1997 BMW 540i Harness

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.-
-6val and Installation -
< Remove intake manifold mounting hardware (arrows).
NOTE-
M52 TU engine shown. M52 and M54 engines are similar.
Liit up manifold just enough to remove positive cables from
starter motor terminal
50 (arrow).
- Remove intake manifold from cylinder head while carefully
checking for electrical connections, tie wraps, and hoses.
CAUTION-
Stuff clean rags into open intake ports to prevent any parts
from falling into the engine intake.
4 Remove fastener (A) and harness connector (B) from
alternator.

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110-12
Engine Removal and Installation
4 Remove hoses from thermostat housing by releasing locks
(arrows). If applicable, detach electrical harness connector
for thermostat housing.
NOTE-
Two different types of hose fasteners are used on the E39
car; lock clamp type as shown above or standard band
clamps.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator as described in
170 Ra-
diator and Cooling
System.
CAUTION-
32 mm radiator fan mounting nut has left hand threads.
4 Disconnect coolant hose (arrow) at rear left side of engine
above starter.
4 Disconnect coolant hose (arrow) at front left side of engine
mount.
- Unbolt power steering fluid reservoir and pull aside without
detaching hoses. Secure to fender with cord or stiff wire.

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Engine Removal and Installation
4 Working at E-box at right rear of engine compartment:
Disconnect engine electrical harness connectors
(arrows).
Lift off harness looms and lay over engine.
- Remove polyribbed drive belts. Mark direction of rotation if
belts will be reused. See 020 Maintenance.
- Remove exhaust system and transmission from car. See 180
Exhaust System, 230 Manual Transmission or 240 Auto-
matic Transmission.
NOJE-
Detach automatic transmission cooler lines from radiator, re-
move brackets holding lines to side of engine, andstore lines
in a clean environment.
- Remove power steering pump:
If necessary, remove steering pump pulley.
Remove front and rear pump mounting bolts.
Suspend pump from body using stiff wire.
4 Remove A/C compressor mounting bolts (arrows) and AIC
compressor from its mounting bracketwithoutdisconnecting,
distorting, or deforming any refrigerant lines. Suspend from
body using stiff wire.
4 If applicable, remove secondary air pump:
Remove hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
- Disconnect electrical harness from bottom of secondary
air pump.
Remove bracket from strut tower.

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110-15
Engine Removal and lnstallation
- Installation is reverse of removal, noting the following:
Replace all gaskets. O-rings and seals.
Use new fuel injector seals
Check that engine drive belts properly engage pulley
grooves.
Inspect O-ring seal between mass air flow sensor and air
filter housing. To facilitate reassembly, coat seal with acid-
free grease.
Change engine oil and filter and
check all other fluid levels.
See
020 Maintenance.
Refill and bleed cooling system. See
170 Radiator and
Cooling System.
CAUTION--
When reattaching throttle assembly harness connectoc con-
nector is
fuNy tightened when arrows on connector and plug
line up.
Tightening torques
Coolant drain plug to cylinder block
25 Nm (18 ft-lb)
Engine mount to
subframe (M10) 45 Nm (33 ft-ib)
Exhaust manifold to cylinder head
M6 10 Nm (89 in-lb)
M7 or ME 20 Nm (15 ft-lb)
Intake manifold to cylinder head
M7 15 Nm (I 1 ft-lb)
ME 22 Nm (16 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb)
Radiator drain screw to radiator
2.5 Nm (22 in-lb)

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- .. -.
-. Engine Removal and in=/
4 Remove left interior ventilation duct:
Release duct locking tabs (A). Early models: release
loclc
ing strap.
* Rotate duct inward (arrow) to detach.
Release spring
loclc (El) to unlock ventilation housing.
Disconnect electrical harness connector from hood switch
(C).
Release locking clip and remove ventilation filter cover (D).
Slide air housing away from inner fender to remove.
Removal
of right side ventilation duct is similar.
4 Remove rear engine compartment bulkhead panel:
Remove rubber sealing strip.
* Remove 3 mounting clips (A).
Remove harness supporting clip
(El).
Unlock panel retainers (arrows).
Lifl out panel.
< Separate engine wiring harness (arrow) from electrical box
at right side of engine compartment:
Remove E-box cover.
Disconnect electrical harness connectors leading from en-
gine wiring harness (arrow). Connectors are labelled (A,
El, C. D, E) for locating purposes.
Lay engine harness on top of engine.
- Drain engine coolant from engine block and radiator. See 170
Radiator and Cooling System.
Remove drain plugs from right and left side of engine
bloclc
(between cylinders 213 and 617).
Afler coolant has drained, reinstall drain plugs using new
sealing washers.
Drain radiator and reinstall drain plug.
Tightening
torques
Coolant drain plug to cylinder block (M14) 25 Nm (18 ft-ib)
Radiator drain screw to radiator 2.5
Nm (22 in-lb)

