How to Replace timing chain on BMW 535D E60 E61 2007-2010

Special tools

• Camshaft alignment tool – BMW No.11 6 321.
• Camshaft locking tool – BMW No.11 6 322.
• Crankshaft alignment tool – BMW No.11 6 480.
• Crankshaft locking tool – BMW No.11 8 010 (AT version GM-5).
• Crankshaft locking tool 1 – BMW No.11 8 182 (AT version 6HP-19).
• Crankshaft locking tool 2 – BMW No.11 8 183 (AT version 6HP-19).
• Crankshaft locking tool 3 – BMW No.11 8 185 (MT version).
• Flywheel timing pin 1 – BMW No.11 5 180.
• Flywheel timing pin 2 – BMW No.11 6 080.
• 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.
• 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:
  • 6 cylinders: 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.
• Remove blanking plug from cylinder block.
• 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.
• Install camshaft alignment/locking tool on exhaust camshaft [5] .
• Ensure camshaft alignment/locking tool abuts cylinder head.
• Ensure timing marks on rear of camshaft gears aligned with upper edge of cylinder head [6] .
• If not, adjust camshafts as follows:
  • Hold inlet camshaft with spanner on hexagon [7] .
  • Slacken inlet camshaft sprocket bolts [8] .
  • Align inlet camshaft. Use camshaft alignment tool [4] .
  • Ensure camshaft alignment tool abuts cylinder head.
  • Lock inlet camshaft alignment tool in position with locking tool [9] .
• Tighten camshaft sprocket bolts [8] :
  • Tightening torque: 4 cylinders – 15 Nm. 6 cylinders – 14 Nm.

  NOTE: Camshaft sprocket bolts MUST only be used once.

• Camshaft rotation can be prevented using spanner at position shown [7] .
• Remove flywheel timing pin.
• Remove camshaft alignment/locking tool.
• 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 [10] .
  • Turn inlet camshaft slowly clockwise to compress the upper timing chain tensioner.
  • Camshaft rotation possible using spanner on hexagon [7] .
  • 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] .
• Fit new crankshaft pulley central bolt.
  • Tightening torque: M10 – 40 Nm + 120°. M18 – 100 Nm + 150°.

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