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  1. #1
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    Yes | No

    540i Valve Cover Gasket Replacement (with pics!)

    When I bought my car the one of the valve cover gaskets was leaking, and the other one was replaced about 6 month earlier. Then within the next year or so, one, then the other one, started leaking oil. I procrastinated for about 2 years, cleaning a couple of drops below the car every day or so, but today I finished the job - hopefully it will last a while ...

    These are the "before" photos:











    There is a good guide with pictures/notes here which I used for assembly and disassembly:
    http://home.comcast.net/~snyderwc/vcgaskete38.html

    So using that guide I proceeded to get my car ready:




    and sure enough, I had oil in the spark plug holes, in both sides!



    Getting the passenger side valve cover was easier than the driver's side. Here is how things look like:






    I though the valve covers looked bad on the outside, but look how the inside looked like!. That stuff/paint is flaking on the freaking inside of the engine!




    I cleaned/scraped/removed all of the loose paint inside and out:



    And then used engine primer and engine enamel to re-coat the valve covers inside and out:




    After I did several coats with the required drying time in between, I got a much nicer finish:










    I then looked at the gaskets that I took out. They look in great shape, but there was oil leaking!. If you look at them you will see that the "top" surface of the gasket that goes in the matching groove in the valve cover was not smooth - there were LOTs of debris, which of course explains how the oil seeps out!. So basically, each time there is an oil leak, the gasket is replaced, but eventually the leak has to come back since the "real problem" is never fixed!









    Although I cleaned the groove in the valve cover as best as I could, I still went ahead and added a small bead of RTV silicone to that groove, which helps keep the gasket in place during installation, and makes a better oil seal than the gasket alone:




    Of course, per the TIS, I added RTV to the "key" places:





    I also cleaned the mounting hardware in my tumbler:




    The old rubber bushings were not only hard, but also impregnated with the peeling paint as well, so they would not do much to seal oil either:




    Putting the valve cover back was not so bad on the passenger side. I used a small mirror to check alignment of the gasket at those "semi-circles" in the back:







    This part broke - it was so old, it was completely brittle:



    On the driver side, I had to re-tap the screws for the Pos Bat terminal (prior mechanics must have used too much force!). The red wire powers my electric fan, part of my Zionsville radiator package:



    So I finished the driver's side. Did I mention it was harder? Man, that is a tight fit, specially to get the read semi-circle gasket part to line up!.




    On the driver side I broke this tube!. I put on my McGiver hat and used RTV and heat shrink tubing to create a seal - lets see how long it holds!:




    OK, so these are the "after" pictures:




    I then of course did a full oil/filter change, and in a few days I will change the filter again, just to be on the safe side. I have been using dino oil since it seeps less than the synthetic, but now I can use it - in fact, since it flows so much better, it will be a good test to see if/when I get a leak again:



    I started the car, and it came right up. Nothing strange. No fluids gushing out anywhere. Then tonight I went out with the family for dinner and when I got back, it was all still dry. At least for now. I will check tomorrow morning to see if I can see any leaks. If I don't, I will just keep checking now and then, but I hope it will be a LONG time before I have to do this again :-)

    Will

    William
    Richardson, Texas
    2010 Honda Accord EX, 4-cyl, auto-tranny (her car)
    2000 BMW 540i Auto, TiSilver, Sport/Prem Package (my car)

    Retired/sold:
    2006 Dodge Charger Daytona - Top Banana
    2005 BMW 330i Auto, Premium Package
    2002 M3 Coupe with SMG
    1995 525i auto
    1991 535i 5-speed manual


  2. #2
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    Yes | No

    Nice job, but I do have to caution you. It seems

    you painted the inside the covers. You do know covers are made out of magnesium. There is a chance that paint might start peeling off. I really hope I'm wrong, but here is what happened to me:
    When I had a shop powder coat my covers, I've asked them to not powder coat inside and they still did. After a short time, I happened to look inside through to oil cap opening and I've seen paint bubbling.
    I went back and they redid the job, but this time they didn't powder coat inside.
    Apparently, there is a special procedure to powder coat magnesium and they didn't know that first time. So I'm just cautioning you to watch for paint holding up and maybe you won't have problem since you painted instead of powder coating.
    Also, you have to wonder that paint peeling off originally might have something to do with magnesium.
    Again, I really, really hope I'm wrong in your case, because it wasn't fun redoing my job in matter of weeks and buying new gaskets and groomets.