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I Engine Removal and Installation
WARNING -
Use extreme caution when draining and disposing of engine
coolant. Coolant is poisonous andlethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingest-
---
Working at rear of intake manifold:
Disconnect brake booster vacuum line (A).
Disconnect fuel tank vent line
(6).
Disconnect hoses (C and D) at coolant manifold
- Remove transmission harness support (E).
- Remove oil filter housing assembly from fender:
- Remove oil filter housing mounting fasteners.
Use stiff wire to secure oil filter housing to engine.
NOTE-
Do not disconnect oil lines from filter housing.
4 Disconnect supply and return fuel lines (where applicable) at
or near fuel rail. Plug open fuel lines.
NOTE-
BMW uses three styles of fuel line connections; a slngle use
clamp, a locking fitting that uses special tool
16 7 050 to re-
lease, and a
quiclc release sleeve (arrows) that disconnects
the line when depressed.
WARNING-
Fuel In fuel line is under pressure (approx. 3 - 5 bar or45 -
75 psi) and may be expelled. Do not smoke or worlc near
heaters or other fire hazards. Keep a fire extinguisher
handy. Before disconnecting fuel hoses, wrap a cloth
around fuel hoses to absorb any lealcing fuel. Catch and
dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before worlcing on the tank or lines.
< Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor (A) and
intalte air temper-
ature sensor
(6) electrical harness connectors.
. Remove air filter housing mounting fastener (arrow).
Loosen intake hose clamp (C).
M62 engine: Remove hose at idle air stabilizer.
Remove air filter housing with mass air flow sensor.
Remove intalte hose from throttle body.

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110-19
Engine Removal and Installation
M62 engine, remove ASC throttle body.
Disconnect electrical harness from throttle position sensor.
- Disconnect ASC actuator cable (arrow).
. Remove mounting fasteners and remove throttle body.
On front of left side cylinder head, disconnect electrical har-
ness connector
(A), and remove and plug fuel tank vent valve
vacuum line
(0).
Raise car and support in a safe manner.
CAUTION-
Male sure the car is stable and well supported at aN times.
Use a professional automotive
lifi orjackstands designed for
I the ouroose. A floor jack is not adequate support.
Working beneath car:
- Remove engine splash shield.
Remove right and left heat shield from front suspension
subframe.
Working underneath engine compartment, disconnect
ground cable on right side engine mount
(arrow).

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11 0-20
Engine Removal and Installation
Working at right side of transmission bellhousing, disconnect
electrical harness connections (arrows) from starter. Re-
move starter retaining bolts and remove starter from trans-
mission mount.
M62 TU engine: Disconnect electrical harness connector
for right oxygen sensor from retaining clip and remove re-
taining clip from transmission.
- Working underneath engine compartment at left side:
Unclip positive battery cable from oil pan.
. Remove alternator cooling duct.
4 M62 engine: Remove fastener A and plug connector B from
alternator.
- M62 TU engine: Remove electrical harness connectors from
front of water cooled alternator.
- Remove exhaust system and transmission. See 180 Ex-
haust System and 230 Manual Transmission or 240 Auto-
matic Transmission.
- Working at front of engine:
Remove upper and lower hoses from radiator.
D~sconnect expansion tank hose from coolant pump.
- Remove belt-driven cooling fan:
Counterhold fan with special tool
11 5 050.
Turn fan mounting nut (32 mm) clockwise (left hand
threads) to loosen.
Rotate fan clockwise to remove.
Remove cooling fan shroud:
Disconnect electrical connectors from coolant level sensor
(B) and coolant temperature sensor (C).
. Remove expansion rivets (A) from each side of shroud
Remove coolant hose
(D).
Slide fan shroud with expansion tank up. Remove radiator
overflow tube from spout of expansion tank. Remove radi-
ator fan shroud with expansion tank.
Remove radiator. See
170 Radiator and Cooling System.