1999 BMW 540i trim

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Engine Removal and installatid
4 Remove cylinder head top cover:
Remove plastic trim caps
(arrows).
Remove cover retaining fasteners and lifl off cover.
- Remove alternator cooling tube.
4 Drain engine coolant and remove coolant hoses:
* Remove expansion tank cap on coolant reservoir.
Place a
3 gallon pail beneath engine to capture coolant,
* Remove coolant drain plug located on exhaust side of
cylinder
2 of engine block (arrow).
NOTE-
Drain plug for M52 TU and M54 engine shown. Plug for M52
located between cylinders 4 and 5.
Drain radiator by removing plastic drain plug (arrow) from
bottom of radiator.
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-
ed.
NOTE-
Catch and dispose of drained coolant according to local,
state, and federal laws.

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110-16
Engine Removal and Installation
ENGINE, REMOVAL AND
INSTALLATION (V-8 MODELS)
NOTE-
Engine removal procedures are similar for all V-8 models.
When differences exist, they are noted at the beginning of
each step. Engine are referred to by engine code. If neces-
sary, See
100 Engine-General for engine code andappli-
cation information.
Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse gaskets, O-rings or seals during reassembly
WARNING
-
Due to risk ofpersonal injury, be sure the engine is cold be-
fore beginning the
removal procedure.
- Disconnect negative (-) cable from battery.
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove engine hood or place hood in service position. See
410 Fenders, Engine Hood.
Remove
intake manifold cover, version 1:
Remove plastic trim caps (arrows).
Remove cover mounting fasteners and
lift off cover.
Remove intake manifold cover, version
2:
Press down on locking pins (arrows) to release locks
Lifl cover straight
up to remove.

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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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-
Cylinder Head Removal and Installation c
q Remove secondary air inject~on check valve (arrow).
4 Remove cylinder head top cover:
Remove plastic trim caps (arrows).
Remove engine oil filler cap.
Remove cover hold down fasteners and lift off cover.
4 Remove ignition coils:
Disconnect ignition coil harness connectors.
. Remove coil mounting fasteners.
Remove coils.
Remove ground straps.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
- Remove sparlc plugs.
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original locations. Make
note of their arrangement during removal.

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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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11 3-27
Cylinder Head Removal and Installation
< Remove fuel rail mounting bolts (arrows):
- Carefully pry fuel rail off manifold.
Separate fuel line support bracket at rear of intake mani-
fold.
Guide fuel
line(s) out of rear of engine compartment while
lifting fuel rail out.
4 Remove intake manifold mountino hardware (arrows).
I from falling into the engine intake. I
4 Remove cylinder head top cover:
- Remove plastic trim caps (arrows).
Remove cover hold down fasteners and
lilt off cover.

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Cylinder Head Removal and Installation
Pry out ignition coil cover trim caps,
covers from lefl and right sides. remove fasteners
and
< Disconnect throttle cables from throttle shafl (A) and remove
cables from support bracket
(B).
< Disconnect cable from jump start post (arrow) on left cylinder
head cover.

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Camshaft Timina chain1
- Remove viscous clutch cooling fan. See 170 Radiator and
Cooling
System.
CA UTlOEIC
The radiator cooling fan nut (32mm wrench) has left- hand
threads.
.
< Remove engine trim covers:
Pry out plastic trim caps (arrows).
. Remove cover fasteners and covers.
4 Remove ignition coils:
0 Disconnect ignition coil electrical harness connectors
Remove
coil mounting fasteners and remove coils.
Remove spark plugs.
NOTE-
Make note of ignition coil ground strap locations.
Disconnect VANOS electrical harness connector
(A) and oil
line fitting
(B) from VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
- Disconnect cranltcase breather by squeezing at arrows,
- Remove cylinder cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas.
kets should be reinstalled in their original positions. Make
note of their arrangement during removal.