engine removal BMW 540i 1997 E39 Workshop Manual

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I Radiator and Cooling System
This section covers component repair information for the en-
gine cooling system.
Heater core replacement is covered in
640 Heating and Air
Conditioning.
Special tools
Special tools are necessaryfor belt-driven fan clutch removal
and also for pressure testing the cooling system.
4 Cooling fan counterhold wrench
(Tool No. BMW
11 5 030)
4 Cooling fan wrench
(Tool No. BMW
11 5 040)
< Expansion tank cap test adaptor
(Tool No.
BMW 17 0 007)
17 0 002 4 Cooling system pressure tester set
1 17 o 005 (Tool No. BMW 17 0 OOZi17 0 005)

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Warnings and cautions
Obse~e the following warnings and cautions when worlting
on the cooling system.
WARNING -
. At normal operating temperature the cooling system is
pressurized. Allow the system to cool as long as possible
before opening (a minimum of one hour), then release the
cap slowly to allow safe release ofpressure.
a Releasing the coolant system pressure lowers the cool-
ant boilingpoint and the coolant may boil suddenly. Use
1 heavy and wear eye and face protection to
guard against scalding.
Use extreme care when draining and disposing of en-
gine coolant. Coolant is poisonous and lethal to hu-
mans andpets. Pets are attracted to coolant because
of its sweet smell and taste. Seek medical attention im-
mediately if coolant is ingested.
CAUTIOG
Avoid adding cold water to the coolant while the engine is
hot or overheated. If it is necessary to add coolant to a
hol
system, do so only with the engine running and coolanl
pump turning.
To avoid excess silicate gel precipitation in the cooling
system and loss of cooling capacity, use BMW coolant
or equivalent low silicate antifreeze.
a If oil enters the cooling system, the radiator, expansion
tank and heating circuit must be flushed with cleaning
agent. BMW recommends removal of the radiator and
expansion
tank to flush.
When
worlcing on the cooling system, cover the alter-
nator to protect it against coolant drips.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in
001 General Warnings
and Cautions.
Begin the diagnosis of cooling system problems with a thor-
ough visual inspection.
If no visual faults are found, it is rec-
ommend that the engine control module (ECM) fault memory
be checked for stored diagnostic trouble codes
(DTCs) using
BMW scan tool
DlSplus or equivalent.

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Radiator and Cooling System
Cooling system, bleeding
Trapped air in the cooling system can prevent proper coolant
circulation and overheating. Wheneverthe coolant is drained
and filled, bleed the cooling system to remove trapped air.
4 Loosen bleed screw (arrow) on radiator expansion tank.
- Set temperature controls in passenger compartment to full
warm, set blower to low setting and turn ignition to
ON posi-
tion (do not start engine).
CAUTIOIG
On late model cars with latent heat pump, do not turn ignition
to ON position.
- Slowly add coolanUdistilled water mixture to expansion tank
until it spills from bleed screw. When coolant spilling from
bleed screws is free of air bubbles, tighten screw and replace
cap on expansion tank.
Run engine until it reaches operating temperature,
- After engine has cooled, recheck coolant level.
Top up so that coolant level indicator is at MAX.
- If trapped air cannot be bled manually, pressure-bleed sys-
tem using cooling system pressure tester.
CA UTlON--
Always use genuine BMW coolant or its equivalent to avoid
the formation of harmful, clogging deposits
in the cooling sys-
tem.
Tightening torque
Radiator bleed screw to radiator 2.5 Nm (22 in-lb)
Mechanical (viscous clutch) cooling fan,
removing and installing
The procedure given here describes the removal of the me-
chanical fan and fan shroud. It is possible to remove the fan
without the shroud.
< Working at top of fan shroud:
Remove expansion tank bleed screw (arrow) and expan-
sion tank locking tabs.
Push top of expansion
tank toward engine and lift to free
from lower mounts.
- Remove two expansion rivets in upper corners of fan shroud.
Unclip expansion tank bleed hose located under shroud.

