Tire BMW 540i 1997 E39 User Guide

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020-30
Maintenance
fluid use and the most-up-to-date information regarding
transmission operating fluids.
The automatic transmission is not equipped with a dipstick.
Therefore, checking the ATF level is an involved procedure
which includes measuring and maintaining a specified ATF
temperature during the checking procedure.
For more complete
ATF service information, including
checking
ATF level and ATF filter replacement procedures,
see
240 Automatic Transmission.
Transmission service, manual
Manual transmission service consists of inspecting for leaks
and checking the fluid. Evidence of transmission leaks is
like-
ly to be seen around the driveshaft mounting flange and at the
bottom of the bellhousing.
NOTE-
For more information on identifying oil
leaks and their
causes, see 230 Manual Transmission and210 Clutch.
Transmission fluid, checking and filling
(manual transmission)
Tne manual transmss'on inslalleo 'n rne E39 models s f;lled
with a special liierime iluid (ivlTF-LT-I). oi. ordinarily
does
not need to be changed.
< Check manual transmission oil level at transmission filler plug
(A). Make sure car is on level surface.
NOTE- Transmission fluid level
checking and replacement
procedures are covered in 230 Manual Transmission.
Wheels, aligning
BMW recommends checking the front and rear alignment
once a year and whenever new tires are installed.
NOTE-
See 320 Steering and Wheel Alignment for a more detailed
discussion of alignment requirements and specifications.

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. .- -
I Engine Removal and Installation I
4 Where applicable, remove schraedervalve cap (arrow) from
air connection on fuel rail. Using a tire chuck, blow fuel back
through feed line using a brief burst of compressed air
(rnax-
imum of 3 bar or 43.5 psi).
WARNING -
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) andmay be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap
a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Alwavs unscrew the Fuel tank cao to release
oressure
I in the tank before working on the tank or lines. I
- Raise car and support in a safe manner.
WARNING-
Male sure the car is stable and we/ supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor jack is not adequate support
- Working underneath car, remove protective engine splash
guard.
4 Disconnect fuel lines by sliding locking collar in (arrows) and
pulling line apart.

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11 3-2
Cylinder Head Removal and Installation
This group covers cylinder head removal and installation as
well as cylinder
headlvalve diagnostic procedures.
In the procedures in this repair group, engines are referred to
by engine code. If necessary, see
100 Engine-General for
engine code and application information.
The information given in this repair group assumes that the
engine is installed in the engine bay. On the
6-cylinder en-
gines, the VANOS control unit must be removed in orderto re-
move the cylinder head from the engine block. On
M52TU
and M54 engines, camshafts must be removed from the cylin-
der head before the head is removed.
The cylinder head removal and installation procedures for the
M62 V-8 are also included, butthe proceduresforthe M62TU
V-8 with VANOS are not provided.
For cylinder head and valvetrain reconditioning information,
see
116 Cylinder Head and Valvetrain.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
If a head gasket problem is suspected, a compression test or
leak-down test will usually detect the fault See Diagnostic
Testing later
in this group.
Special tools
Special BMW service tools are required to properly remove
and install the cylinder head on engines covered by this man-
ual. The special tools are used to time the valvetrain to the
crankshaft, and to remove the VANOS control unit, the cam-
shafts and the
Tom (El2) head bolts. Read the entire proce-
dure through before beginning the job.

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113-8
[cylinder Head Removal and Installation 1
Cylinder leak-down test
The most conclusive diagnosis of low compression symp-
toms requires a cylinder leak-down test. Using a special
tester and compressed air, each cylinder, in turn, is pressur-
ized. The rate at which the air leaks out of the cylinder, as well
as where the air leaks out, can accurately pinpoint the magni-
tude and location of the leakage.
Before attempting any repair that requires major engine dis-
assembly, use a leak-down test to confirm low compression.
~YL~NDER HEAD REMOVAL AND
~NSTALLATION (M52 ENGINE)
WARNING-
Due to rislc of personal fnjur~: be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation is a time consuming
repair procedure requiring multiple special
service tools.
Read the entire procedure before beginning the repair.
This procedure includes the following steps:
Cylinder head, removing,
M52 engine
Cylinder head, installing,
M52 engine
Cylinder head, removing, M52 engine
- Disconnect negative (-) cable from battery in luggage com-
partment.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions in 001 General Cautions and Warnings.
-

