2001 BMW 540i AC line

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Engine Removal and lnstallationl
NOTE-
BMW uses three styles of fuel line connections; a one-time
single use clamp, a locking fitting that uses special tool
16 1
050 to release, and a quick release sleeve (arrow) that dis-
connects the line when depressed.
WARNING-
Fuel may be expelled under pressure. Do not smoke or work
near heaters or other fire hazards. Keep a fire extinguisher
handy Before disconnecting fuel hoses, wrap a cloth around
fuel hoses to absorb any leaking fuel. Plug all
oDen fuel lines.
< M52 engine: Remove throttle valve and ASC throttle
assemblies.
Disconnect ASC throttle cable
(A).
Remove ASC throttle housing mounting fasteners (El).
Clamp off, disconnect, and plug coolant hoses (C).
Disconnect throttle and cruise control cables (D).
Remove throttle housing mounting hardware and throttle
valve.
NOTE-
M52 TU, M54 engine: Throttle body is removed with intake
manifold.
< M52 TU engine: Pull throttle cable out of rubber retainer (A)
and unloclc ball end of cable (6) from throttle actuator.

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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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Engine Removal and Installation
4 Working at E-box at right rear of engine compartment:
Disconnect engine electrical harness connectors
(arrows).
Lift off harness looms and lay over engine.
- Remove polyribbed drive belts. Mark direction of rotation if
belts will be reused. See 020 Maintenance.
- Remove exhaust system and transmission from car. See 180
Exhaust System, 230 Manual Transmission or 240 Auto-
matic Transmission.
NOJE-
Detach automatic transmission cooler lines from radiator, re-
move brackets holding lines to side of engine, andstore lines
in a clean environment.
- Remove power steering pump:
If necessary, remove steering pump pulley.
Remove front and rear pump mounting bolts.
Suspend pump from body using stiff wire.
4 Remove A/C compressor mounting bolts (arrows) and AIC
compressor from its mounting bracketwithoutdisconnecting,
distorting, or deforming any refrigerant lines. Suspend from
body using stiff wire.
4 If applicable, remove secondary air pump:
Remove hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
- Disconnect electrical harness from bottom of secondary
air pump.
Remove bracket from strut tower.

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110-14
I Engine Removal and Installation
4 M52 TU, M54 engine: Separate oxygen sensor electrical har-
ness connectors
(arrows) and mounting clip (A) on right side
of engine.
CA UTIOW
Be sure to mark oxygen sensor connectors so that they can
be assembled correctly Do not interchange connectors.
4 Remove chassis ground strap (arrow) at right engine rnount-
ing pedestal.
4 Install an engine lifting device (BMW 11 0 000 or equivalent)
to the front and rear engine supports and raise engine until
its weight is supported. Detach left and right engine mounts.
- Carefully raise engine out of car, checking for any wiring, fuel
lines, or mechanical parts that might become snagged as en-
gine is removed.
-
. ..
- .- -
-

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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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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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110-19
Engine Removal and Installation
M62 engine, remove ASC throttle body.
Disconnect electrical harness from throttle position sensor.
- Disconnect ASC actuator cable (arrow).
. Remove mounting fasteners and remove throttle body.
On front of left side cylinder head, disconnect electrical har-
ness connector
(A), and remove and plug fuel tank vent valve
vacuum line
(0).
Raise car and support in a safe manner.
CAUTION-
Male sure the car is stable and well supported at aN times.
Use a professional automotive
lifi orjackstands designed for
I the ouroose. A floor jack is not adequate support.
Working beneath car:
- Remove engine splash shield.
Remove right and left heat shield from front suspension
subframe.
Working underneath engine compartment, disconnect
ground cable on right side engine mount
(arrow).

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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