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Radiator and Cooling System
Remove rubber trim strip between top of shroud and radiator.
Using 32 mm wrench
(BMW special tool 11 5 040) on fan
clutch nut (arrow), turn wrench in a clockwise direction
(working from front of car) while counterholding pulley with
BMW special tool
11 5 030. Spin fan off coolant pump.
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
Unclip AUC (air quality) sensor from shroud,
M54 engine: Disconnect auxiliary coolant pump from base of
fan shroud.
Lift fan and shroud together out of engine compartment.
To replace fan clutch, remove fan mounting bolts and sepa-
rate viscous clutch from fan.
Installation is reverse of removal.
Tightening
torques
Clutch nut to pump
Without
BMW tool 11 5 040 40 Nm (29 ft-lb)
With BMW tool 11 5 040 30 Nm
(22 ft-lb)
Fan to viscous clutch 10 Nm (89 in-lb)
Electric cooling fan, removing and
installing
The electric cooling fan is mounted behind the front bumper,
in front of the
A/C condenser.
- Remove front bumper. See 510 Exterior Trim, Bumpers.
- Remove left and right headlights. See 630 Lights,
- Where applicable, detach horizontal air ducts behind front
bumper and fold to side.
- Disconnect fan electrical connector on right side of radiator
shroud and lay aside.
- Detach wire loom from air duct in front of cooling fan
- Pry out expansion rivets holding air duct. Slide air duct down-
ward to remove.

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170-1 6
I Radiator and Cooling System
- Remove fan and fan shroud mounting fasteners. Slide fan
and fan shroud downward to remove.
- Reinstallation is reverse of removal.
Thermostat, removing and installing
(M52 engine)
The coolant thermostat is installed in a housing at the front of
the engine.
- Drain coolant from radiator and engine block. See Coolant,
draining and filling (6-cylinder models).
WARNING -
Allow the cooling system to cool before opening or draining
the system.
- Remove mechanical cooling fan and fan shroud. See Me-
chanical (viscous clutch) cooling fan, removing and in-
stalling.
- Disconnect coolant hoses from thermostat housing.
- Remove thermostat housing from front of engine.
- Remove thermostat. Note thermostat direction and orienta-
tion before removing.
- Installation is reverse of removal, noting the following:
- Use new O-ring and gasket(s) when installing thermostat
and housing.
NOTE-
Some thermostats have a direction arrow or vent hole near
the edge. Install the thermostat so that either the arrow or
hole are at the top.
Fill system with coolant as described in Coolant, draining
and filling (6-cylinder models).
CAUTION-
Be sure to reconnect ground wire@) at thermostat housing
mounting bolt, where applicable.

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Radiator and Cooling systeml
Tightening torques
Block drain plug to block 25 Nm
(18
it-lb)
Coolant hose clamp (32 - 48 2.
5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator
2-3Nm(l8-27in-lb)
Thermostat housing to cylinder
head 10 Nm (89 in-lb)
I Coolant thermostat housing assmbly- - I
Thermostat, removing and installing
(M52 TU or M54 engine)
4 The electric map-controlled thermostat is part of the thermo-
stat housing at the front of the cylinder head.
1. Bolts (M6)
2 Bolt (ME)
3. Housing with thermostat
4. Gasket
- If a faulty thermostat is suspected, use appropriate scan tool
to interrogate
ECM for stored fault codes.
- Drain radiator and engine block. See Coolant, draining and
filling (6-cylinder models).
CAUTION-
Allow cooling system to cool before opening or draining the
system.
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Disconnect electrical harness connector from thermostat
housina.
4 Lever out retaining clips (arrows) and pull hose fittings off
thermostat housing.
- Unbolt and remove thermostat housing from front of engine.
Loosen nut at top of engine lifting eye to facilitate removal.
- Installation is reverse of removal, noting the following:
Keep sealing faces free of oil.
* Use new sealing gasket.
When reinstalling hose to thermostat housing, install clip
on hose end fitting, then push hose onto housing until it
clicks into place.
Fill system with coolant. See Coolant, draining and fill-
ing (6-cylinder models).

