2000 BMW 540i Light

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11 3-44
I Cylinder Head Removal and Installation
4 Secure camshafts in TDC position using BMW special tool
set
11 3 240.
4 In necessary, turn camshaft slightly so that special tools are
squarely seated on cylinder head.
4 Lift timing chain and hold under tension.

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Cylinder Head Removal and Installation /
4 Remove top engine cover by releasing quick release fasten-
ers (arrows) by pressing down.
NOTE-
Earlier models may have an engine cover with pry off caps
and fasteners
In place of quick release fasteners.
4 Remove left and right interior ventilation ducts (left side
shown):
- Release locking tabs (A) or locking strap (early models, not
shown).
Release spring lock (B).
* Rotate duct inward (arrow) to remove.
Disconnect electrical harness from hood light switch (C).
Release locking clip and remove ventilation housing cover
(D).
Lift out housing from inner fender.
- Removal of right side ventilation housing is similar.
4 Air filter housing assembly, removing:
Disconnect electrical harness connectors from mass air
flow sensor (A) and temperature sensor (B).
Loosen hose clamp (C).
Remove filter housing mounting fastener (arrow) and re-
move filter housing with mass air flow sensor.

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Cylinder Head and Valvetrain
< Remove oil baffle cover from above intake camshaft(s)
- Rotate engine at crankshaft vibration damper center bolt in
normal direction of rotation (clockwise) until camshaft lobe of
lifter to be tested points away from the lifter, allowing valve to
be completely closed.
Use a plastic or wooden stick to press down on top of lifter
with approximately 3.5 Nm
(2.25 ft-ib) of force.
If the lifter collapses slightly as though spring loaded, air
may be trapped in the lifter.
NOTE-
Air trapped in hydraulic lifters may result from oil foaming (air
being drawn
in by the oil pump). This may be caused by a
faulty oil pump control valve O-ring; leaking oil pump pickup
gaslcet; or by oil starvation to pump.
Press down on top of lifter for
10 to 15 seconds uslng approx-
lmately 6 to 9 Nm (4.5 to 6.75 ft-lb) of force.
If anv clearance is created between the lifter and the
cam-
shafi lobe, the check valve in the lifter is not closing. Re-
place lifter.
- To replace a hydraulic lifter, remove appropriate camshaft.
Refer to camshaft removal procedures given in Camshaft
and lifter removal and installation.
Once camshaft is removed, withdraw faulty
lifter(s) and re-
place with new
lifter(s). Inspect lifter bores for wear and scor-
ing at arrows.
- Reinstall camshafts. See Camshaft and lifter removal and
installation.

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(camshaft Timing Chain
- To install lower timing case cover:
- Clean cover and cylinder block sealing surfaces
Use new
gaskets and coolant pipe O-ring.
Remove timing chain cover dowel pins from engine block.
Drive timing cover dowels in until they just protrude slightly
from sealing surface.
Apply a small bead of silicon sealer (Three Bond 1209
63
or equivalent) to corners of cylinder head where timing
cover meets cylinder head and engine block.
Tap cover into position until firmly seated.
lnstall all bolts hand tight, including two Torx bolts from
above.
Install secondary chain lower guide.
Tighten cover mounting bolts alternately and in stages.
Tightening torque
Lower timing cover to cylinder
bloclc (M6) 10 Nrn (89 in-lb)
- Install oil pan with new gasket. See 119 Lubrication Sys-
tem.
Tightening torque
Oil pan
to engine bloclc (M6)
8.8 grade
10.9 grade 10 Nrn (89 in-lb)
12 Nm
(9 ft-lb)
- Align damper assembly with lteyway and tap into place. In-
sert new center bolt with washer.
CAUTION-
Inspect woodruff key for damage before installing hub
assembly.
- Attach special tools 11 8 20011 1 8 190 to damper assembly.
Counterhold damper with
11 8 190 while tightening center
bolt.
CAUTION-
Do not use BMW special tool 1 I 2 300 to hold crankshaft
stationary to tighten cranl(shaft hub center bolt. Use only
the special tools specified, or equivalent hub holding tool.
Have a second person hold special tool
11 8 190 while
tightening center crankshaft bolt.
Tightening torque Crankshaft hub to crankshaft 410 Nrn
(300
ft-lb)