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113-10
Cylinder Head Removal and Installation
4 Working above engine, disconnect the following:
Vent line from cylinder head cover
(A).
. Oxygen sensor connectors (B).
Electrical harness connector from VANOS solenoid
valve
(C).
Electrical harness connectors at throttle valve position
switch
(D), ASC valve position switch (E), fuel injector har-
ness
(F) and vent valve (G).
CAUTION-
Be sure to mark oxygen sensor harness connectors so that
they can be reassembled correctly Do not interchange con-
nectors.
4 Where applicable, remove schraeder valve cap (arrow) from
air connection on fuel rail. Using a tire chuck, blow fuel back
through feed line using a brief burst of compressed air (max-
imum of
3 bar or 43.5 psi).
WARNING-
. Fuel in fuel line is underpressure (approx. 3 - 5 bar or 45 -
75 psi) and may be expelled. 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. Catch and
dispose of escaped fuel. Plug open fuel lines.
- Always unscrew the fuel rank cap ro release pressure
;n the tank before working on the tank or lines.
Disconnect fuel lines by sliding locking collar in (arrows) and
pulling lines apart.
NOTE-
BMW uses three styles of fuel line connections; a one-time
use
clamp; a locking fitting that uses BMWspecial tool 16 1
050 to release; and a quick release sleeve (above) that dis-
connects the line when depressed.

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1 13-22
Cylinder Head Removal and Installation
CYLINDER HEAD REMOVAL AND
~NSTALLATION (M52 TU AND N154
ENGINES)
WARNING -
Due to risk ofpersonal injur)c be sure the engine is cold be-
fore
beqinning the removal procedure.
Cylinder head removal and installation is a time consuming
repair procedure requiring multiple special service tools.
Read the entire procedure before beginning the repair.
This topic includes the following procedures:
* Cylinder head, removing, M52 TU and M54 engines
Cylinder head, installing,
M52 TU and M54 engines
Cylinder head, removing,
M52 TU and M54 engines
Allow engine to cool before beginning this procedure.
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions in
001 General Cautions and Warnings.
4 Remove left and right interior ventilation ducts (left side
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).
= Turn duct counterclocltwise to unlock from bullthead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring lock fastener
(D).
- Slide filter housing away from inner fender to remove.
Removal of right side ventilation
dud
Remove rear bulkhead panel:
Lift off rubber sealing
gasket (arrow)
- Remove 3 mounting clips (A).
Remove 4 retaining screws (6).
Lift off panel.
: is similar

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. .- -
Cylinder Head Removal and Installation
- Working at side of intake manifold near left strut tower, dis-
connect intake manifold resonance valve electrical harness
connector.
4 Disconnect fuel injector electrical harness connectors from
injectors.
- Use small screwdriver to pry out wire lock clip on fuel injec-
tor
1 connector.
Repeat for remaining injectors.
Release harness conduit fasteners from injector rail.
- Disconnect intake air temperature sensor electrical har-
ness connection (between intake runners for cylinders
3
and 4).
Lift off connector assembly and lay aside.
4 Where applicable, remove schraeder valve cap (arrow) from
fuel
ra~l. Using a tire chuck, blow fuel back through feed line
using a brief burst of compressed air (maximum of
3 bar or
43.5 psi).
WARNING-
Fuel is underpressure (approx. 3 - 5 bar or 45 - 75psi) and
may be expelled. Do not smoke or
work near heaters or
other fire hazards. Keep a fire extinguisher handy Before
d~sconnecting fuel hoses, wrap a cloth around fuel hoses
to absorb any leaking fuel. Catch and
dfspose of escaped
fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
I in the tank before working on the tank or lines.
Disconnect manifold vacuum line (arrow)
Raise car and support in a safe manner,
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A
floorjack is not adequate support.
Remove protective engine splash guard from below engine.

