2000 BMW 540i intake

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Engine Removal and lnstallationl
M52 TU, M54 engine: Disconnect electrical harness connec-
tor at fuel tank venting valve
(A). Disconnect vent hose at fit-
ting (arrow).
- Working under intake manifold, disconnect the following:
Engine oil dipstick tube support.
Oil separator return line from
dipsticlc tube.
Intake air temperature sensorelectrical harness connector
(underside of intake manifold near throttle body).
M52 TU, M54 engine: Resonance valve electrical harness
connector.
M52 engine: Fuel tank vent line and harness.
< Working underneath car, remove lower intalte manifold sup-
port mounting bolts (arrows).
4 M52 TU. M54 engine: Remove fuel rail mounting bolts
(arrows):
Carefully pry fuel rail off manifold.
Separate fuel line support bracket at rear of intake
manifold.
NOTE-
* M52 TU engine shown. M54 engine is similar.
M52 engine: Fuel rail is removed with intalte manifold.

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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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110-15
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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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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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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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 3-9
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 1
< Remove intake throttle valve and ASC throttle assemblies:
Disconnect ASC throttle cable
(A).
- Remove ASC throttle housing mounting fasteners (B).
NOTE-
It is not necessary to disconnect coolant hoses (C) 01
bowden cables (D).
Remove intake throttle housing mounting hardware, pull
throttle housing off
intake manifold, and set aside.
- Working under intake manifold, disconnect the following:
Engine oil dipstick tube support.
Oil separator return line from dipstick tube.
Intake air temperature sensor electrical harness connector
(underside of intake manifold near throttle body).
* Fuel tank vent line and electrical harness at canister vent
valve.
Remove lower intake manifold supports (arrows).
- Disconnect coolant line retaining bracket at cylinder block.
4 Remove manifold mounting hardware (arrows).
- Remove intake manifold from cylinder head while carefully
checking for electrical connections or hoses.
NOTE-
Fuel rail is removed with intake manifold,
CAUTIOI\C
Stuff clean rags into open intake ports to prevent any parts
from falling into
Nie engine intake.
- Drain cooling system (engine block and radiator), then re-
move radiator cooling fan and fan shroud. See
170 Radiator
and Cooling System.
- Disconnect coolant hoses from thermostat housing.