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1 19-3
Lubrication System
V-8 crankshaft rear main seal tool
(Tool No. BMW
11 1 230)
I i 4 V-8 crankshaft rear main seal ouide
4 Adapter for BMW oil pressure gauge
(Tool No. BMW
11 4 050)
Engine lubrication
Oil pressure is generated by a gear-type pump bolted to the
bottom oi the engine block. The oil pump is chain driven off
the front of the crankshaft.
Table a. Engine oil capacity (includes oil filter replacement)
6-cylinder 6.5
liters (6.9
US qt)
V-8 7.5 liters (7.9 US qt)
The oil pressure warning system consists of an oil pressure
switch mounted in the oil circuit and an instrument
panel
warning light. Other saiety features include:
Q A filter bypass to provide lubrication should the oil filter be-
come clogged.
An oil pump pressure relief valve to prevent excessive sys-
tem pressure.
CAUTIOI\C
If the red oil pressure warning light comes on or flashes on
while driving, always assume that the oilpressure is low. Stop
the engine immediately and make arrangements to test oil
pressure.

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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.

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Lubrication System
To test switch, connect an ohmmeter between terminal in
switch body (arrow) and ground. With engine off, there
should be continuity. With engine running, oil pressure
should open switch and there should be no continuity. Re-
place a faulty switch.
CAUTION-
Keep in mind that low oil pressure may be preventing the
switch from turning the light out
If the light remains on while
the engine is running, check the oil pressure as described
earlier. Do not drive the car until the problem is corrected. The
engine may be severely damaged.
Crankshaft rear main seal replacement requires removal of
the transmission and flywheel.
Crankshaft rear main seal, replacing
(&cylinder)
- Remove transmission. See 230 Manual Transmission or
240 Automatic Transmission.
- Manual transmission vehicles: Remove clutch pressure plate
and disc. See
210 Clutch.
- Remove flywheel. See 210 Clutch or 240 Automatic Trans-
mission.
- Drain engine oil.
4 Remove seal carrier bolts from oil pan (arrows). Loosen all
oil pan bolts.

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-- . - .. . - Lubrication system]
- Remainder of installation is reverse of removal.
Replace self-locking nuts when reinstalling front suspen-
sion components.
Use new oil dipstick tube sealing O-ring.
After adding engine oil, start and run engine. Raise engine
speed to 2,500 rpm until oil pressure warning light goes out
(about 5 seconds).
NOTE-
BMW does not specify a front end alignment following this
procedure.
Tightening torques Front subfrarne to body rail
(M12, use new bolts)
8.8 grade
10.9 grade
12.9 grade 77 Nrn
(57 ft-lb)
105 Nrn (77 ft-lb)
110 Nrn (81 ft-lb)
Stabilizer bar link to stabilizer bar
65 Nrn (48 ft-lb)
Steering shaft universal joint clamping bolt
(use new bolt)
19 Nrn (14 it-lb)
Lower oil pan, removing and installing (V-8)
- The V-8 engine is equipped with a 2-piece oil pan. The fas-
teners in
V-8 engine oil pump assembly, including the
sprocket retaining nut, are known to loosen and fall off into
the oil pan. Be sure to install these fasteners with Loctite
O
or equivalent thread locking product and torque to specifica-
tions.
CAUTION-
It is recommended that the oil pump retaining bolts and oil
pump drive sprocket retaining nut tightening torque be
checkedany time the
oilpan is removed.
- Raise car and place securely on jack stands.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
- Remove splash shield from under engine.
- Drain engine oil
- On cars with automatic transmission, remove ATF cooler line
brackets from oil pan.