ensure camshaft alignment/locking tool abuts cylinder head.
  • Hold exhaust camshaft with spanner on hexagon [6] .
  • Tighten exhaust camshaft sprocket bolt [7] . Tightening torque: 20 Nm + 50°.

  NOTE: Camshaft sprocket bolt MUST only be used once.

  • Remove camshaft alignment/locking tool.
• Remove flywheel timing pin.
• Turn crankshaft two turns clockwise. Check valve timing.
• To lock upper timing chain tensioner:

  NOTE: Only upper timing chain tensioner can be reset with front timing chain cover in place.

  • Remove blanking plug [9] .
  • Slacken oil pressure relief bolt [10] .
  • Turn inlet camshaft slowly clockwise to compress the upper timing chain tensioner.
  • Camshaft rotation possible using spanner on hexagon [6] .
  • Insert timing chain tensioner locking pin [11] .
• To lock lower timing chain tensioner:
  • Remove timing chain cover.
  • Compress tensioner plunger. Fit timing chain tensioner locking pin [12] .
• To unlock timing chain tensioners:
  • Remove locking pins [11] & [12] .
  • Tighten oil pressure relief bolt [10] .
• Fit new crankshaft pulley bolts. Tightening torque: 40 Nm + 60° + 60°.

NOTE: Camshafts can be fitted without valves contacting pistons when crankshaft is set at 45° BTDC on No.1 cylinder.