1999 BMW 540i air filter

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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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--
-- 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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11 3-9
Cylinder Head Removal and Installation
< Remove left and right interior ventilation ducts (left shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic locking tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclockwise to unlock from bulkhead and
remove (arrow).
Disconnect electrical connector from hood switch
(C).
Release spring lock (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel: Remove rubber sealing
gasket (arrow).
0 Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift out panel.
< Remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from
~ntake
duct (6) and disconnect Idle speed control valve electr~cal
harness connector.
Disconnect
electr~cal harness connector (C) from mass alr
flow sensor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.
4 Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jumper post (A).
Loosen and remove battery lead mounting nut.
Remove battery lead and push down through intake mani-
fold.
Remove trim caps (arrows) from fuel injector cover.
Remove cover hold down fasteners and lift off cover.

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1 13-22
Cylinder Head Removal and Installation
CYLINDER HEAD REMOVAL AND
~NSTALLATION (M52 TU AND N154
ENGINES)
WARNING -
Due to risk ofpersonal injur)c be sure the engine is cold be-
fore
beqinning the removal procedure.
Cylinder head removal and installation is a time consuming
repair procedure requiring multiple special service tools.
Read the entire procedure before beginning the repair.
This topic includes the following procedures:
* Cylinder head, removing, M52 TU and M54 engines
Cylinder head, installing,
M52 TU and M54 engines
Cylinder head, removing,
M52 TU and M54 engines
Allow engine to cool before beginning this procedure.
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions in
001 General Cautions and Warnings.
4 Remove left and right interior ventilation ducts (left side
shown):
Release ventilation filter cover latch
(A) and remove cover.
Release plastic locking tab
(6) or release locking tabs on
top of duct (later models).
= Turn duct counterclocltwise to unlock from bullthead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring lock fastener
(D).
- Slide filter housing away from inner fender to remove.
Removal of right side ventilation
dud
Remove rear bulkhead panel:
Lift off rubber sealing
gasket (arrow)
- Remove 3 mounting clips (A).
Remove 4 retaining screws (6).
Lift off panel.
: is similar

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- --
Cylinder Head Removal and Installation 1 --
< Remove complete air filter housing assembly with mass air
flow sensor:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intake duct
(B) and disconnect idle speed control valve electrical har-
ness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
. Loosen air intalte duct clamp (F).
Carefully lifl air filter housing, mass air flow sensor, and in-
take duct hose out of engine bay.
4 Disconnect positive battery cable and remove intake rnani-
fold cover:
Remove protective cover from positive (+)jumper post.
Loosen and remove battery lead mounting nut (A).
Remove lead and push down through intake manifold.
* Remove trim covers (arrows) from fuel injector cover.
Remove cover hold down fasteners and lifl off cover.
4 Worlting above engine, disconnect the following:
Vent line from cylinder head cover. To remove, pinch clips
(arrows).
Electrical harness connector from VANOS solenoid valve
(A).
- Remove oxygen sensors and exhaust manifolds. See 180
Exhaust System.
CAUTION-
Remove oxygen sensors before removing exhaust mani-
fold to prevent damage.
Label oxygen sensor harness connectors so that they
can be reassembled correctly Do not interchange con-
nectors.
NOTE-
Front exhaust manifold must be removed before rear
manifold.

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Cylinder Head Removal and Installation
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Tightening torque Exhaust
maniiold to cylinder head (M7)
20 Nm (15 ft-lb)
- Install electrical harness connectors for oil pressure sender
and coolant temperature sensor before installing
intalte man-
ifold.
7 Install intake manifold:
1. Manifold mounting nuts: tighten to 15 Nm (1 1 ft-lb)
2. Fuel pipe bracltet
3. Fuel pipe bracltet
4. Vacuum pump bracltet
5. Manifold mounting bracltet
6.
Tank venting valve bracltet
7. Mounting bracket to manifold bolt (M6)
8. Mounting bracket to cylinder block nut (MIO), tighten to
47 Nm (33 fi-lb)
Intake manifold installation is reverse of removal, noting the
following:
* Use new fuel injector seals.
Carefully
check intake manifold gasket and replace if nec-
essary.
Inspect O-ring seal between mass air flow sensor and air
filter housing. To facilitate reassembly, coat seal with
acid-
free grease.
Use new fuel injector seals.
Carefully check intake manifold gasket and replace if
necessary.
CA UTIOPI-
When reattaching throttle assembly harness connector, con-
nector is fully tightened when arrows on connector
andplug
line up.
Tightening torque
lntalte manifold to cylinder
head (M7)
15 Nm (1 1 it-lb) ~ ~- Mounting bracket to cylinder bloclt (M10) 47 Nm (33 ft-lb)
Mounting bracket to intake manifold (MI?) 10 Nm (89 in-lb)

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11 3-56
I Cvlinder Head Removal and Installation
- Installation of the remaining parts is reverse or removal, not-
ing the following:
- Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
If necessary, adjust accelerator cable.
a Reconnect battery.
CAUTION- To prevent damaging the engine electronic systems, installall
ground wire previously removed, including the ground wires
for the
ionition coils.
Tightening torque Coolant drain
pluq to cylinder bloclc 25 Nm (1 8 ft-lb)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb) -
Radiator drain screw to radiator 2.5
Nm (22 in-lb)
spark plug to cylinder head 25
Nm (1 8 ft-lb)
CYLINDER MEAD REMOVAL AND
INSTALLATION (M62 ENGINE)
This procedure covers cylinder head removal and installation
for the
M62 V-8 engine. Procedures forthe M62 TU VANOS
engine are not covered in this manual.
Intake manifold, left cylinder head, and right cylinder head re-
moval and installation are written as separate procedures.
The intake manifold must be removed before the cylinder
heads can be removed.
WARNING
-
Due to risk of personal injuv be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation requires multiple spe-
cial service tools. Read the entire procedure before beginning
the repair.
Intake manifold, removal and installation,
M62 engine
- Disconnect negative (-) battery cable.
CAUTION- Prior to disconnecting the
batterj read the baitery discon-
nection cautions
in 001 General Cautions and Warnings.