1999 BMW 540i electrical

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Camshaft Timing Chain
- Connect electrical harness connectors to camshaft position
sensors and VANOS solenoid valves.
- Remove BMW special locking tools from rear of cylinder
head.
- Remove cranltshaft locking tool and replace sealing plug.
Install intake camshaft baffle and cylinder head cover.
Checlc for correct seating of half-moon seals (A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
O or equivalent
sealant at corners
(B) of half-moon cutouts.
Similarly, seat gasket and
seal corners in front of cylinder
head, at VANOS control unit.
Tightening torque
Cylinder head cover to cylinder head
(M6) 10 Nm (89 in-lb)
- Remainder of installation is reverse of removal.
Tightening torques
Radiator fan (viscous clutch) to
coolant pump 40
Nm (30 ft-lb)
Spark plug to cylinder head
25 Nrn (18 ft-lb)
VANOS timing, checking and adjusting
(M52 TU and M54 engines)
Use this procedure to check and, if necessary, adjust cam-
shaft timing. This procedure assumes that the cylinder head
cover and intake
camshaft plastic baffle have been removed.
Also, be sure the cooling fan and the spark plugs have been
removed.
Remove primary camshaft chain tensioner cylinder
(arrow).
~~ ~ ~~ ~--~
CA UTlOAC
Primary camshaft chain tensioning piston is under spring
pressure.

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Camshaft Timing chain1
- Disconnect negative cable (-) from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Cautions and
Warnings.
4 Removing top and side engine covers:
Press down on locking pins (arrows) to release locks. Lifl
intake manifold cover straight up to remove.
Pry out caps from side covers.
Remove fasteners
and covers.
NOTE-
Some early models use
pry out trim caps and fasteners to
hold the top cover in place.
Disconnect electrical harness connectors at ignition coils
(A).
Remove left and right side ignition coil mounting fasteners
and coils.
NOTE-
Make note of location of ground strap (arrow).
Remove spark plugs.
- Remove posltlve (+) terminal cable from left cylrnder head
cover.
- Unbolt left and right side cable ducts from fuel rail
Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor and intake air tempera-
ture sensor electrical harnesses
(A and B).
Remove air filter housing mounting fastener (arrow)
Loosen intake hose clamp
(C).
Remove air filter housing with mass air sensor and intake
duct from throttle body assembly.

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1 17-68
Camshaft Timing Chain
4 Remove left and right side ignition coils and spark plugs:
- Remove positive (+) terminal cable from left cylinder head
cover.
- Unbolt lefl and right side cable ducts from fuel rail,
4 Disconnect fuel injector electrical connectors:
Pry corner of wire lock clip to release connector from injec-
tor
(arrow).
Repeat for all injectors.
Lift off wiring ducts.
4 Remove Fasteners (arrow) from lefl and right cylinder head
cover fasteners and remove covers.

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Camshaft Timing chain1
< Remove Automatic Stability Control (ASC) throttle body:
Disconnect electrical harness from throttle position sensor.
Disconnect ASC actuator cable (arrow).
Remove
3 mounting fasteners and remove throttle body.
4 Disconnect fuel tank vent valve line and cap off line (arrow).
- Drain engine coolant and remove hoses from thermostat
housing. See
170 Radiator and Cooling System.
- Remove water pump and thermostat housing. See 170 Ra-
diator and Cooling System.
- Remove left side upper timing chain cover retaining bolts and
remove cover.
4 Counter hold right intake camshaft
CAUTION-
Counter hold camshaft with a 27mm open-end wrench while
loosening sprocket bolts. Grind wrench if necessary to pre-
vent damage to head.

