1999 BMW 525i Workshop Manual

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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.

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--
-- Engine Removal and installation' -
Remove polyribbed A/C compressor belt:
Mark direction of belt travel if belts are to be reused.
Loosen bolts
(A).
Turn adjusting lug (B) clocltwise to release belt tension.
Working beneath car, remove power steering pump and air
conditioner compressor. Suspend from body using stiff wire.
Remove exhaust manifolds. See
180 Exhaust System.
< lnstall engine lifting device (BMW 11 0 000 or equivalent) to
front and rear engine supports and raise engine until it's
weight is supported. Detach engine mounts.
a Watch carefully for hoses and electrical wires that might
snag.
- installation is reverse of removal:
Replace all gaskets, O-rings and seals.
V-8 engine mounts have two sets of mounting holes. E39
cars use front most mounting holes.
* On cars with automatic transmission, use new O-rings at
ATF cooler lines.
Use new alignment sleeves when installing transmission.
Be sure engine drive belts properly engage pulley grooves.
When installing belt, preload tensioner to stop (toward
belt), then tighten tensioner clamping nut.
lnstall front exhaust pipes using new gasltets and copper
paste and new mounting hardware. See
180 Exhaust
System.
Change engine oil and filter. Check all other fluid levels as
described in
020 Maintenance.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
CAUTION-
Do not interchange knoclc sensor harness connectors. Seri-
ous engine damage may result

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Engine Removal and Installation
Tightening torques
ATF cooler lines to radiator
(use new O-rings)
MI8 cap nut 20 Nm (15 ft-lb)
M22 cap nut
22
Nm (17 ft-lb
Coolant drain plug to cylinder
blocic (M14) 25 Nm (18 ft-lb)
Engine mount to engine bracket or 47 Nm (35 ft-lb)
subframe (M10)
Exhaust flange nuts (8 mm) 25 Nm (18 ff-ib)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb)
(left-hand threads)
Radiator drain screw to radiator 2.5 Nm (22 in-lb)
Wirino to alternator
(ME nut) 13 Nm (9.5 ft-lb)

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113-1
11 3 Cylinder Head
Removal and Installation
General ........................... .I 13-2
Special tools ........................ .I 13-2
Diagnostic Testing. ................ .I1 3-5
Cylinder compression, checking ......... ,113-5
Wet compression test ................. .I1 3-7
Cylinder leak-down test. ................ 11 3-8
Cylinder Head Removal and Installation
(M52 Engine) ...................... .I1 3-8
Cylinder head, removing, M52 engine .... ,113-8
Cylinder head, installing, M52 engine ... ,113-17
Cylinder Head Removal and Installation
(M52 TU and M54 Engines). ........ ,113-22
Cylinder head, removing, M52 TU
and
M54 engines. ................... .I1 3-22
Cylinder head, installing, M52 TU
and
M54 engine. .................... .I1 3-39
Double VANOS Timing
Chain Components
................ 11 3-46
Double VANOS timing chain components,
installing,
M52 TU and M54 engines ..... 113-46
Cylinder Head Removal and Installation
(M62 Engine). ..................... 11 3-56
Intake manifold, removal and installation,
M62 engine. ........................ 11 3-66
Left cylinder head, removing,
M62 engine. ........................ 11 3-61
Left cylinder head, installing,
M62 engine. ........................ 11 3-66
Right cylinder head, removing,
M62 engine ........................ 11 3-72
Right cylinder head, installing,
M62 engine ........................ 11 3-77

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11 3-2
Cylinder Head Removal and Installation
This group covers cylinder head removal and installation as
well as cylinder
headlvalve diagnostic procedures.
In the procedures in this repair group, engines are referred to
by engine code. If necessary, see
100 Engine-General for
engine code and application information.
The information given in this repair group assumes that the
engine is installed in the engine bay. On the
6-cylinder en-
gines, the VANOS control unit must be removed in orderto re-
move the cylinder head from the engine block. On
M52TU
and M54 engines, camshafts must be removed from the cylin-
der head before the head is removed.
The cylinder head removal and installation procedures for the
M62 V-8 are also included, butthe proceduresforthe M62TU
V-8 with VANOS are not provided.
For cylinder head and valvetrain reconditioning information,
see
116 Cylinder Head and Valvetrain.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
If a head gasket problem is suspected, a compression test or
leak-down test will usually detect the fault See Diagnostic
Testing later
in this group.
Special tools
Special BMW service tools are required to properly remove
and install the cylinder head on engines covered by this man-
ual. The special tools are used to time the valvetrain to the
crankshaft, and to remove the VANOS control unit, the cam-
shafts and the
Tom (El2) head bolts. Read the entire proce-
dure through before beginning the job.