540i Valve Cover Gasket Replacement (with pics!)

[CenTex]

all you need was a few of them doodads painted blue!

Seriously, a very nice writeup on this job and the photos are extremely helpful. Getting that paint off the VCs (whatever is left) is a real pain. After a week of part-time scraping I gave up and found a company that blasted and PC'd them for $85.

[JimLev]

all of the old valve cover paint I used paint stripper that I got at the local hardware store. I think each VC took about 2.5 hours to get it ready for the powder.

[bmwm3coupe]

and a screwdriver to fish out crap/crud from within the gasket channel on the valve cover (the same channel I later put on some RTV to improve the seal). Some of the original paint is still tenaciously good, so I just concentrated on everything loose, and of course all of the rust/flakes on the inside.

If I had a lot more time, I would have probably taken the valve covers to have them sandblasted really good, to remove everything down to bare metal, but so far (about a week) I have gotten the engine to full temp several times and I still have not seen any bubbling/peeling outside, nor inside (when looking through the oil fill hole on the passenger side). I will keep checking about every couple of weeks to see how it holds up.

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

[bmwm3coupe]

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

[rwthomas1]

Dunno why BMW chose to paint the inside of the valve cover. Not necessary. In fact, the covers could be simply bead blasted and left raw. If you need a decent high temp paint I like POR15 engine enamel. Just used it on an engine rebuild project last winter and it works really nicely. It is in a can, you have to brush it on, but it flows out and dries very smooth. Works well. RT

[ultamte]

[bmwm3coupe]

So far there is no leak from the valvecovers, even using the "light" 0W European Mobil 1 synthetic oil. Also, it has only been 3-4 weeks of use, I have not seen "any" signs of the paint peeling off, neither outside nor inside (peeking through the oil fill hole). The highest temps I have measured on the valve covers were near the top of them, right after turning the engine off, at about 198-200 F, and the primer and paint were rated to 500 F, but I will keep checking for the foreseeable future.

The bad news, now that I got the valve cover gasket area cleaned and dry, it is allowing me to find another minor oil leak that I need to look into, specifically it looks like it is coming from the crank sensor gasket, picture #9 in this image, on both sides of the engine:
link

By the way, I don't have any codes/problems, but should I replace the sensors anyway (car has 129K miles, and those are probably original).

So making progress, but still some work ahead of me :-)
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

[Craig in Canada]

Great feedback on the paint.

On the sensor, I wouldn't change them until you have codes unless they are extremely difficult to access and they become a "while you're in there" for changing the #9s. Personally I'd just change the #9s and save the $$$ for something else that actually needs replacing. :)

[JimLev]

Both of mine are original and showing sings of slightly leaking. I bought new ones last week and will probably change them today. $10 each. I wouldn't replace the solenoids unless t=you were getting codes, they aren't cheap.

[Bmw540san]

Good to hear. I think what helped you was using paint instead of powder coat. I believe magnesium doesn't react to it like in my case.
By the way, I did the same thing with my CAI heat shield. That was a lot room for hot air form radiator to get sucked in the intake.
I've used stuff from this company and I should've measured the intake air temp. before and after to see the difference.

http://www.designengineering.com/cat...er/heat-screen



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

[bmwm3coupe]

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

[m5mel]

Both of mine are original and showing sings of slightly leaking. I bought new ones last week and will probably change them today. $10 each. I wouldn't replace the solenoids unless t=you were getting codes, they aren't cheap.

Jim did you powder coat the insides of your VC's also? or left them raw?

[JimLev]

Jim did you powder coat the insides of your VC's also? or left them raw?

No, just sand blasted them to get them clean. I'll be doing another set in a few weeks.

[m5mel]

No, just sand blasted them to get them clean. I'll be doing another set in a few weeks.

JIM I tyried to PM you but ur mail box is full...

Jim i'm trying to find an extra set but no luck,, as I will be re sealing my VC'ers,,, if you have an extra set yiou wanna sell? or if you wanna sell them powder coated :) let me know pls :) what color are u planning to do this other set?

[JimLev]

JIM I tyried to PM you but ur mail box is full...

Jim i'm trying to find an extra set but no luck,, as I will be re sealing my VC'ers,,, if you have an extra set you wanna sell? or if you wanna sell them powder coated :) let me know pls :) what color are u planning to do this other set?

Mel, just emptied my email box.
I'm PC them and going to sell them.
There another RF guy did want them, I'll have to check with him to see if he still wants them.
The color might be black, but hasn't really been settled on yet.
I have a bunch of different color powder, but if it's a color I don't have it ranges from $10 to $17, plus shipping.
I've mostly been using the $15 speciality colors.

I do have a spare PC gun (15KV output) that I'll sell for 1/2 price, $50. I'll even include a "how to PC book" with it.
I bought a bigger gun last year it's has a dual voltage a output (15 and 25KV) and will cover larger areas quicker.