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170-1 9
Radiator and Cooling System
Coolant pump Remove thermostat housing fasteners
(arrows) and remove
thermostat housing.
Installation is reverse of removal, noting the following:
- Keep sealing faces clean and free of oil.
Use new sealing gasket.
Fill system with coolant. See Coolant, draining and fill-
ing
(V-8 models).
Tightening torques
Block drain plug to block 25 Nm (18 it-lb)
Coolant hose clamp (32
- 48 2. 5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator 2
- 3 Nm (18 - 27 In-lb)
Thermostat cover to
coolant pump 10 Nm (89 in-lb)
Coolant pump, replacing (6-cylinder
models)
< The engine coolant pump is mounted in the front of the en-
gine in the timing chain cover.
- Drain cooling system as described earlier. See Coolant,
draining and filling (6-cylinder models).
WARNING-
Allow cooling system to cool before opening or draining sys-
tem.
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Remove coolant pump drive belt. See 020 Maintenance.
4 Remove coolant pump pulley bolts (arrows) and remove pul-
ley from pump.
- Remove nuts retaining pump to engine block.
NOTE-
The coolant pump is mounted on studs and retained by nuts.

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.," --
Radiator and Cooling System --- 1
insert two M6 screws (arrows) in tapped bores and tighten
uniformly until pump is free from timing chain cover (thermo-
stat and hoses have been removed for purposes of visual
clarity).
Installation is reverse of removal, noting the following:
Be sure to replace sealing O-ring and gaskets.
Coat O-ring with water-based lubricant during installation.
Refill with coolant. See Coolant, draining and filling
(6-
cylinder models).
Tightening torques
-
Coolant pump to timing chain 10 Nm (89 in-lb)
cover
Coolant pump pulley to coolant
10 Nm (89 in-lb
pump
Engine block drain plug to block 25 Nm (1 8 It-lb)
Radiator drain plug to radiator 2 - 3 Nm (I8 - 27 in-lb)
Coolant pump, replacing (V-8 models)
I 1 < The engine coolant pump is mounted in the front of the en-
gine in ;he timing chain cover.
1. Thermostat housing
2. Thermostat
3. Thermostat sealing O-ring
4. Water pump
5. Water pump gasket
- Drain cooling system. See Coolant, draining and filling (V-
8 models).
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Remove engine drive belts: See 020 Maintenance.
NOTE-
Mark direction of drive belt rotation if reusing belt,
- Remove vibration dampener. See 117 Camshaft and Tim-
ing Chain.
- Disconnect mass air flow (MAF) sensor electrical harness
connector. Remove air intake duct together with
MAF sensor.
- Disconnect coolant hoses from thermostat housing and cool-
ant pump housing.

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Radiator and Coolina ~vsteml
- Disconnect thermostat and cooling system temperature sen-
sor plug connectors.
4 Remove thermostat housing fasteners and remove housing.
- Remove coolant pump pulley bolts and remove pulley from
pump.
Remove fasteners A and B (arrows).
NOTE-
* The coolant pump is retained to the block using different
length bolts.
0 Bolts A: M6 X 105 mm
0 Bolts 8: M6 X 35 mm
Slide coolant pump away from coolant pipes (arrows) while
being careful not to dislodge pipes from fittings at rear of en-
gine.
- Installation is reverse of removal, noting the following:
Replace all sealing O-rings and washers.
Coat O-rings with water-based lubricant during installation.
Fill system with coolant. See Coolant, draining and fill-
ing (6-cylinder models) or Coolant, draining and filling
(V-8 models).

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.. - --
Radiator and Cooling System
Tightening torques
Coolant pump to timing chain 10
Nm (89 in-lb)
cover
Coolant pump
pulley to coolant
pump
10 Nm (89 in-lb
Engine
blocic drain plug to block 25 Nm (18 ft-lb)
Radiator drain plug to radiator
2-3Nm(18-27in-lb)
Thermostat cover to coolant
pump assembly 10 Nm (89 in-lb)
Radiator, removing and installing
Removal of the radiator is similar for V-8 and 6-cylinder mod-
els.
- Raise front of car and support safely.
WARNING -
Make sure the car is stable and well supported at aN times.
Use a professional automotive liff
orjaclc stands designed for
- Remove splash shield from under engine.
- Drain radiator and engine block. See Coolant, draining and
filling
(V-8 models).
WARNING -
Allow cooling system to cool before opening or draining sys-
tem.
< Remove air filter housing:
Disconnect electrical harness connectors
(A and B).
Loosen clamps (C and D).
Remove mounting fastener (arrow) and remove air filter
housing together with mass air flow
(MAF) sensor.