    1998 BMW 540i 6 speed
    Arctic silver, M sport suspension (euro delivery), prod. date 05/98, non VANOS
    Staggered 18" style 32 OEM wheels
    3.15 open differential
    Remus exhaust
    AFE CAI with improved heat shield
    Z3 shifter
    VDO oil pressure and temperature gauges in place of headlight/fog switches
    Powder coated valve covers-satin black
    CDV delete
    Debadged
    AEA DRL module (aftermarket daytime running lights)

    1997 BMW 528iA
    Alpine white, premium package, prod. date 04/97, single VANOS
    Staggered 17" style 32 OEM wheels
    Debadged
    AEA DRL module
    Custom made sun blinds for rear seating area

    2000 Nissan Frontier Desert Runner, AKA "The Work Horse"

    Garage aids:
    Direct Lift Pro Park 8
    Campbell Hausfeld 28 gallon oil lubricated air compressor
    Newair ACP-1400H portable air conditioner and heater
    Auto Enginuity scan tool with BMW enhanced option
    Actron 9135 scan tool-for quick readouts



  3. #3
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    Yes | No

    Sounds good - thanks for the advice (m)

    I will check every couple of days (looking through the oil fill hole) to check how good (or bad) the primmer/paint are holding on. That was the main reason I used the primer first - lets see how it goes :-)

    Will
    William
    Richardson, Texas
    2010 Honda Accord EX, 4-cyl, auto-tranny (her car)
    2000 BMW 540i Auto, TiSilver, Sport/Prem Package (my car)

    Retired/sold:
    2006 Dodge Charger Daytona - Top Banana
    2005 BMW 330i Auto, Premium Package
    2002 M3 Coupe with SMG
    1995 525i auto
    1991 535i 5-speed manual

  4. #4
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    Yes | No

    I agree. BMW did a lousy job painting the inside

    and when I redid mine on the 840 I left the inside alone. The hot oil and paint in a confined space just don't mixes very well.

    I had the valve cover media blasted and the inside was left alone as it is.

    On the 840 the driver side is even harder due to the brake setup. Very tight fit.

    I would also use black paint as I did what you, silver like the factory. 4 years and 8k miles later the silver paint is yellowish and looks like crap. The yellow discoloration could have been less visible had I use a black paint. Also instead of engine paint which is about 500degree I would use a barbecue paint or caliper paint. Both 900-1200F paints and therefore less chance for the yellow discoloration.

    I will tackled this job soon - again - and will use the highest temp black paint. My paint is holding up good, no bubbles or anything but the discoloration is ugly.

    1997 BMW 840CiA
    1990 BMW Z1
    1999 BMW 528iT (Hauler mobile)
    2002 Astro Van AWD
    2003 Nissan 350Z Enthusiast Package
    1987 BMW 535i with 5spd manual (for sale)
    1992 BMW 735iL (needs head and interior)
    1977 BMW 320i (project racecar)
    2007 Mazda CX9 AWD (Wife mobile)
    1998 Yamaha Blaster+Breeze

    1995 850CSI CD00177 (SOLD)

  5. #5
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    Member No: 4328 jimlev will become famous soon enough jimlev will become famous soon enough jimlev's Avatar
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    Yes | No

    The line U fixed goes to the fuel press regulator(

    Just to be on the safe side, you may want to keep an eye on it.

  6. #6
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    Yes | No

    Ouch - thanks for the heads-up (m)

    I applied the RTV on both ends, slip the heat shrinking tube, applied more RTV on the two exposed ends, and then applied the heat gun. It was cool to see a small amount of RTV ooze out as the heat shrink tubing got smaller and tied both sides together.

    If this "fix" fails and I get a leak, what are the symptoms that it has failed?

    William
    Richardson, Texas
    2010 Honda Accord EX, 4-cyl, auto-tranny (her car)
    2000 BMW 540i Auto, TiSilver, Sport/Prem Package (my car)

    Retired/sold:
    2006 Dodge Charger Daytona - Top Banana
    2005 BMW 330i Auto, Premium Package
    2002 M3 Coupe with SMG
    1995 525i auto
    1991 535i 5-speed manual

  7. #7
    my own V8 someday ;-( Eurodavid
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    Yes | No

    Great writeup, William! Thks! Hopefully I'll hav


  8. #8
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    Re: 540i Valve Cover Gasket Replacement (with pics!)