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11 3-56
I Cvlinder Head Removal and Installation
- Installation of the remaining parts is reverse or removal, not-
ing the following:
- Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
If necessary, adjust accelerator cable.
a Reconnect battery.
CAUTION- To prevent damaging the engine electronic systems, installall
ground wire previously removed, including the ground wires
for the
ionition coils.
Tightening torque Coolant drain
pluq to cylinder bloclc 25 Nm (1 8 ft-lb)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb) -
Radiator drain screw to radiator 2.5
Nm (22 in-lb)
spark plug to cylinder head 25
Nm (1 8 ft-lb)
CYLINDER MEAD REMOVAL AND
INSTALLATION (M62 ENGINE)
This procedure covers cylinder head removal and installation
for the
M62 V-8 engine. Procedures forthe M62 TU VANOS
engine are not covered in this manual.
Intake manifold, left cylinder head, and right cylinder head re-
moval and installation are written as separate procedures.
The intake manifold must be removed before the cylinder
heads can be removed.
WARNING
-
Due to risk of personal injuv be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation requires multiple spe-
cial service tools. Read the entire procedure before beginning
the repair.
Intake manifold, removal and installation,
M62 engine
- Disconnect negative (-) battery cable.
CAUTION- Prior to disconnecting the
batterj read the baitery discon-
nection cautions
in 001 General Cautions and Warnings.

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I Fuel Tank and Fuel Pump --
Fuel pressure gauge, installing
(6-cylinder models)
4 Remove fuel rail cover by prying off trim covers (arrows) and
removing nuts.
4 If equipped, remove schraeder valve cap (arrow). Blow fuel
back through feed line using a brief burst of compressed air
(maximum
3 bar or 43.5 psi).
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or 45 -
75psi) andmay be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking 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 working on the tank or lines.
4 Attach fuel pressure gauge to BMW special tool 13 5 220
(T-fittlng) or equivalent and attach to schraeder valve.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from
coming loose underpressure.
CAUTION-
When using the BMWspecial tool, use care when turning the
T-handle in to open the schraeder valve. Screw the handle in
just until the schraeder valve opens. Turning the handle in too
far will damage the schraeder valve.
NOTE-
* The schraeder valve must be opened to the fuel pressure
gauge connection. Either remove the valve using a stan-
dard tire valve removal tool or use the BMW special tool
15 5 220.
* The fuel pressure gauge should have a minimum range of
0 to 5 bar (0 to 75 psi).
- For vehicles without the schraeder valve on the fuel rail, at-
tach the fuel pressure gauge in line with the fuel supply line
to the fuel rail.

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Driveshaft
4 Driveshaft center slide nut spanner
(Tool No. BMW
26 1 040)
7, 25 1 Ho 4 cv joint removal tool
(Tool No. BMW 26 1 11 0)
support assembly
Driveshaft description
4 The two-piece driveshaft is connected to the transmission by
a rubber flex-disc and to the rear final drive by a constant ve-
locity (CV) joint.
A universal joint is used at the center of the driveshaft and
the shaft is supported in the middle by a center support
bearing. The bearing is mounted in rubber to isolate vibra-
tion.
- The rear constant velocity joint compensates for fore and
aft movement of the drive line.
Troubleshooting
The source of driveline vibrations and noise can be difficultto pin-
point. Engine, transmission, rear axle, or wheel vibrations can be
transmitted through thedriveshaftto the car body. Noises from
thecar may be caused by final drive problems, or by faulty wheel
bearings, drive axles, or even
wom or improperly inflated tires.
NOTE-
For drive axle repair information, see 331 Final Drive
Driveshaft noise or vibration may be caused by worn
ordam-
aged components. Check the universal joint for play. With the
driveshaft installed, pull and twist the driveshaft while watch-
ing the joint. The
BMW specification for play is very small, so
almost any noticeable play could indicate a problem.
Check the torque of the fasteners at the flange connections.
Check the rubber of the flex-disc and center bearing for dete-
rioration or tearing. Check the driveshaft for broken or miss-
ing balance weights. The weights are welded tabs on the
driveshaft tubes. In addition to inspecting for faulty driveshaft
parts, the installed angles of the driveshaft should also be
considered.