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[camshaft Timina Chain
< Remove cylinder head cover sealing gaskets from lefl cylin-
der head cover. Install
BMW special tool 11 1 412 into gasket
groove of cylinder head cover.
Install lefl cylinder head cover. Fit cylinder head cover re-
taining nuts to cylinder head cover studs at cylinders
5 and
6 (first two cylinders on left side cylinder bank).
Tighten nuts uniformly in
'I2 turn steps
Tightening torque
Timing case cover to head
15 Nm (1 1 ft-lb)
- Remove special tool 11 1 41 2 and install new gaskets to cyl-
inder head cover:
Clean gasket groove and install new gasket.
Apply Three Bond
12098sealant tojoint between cylinder
head and timing cover and at half-moon shaped cut-outs.
Tighten cylinder head cover nuts.
Tightening torque Cylinder head cover to head
I5 Nm (1 1 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Where applicable remove protective film from gaskets.
Use new gaskets when mounting intake manifold. Tighten
nuts finger tight first, then torque to specification in stages
worlting diagonally from center out.
Ground straps for ignition coil harnesses are at cylinders
no.
3 and no. 7. See 120 Ignition System.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
CAUTIOI\C
To prevent damaging engine electrical systems, be sure to in-
stall ail ground wires previously removed.

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Camshaft Timing chain/
Camshaft timing, checking and adjusting
(M62 engine)
WARNING -
Allow engine to cool before beginning this procedure. 1
- Working inside luggage compartment, disconnect negative
battery cable.
CAUTIOI\C
Prior to disconnecting battery cable, read the battery discon-
nection cautions given
in 001 General Cautions and
Warninss.
4 Removing plastic top covers:
Press down on locking pins (arrows) to release locks. Lift
intake manifold cover straight up to remove.
Pry out caps from side covers.
Remove fasteners from beneath
caDs. Lift off covers.
4 Remove air filter housing and ducts:
Disconnect mass air flow sensor and intake air tempera-
ture sensor electrical harnesses
(A and B).
Remove air filter housing mounting fastener (arrow).
Release hose clamp at intake air duct on base of air filter
housing.
Loosen intake hose clamp
(C) and release hose from
mass air flow sensor.
Remove hose at idle air stabilizer.
Release hose clamp at throttle body and remove hose.
Remove upper air filter housing with mass air flow sensor.
- Unbolt left and right side cable ducts from fuel rail.

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Camshaft Timing Chain LL. .- - - - I
4 Remove left and right side ignition coils and spark plugs:
- Disconnect electrical harness connectors at ignition coils
(A).
Remove left and right side ignition coil mounting fasteners
and coils.
NOTE-
Make note of location of ground strap (arrow).
Remove sparlc plugs.
- Remove positive (+) terminal cable from left cylinder head
cover.
- Unbolt cable ducts from fuel rail at left and right sides.
Disconnect fuel injector electrical connectors from injectors:
Pry corner of wire
loclc clip (arrow) to release connector.
Repeat for remaining injectors.
* Lift off wiring ducts.

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. .- -
L
- --
- - -. - -- Lubrication ~~stern
- Remove pressure gauge and reinstall pressure switch with
new sealing washer.
Tightening torque
Oil pressure switch to oil filter housing 27 Nm (20 ft-lb)
If testing shows low oil pressure, one or more of the following
conditions may be indicated:
Worn or faulty oil pump or faulty pump pressure relief valve
Worn or damaged engine bearings
Severe engine wear
Any of these conditions indicate the need for major repairs.
Oil pressure warning system, testing
4 When the ignition is turned on, the oil pressure warning light
comes on. When the engine is started and the oil pressure
rises slightly, the oil pressure switch (arrow) contact opens
and the warning light goes out. Make sure the oil level is cor-
rect before making tests.
- Turn ignition switch on.
- Warning light on instrument panel must light up
- Remove connector from oil pressure switch.
Warning light on instrument panel must go out.
NOTE-
If the light does not go out, the wiring to the switch is most
likely grounded somewhere between the switch terminaland
the warning light See
ELE Electrical Wiring Diagrams for
electrical schematics.
- If warning light does not light when ignition is on, remove con-
nector from oil pressure switch and use a jumper wire to
ground connector terminal to a clean metal surface. The oil
pressure warning light should come on.
NOTE-
If there are two wires to the oil pressure switch, ground the
brown/green wire that carries the signal to the warning light.
- If the warning light comes on, check the switch as described
in the next step. If the warning light does not come on, the
wiring to the instrument cluster or to the light itself is faulty.