    Great writeup. I did the same job this past summer and decided to go with black wrinkle paint to help hide the pitting. I sanded the covers as smooth as possible, primed them with hi-temp primer, and then coated them with wrinkle paint. I let them cure outside in the hot sun.

    Six months later they are holding up very well. I didn't have much paint flaking inside the covers so I just cleaned and sanded them thoroughly and didn't paint the insides. I coated the gaskets in glycrine which held them in place in the cover grooves.

    I disconnected the fuel line hose at the rear of the left cover which gave the extra room needed to make the cover relatively easy to fit on. There is a Schrader valve on the metal crossover fuel line at the front of the engine which you can press to release the fuel pressure so very little fuel leaks out.

    Here is a link to some photos I took of the job:

    http://demandred.dyndns.org/540i/gallery/album19?page=1

    Steve D

  9. #9
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    I really like that wrinkle paint job ...

    I wanted things to look more or less stock, but I like that black paint you used - it looks really good.

    I am "hopeful" that the cleaning/degreasing (I even used oven cleaner!) and the use of high temp primer and high temp paint will keep it from flaking. I will just have to watch it carefully and monitor the condition :-)

    Will
    William
    Richardson, Texas
    2010 Honda Accord EX, 4-cyl, auto-tranny (her car)
    2000 BMW 540i Auto, TiSilver, Sport/Prem Package (my car)

    Retired/sold:
    2006 Dodge Charger Daytona - Top Banana
    2005 BMW 330i Auto, Premium Package
    2002 M3 Coupe with SMG
    1995 525i auto
    1991 535i 5-speed manual

  10. #10
    Bimmer5Michael
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    Yes | No

    My paint is already bubbling again on the outside

    I did not paint the inside of my covers. That powder coatr still has my old VCs so Bubba should be able to have that powder coating on magnesium down pat.

    I hate the thought of removing those damn things again to repaint them but I just cant stand the bubling paint and flaking on the outside. Other than that you could eat of the engine bay at any time.

    I wonder if any of the local machine shops will make a set of aluminum or steel valve covers.

    Hey ever thought of being the ChooChoo Bimmers club president?

    Michael
    00 540 sport 6 speed

  11. #11
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    Yes | No

    Just remember that the V8 is like the (m)

    - expensive mistress, or
    - the supermodel girlfriend

    both are HIGH maintenance!

    Luckily you will buy the manual speed version, which is what I would have preferred as well, but when I bought mine used, it was a good deal hard to pass :-)

    Will
    William
    Richardson, Texas
    2010 Honda Accord EX, 4-cyl, auto-tranny (her car)
    2000 BMW 540i Auto, TiSilver, Sport/Prem Package (my car)

    Retired/sold:
    2006 Dodge Charger Daytona - Top Banana
    2005 BMW 330i Auto, Premium Package
    2002 M3 Coupe with SMG
    1995 525i auto
    1991 535i 5-speed manual

  12. #12
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    Yes | No

    wel have collection for 2 extra cylinders for you



    Jay Gans 2000 528 MT Non-sport.Titanium Silver, Grey Leather. Premium Package, Cold Weather, Fold down seats. Oct 99 production.ash try mod so not bone stock. CD changer. Garmin C510 Nav..Honda CH150D scooter







  13. #13
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    Yes | No

    Michael, we've used the same place, so let me

    ask you something. In my case, when first powder coating job failed, I've talked to the owner and he was very apologetic. He called the powder coat supplier in front of me and found out that there is different procedure to powder coat magnesium. I can't remember exactly, but it was something about escaping gases causing coat to bubble.
    Anyway, after we did it the second time, it never caused the problem since and it's probably been more than 2 years now. So if you want do it again, just find out more about it and you should be able to do it correctly this time.
    I don't know if you're joking about being the chapter president, but I think there are probably more deserving people than me.



    1998 BMW 540i 6 speed
    Arctic silver, M sport suspension (euro delivery), prod. date 05/98, non VANOS
    Staggered 18" style 32 OEM wheels
    3.15 open differential
    Remus exhaust
    AFE CAI with improved heat shield
    Z3 shifter
    VDO oil pressure and temperature gauges in place of headlight/fog switches
    Powder coated valve covers-satin black
    CDV delete
    Debadged
    AEA DRL module (aftermarket daytime running lights)

    1997 BMW 528iA
    Alpine white, premium package, prod. date 04/97, single VANOS
    Staggered 17" style 32 OEM wheels
    Debadged
    AEA DRL module
    Custom made sun blinds for rear seating area

    2000 Nissan Frontier Desert Runner, AKA "The Work Horse"

    Garage aids:
    Direct Lift Pro Park 8
    Campbell Hausfeld 28 gallon oil lubricated air compressor
    Newair ACP-1400H portable air conditioner and heater
    Auto Enginuity scan tool with BMW enhanced option
    Actron 9135 scan tool-for quick readouts



  14. #14
    Registered Member
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    Yes | No

    +1 on wrinkle paint. I wish I thought of that as

    well. It really does hide the imperfections after sand blasting and it looks awesome.



    1998 BMW 540i 6 speed
    Arctic silver, M sport suspension (euro delivery), prod. date 05/98, non VANOS
    Staggered 18" style 32 OEM wheels
    3.15 open differential
    Remus exhaust
    AFE CAI with improved heat shield
    Z3 shifter
    VDO oil pressure and temperature gauges in place of headlight/fog switches
    Powder coated valve covers-satin black
    CDV delete
    Debadged
    AEA DRL module (aftermarket daytime running lights)

    1997 BMW 528iA
    Alpine white, premium package, prod. date 04/97, single VANOS
    Staggered 17" style 32 OEM wheels
    Debadged
    AEA DRL module
    Custom made sun blinds for rear seating area

    2000 Nissan Frontier Desert Runner, AKA "The Work Horse"

    Garage aids:
    Direct Lift Pro Park 8
    Campbell Hausfeld 28 gallon oil lubricated air compressor
    Newair ACP-1400H portable air conditioner and heater
    Auto Enginuity scan tool with BMW enhanced option
    Actron 9135 scan tool-for quick readouts



  15. #15
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    Yes | No

    It will change the fuel pressure (m)

    IF I get a chance this weekend I'll test it to see which way the pressure goes.

  16. #16
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    Yes | No

    thanks Jim!

    William
    Richardson, Texas
    2010 Honda Accord EX, 4-cyl, auto-tranny (her car)
    2000 BMW 540i Auto, TiSilver, Sport/Prem Package (my car)

    Retired/sold:
    2006 Dodge Charger Daytona - Top Banana
    2005 BMW 330i Auto, Premium Package
    2002 M3 Coupe with SMG
    1995 525i auto
    1991 535i 5-speed manual

  17. #17
    Bimmer5Michael
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    Yes | No

    I wound up with a hole the size of a half dollar

    and tears everywhere. The guy said that the casting were full of "air pockets" causing blow through.

    I bought new ones at the dealer for 375.00, 2 years later they were leaking and bubbling and flaking. I sandblasted them inside and out. While the castings are far from smooth, I found no "air pockets" that resulted in holes in the covers. The reason for the thick original primer was to cover up all the imperfections.

    I used JB Weld slow curing to smooth out any imperfections, sanded that down for a smooth surface, primed with high temp (Outside only)then painted with hi temp paint. Result 2 years later they need painting again.

    I will look for another coater in town or Dalton to attempt the next coating but I will prepare them myself before dropping them off.

    My experience with the same coater was not a good one in any way, he would have to do them for free and warranty the results before I would do it again.

    Dont know why BMW chose magnesium for these parts.

    The president is mostly a smuuuuzer, inviting interesting people to meetings, selecting locations for meetings (usually fine eateries around town), selecting the seasonal drive routs, solisiting for the Christmas party location and such. Currently the club is mostly a social event but many including my son would like to see it more technical with events at the dealer and other local repair facilities. Unfortunately many of the members are too well off to bother with wrenching. Several have motorcycles and do wrench. 3 years ago, we joined up with the Smokey Mountain Chapter and had a ball that ended in a large picknic. I think the job is coming available if you might be interested. Energy, time, experiemce, desire, love of BMWs highly desireable.

    Michael
    00 540 Sport 6 speed

  18. #18
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    Yes | No

    Re: I wound up with a hole the size of a half dollar

    I can't blame you for not going back. They redid mine for free, but I do agree with you, I wasn't really impressed with the place. I was still out set of gaskets and my time to remove and reinstall the covers, so that's not really free.
    I don't know if Jimlev would be interested, but we both know he would do superb job and charge you fair price.
    I really need to join BMW CCA as I'm interested to meet few gearheads. President, like you said, need to be somebody who knows people and is kind of politician alike, so definitely not me. I got to run but if you ever need me, drop me an e mail @[email protected] and we can exchange cell numbers and meet if you're interested.



    1998 BMW 540i 6 speed
    Arctic silver, M sport suspension (euro delivery), prod. date 05/98, non VANOS
    Staggered 18" style 32 OEM wheels
    3.15 open differential
    Remus exhaust
    AFE CAI with improved heat shield
    Z3 shifter
    VDO oil pressure and temperature gauges in place of headlight/fog switches
    Powder coated valve covers-satin black
    CDV delete
    Debadged
    AEA DRL module (aftermarket daytime running lights)

    1997 BMW 528iA
    Alpine white, premium package, prod. date 04/97, single VANOS
    Staggered 17" style 32 OEM wheels
    Debadged
    AEA DRL module
    Custom made sun blinds for rear seating area

    2000 Nissan Frontier Desert Runner, AKA "The Work Horse"

    Garage aids:
    Direct Lift Pro Park 8
    Campbell Hausfeld 28 gallon oil lubricated air compressor
    Newair ACP-1400H portable air conditioner and heater
    Auto Enginuity scan tool with BMW enhanced option
    Actron 9135 scan tool-for quick readouts



  19. #19
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    Yes | No

    Don't worry about it too much, the change in (m)

    fuel pressure was minimal. A little increase in vacuum at this line lowered the fuel pressure a few PSI.
    The regulator sets the base fuel pressure and this vac line adjusts it slightly. If your connection comes apart I think the worse thing would be a little extra air being sucked in past the MAF. The O2 sensors could partially compensate for this, you could get a lean CEL once the Long Term adjustment got past 10%.

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    Yes | No

    Probably a crazy question but what did u use

    to sand them i.e, tools and supplies?

    Thanks





    K-Bud ([email protected])
    Baltimore, MD
    Join the BMW E39 / 5 Series Group here: http://www.facebook.com/group.php?gid=347966936053

    99' BMW E39 540iA Sp. (Prod. 11/98)
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    Roadfly Member #71563 est. 06/03
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    ****Disclaimer: Down the page alot farther after all the absurd amount of pictures & vids I've posted of my current rides you'll find the "mods" for my BMW****



    Lexus rf sig
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    Mods to Date:
    DINAN Stage II, DINAN Tranny SW, DINAN Fr. Strut Bar, RevHigh CAI w/ PC'd Gunmetal Metallic Pipe, Breyton Fr. Lip Spoiler, Fr. Lip RaceMesh Grill 5/8" PC'd Black, Hella Celis Clear Rears, Clear Fronts, Clear Sides, 19" RDSport S4's w/ Gunmetal Metallic PC'd Centers 19x9 et18 Fr. & 19x10 et20 Rr., Toyo T1R's 245/35 Fr. & 275/30 Rr., Eisenmann Sport Quad Exhaust w/Resonator Removed, McGard Wheel Locks, Rolled Rr. Fenders, ///M5 Rr. Wheel Liners, H&R Sp. Springs, Koni Adj. Sp. Struts, Energy Suspension Polyurethane Bushings, ///M5 Fr. Brakes w/ SS Lines, Brembo Rr. Brakes w/SS Lines, Axxis Deluxe Brake Pads, ///M5 Fr. & Rr. Swaybars, ///M5 Kidney Grills, ///M5 Brushed Gauge Rings, 2.25" Magnaflow High Flow Cats, ///M-Tech Rr. Bumper, ///M5 Trunk Lip Spoiler, ///M5 Style Side Mirrors ,DDE Xenon Match Angel Eyes, Xenon Match H7 Fog Bulbs, AC Schnitzer Alum. Pedals, Denso Iridium Plugs, In-Dash Business CD Player, Blk. Metallic Int. Trim, Brushed Alum. & Blk. Lthr. Shift Selector Knob, 35% Window Tint, Homelink UGDO, Trunk Storage Bin, Carbon Fiber Roundels, Black ///M Logo Oil Cap, Fr. Plate Delete, Black BMW Rr. Tag Holder, & Debadged


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