Trim BMW 540i 1998 E39 User Guide

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
-
Cylinder Head Removal and Installation c
q Remove secondary air inject~on check valve (arrow).
4 Remove cylinder head top cover:
Remove plastic trim caps (arrows).
Remove engine oil filler cap.
Remove cover hold down fasteners and lift off cover.
4 Remove ignition coils:
Disconnect ignition coil harness connectors.
. Remove coil mounting fasteners.
Remove coils.
Remove ground straps.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
- Remove sparlc plugs.
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original locations. Make
note of their arrangement during removal.

Downloaded from www.Manualslib.com manuals search engine
- --
Cylinder Head Removal and Installation 1 --
< Remove complete air filter housing assembly with mass air
flow sensor:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intake duct
(B) and disconnect idle speed control valve electrical har-
ness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
. Loosen air intalte duct clamp (F).
Carefully lifl air filter housing, mass air flow sensor, and in-
take duct hose out of engine bay.
4 Disconnect positive battery cable and remove intake rnani-
fold cover:
Remove protective cover from positive (+)jumper post.
Loosen and remove battery lead mounting nut (A).
Remove lead and push down through intake manifold.
* Remove trim covers (arrows) from fuel injector cover.
Remove cover hold down fasteners and lifl off cover.
4 Worlting above engine, disconnect the following:
Vent line from cylinder head cover. To remove, pinch clips
(arrows).
Electrical harness connector from VANOS solenoid valve
(A).
- Remove oxygen sensors and exhaust manifolds. See 180
Exhaust System.
CAUTION-
Remove oxygen sensors before removing exhaust mani-
fold to prevent damage.
Label oxygen sensor harness connectors so that they
can be reassembled correctly Do not interchange con-
nectors.
NOTE-
Front exhaust manifold must be removed before rear
manifold.

Downloaded from www.Manualslib.com manuals search engine
11 3-27
Cylinder Head Removal and Installation
< Remove fuel rail mounting bolts (arrows):
- Carefully pry fuel rail off manifold.
Separate fuel line support bracket at rear of intake mani-
fold.
Guide fuel
line(s) out of rear of engine compartment while
lifting fuel rail out.
4 Remove intake manifold mountino hardware (arrows).
I from falling into the engine intake. I
4 Remove cylinder head top cover:
- Remove plastic trim caps (arrows).
Remove cover hold down fasteners and
lilt off cover.

Downloaded from www.Manualslib.com manuals search engine
Cylinder Head Removal and Installation
Pry out ignition coil cover trim caps,
covers from lefl and right sides. remove fasteners
and
< Disconnect throttle cables from throttle shafl (A) and remove
cables from support bracket
(B).
< Disconnect cable from jump start post (arrow) on left cylinder
head cover.

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timina chain1
- Remove viscous clutch cooling fan. See 170 Radiator and
Cooling
System.
CA UTlOEIC
The radiator cooling fan nut (32mm wrench) has left- hand
threads.
.
< Remove engine trim covers:
Pry out plastic trim caps (arrows).
. Remove cover fasteners and covers.
4 Remove ignition coils:
0 Disconnect ignition coil electrical harness connectors
Remove
coil mounting fasteners and remove coils.
Remove spark plugs.
NOTE-
Make note of ignition coil ground strap locations.
Disconnect VANOS electrical harness connector
(A) and oil
line fitting
(B) from VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
- Disconnect cranltcase breather by squeezing at arrows,
- Remove cylinder cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas.
kets should be reinstalled in their original positions. Make
note of their arrangement during removal.

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing Chain
VANOS control unit, removing
(M52 TU and M54 engines)
This procedure includes removal of the Double VANOS con-
trol unit.
NOTE-
If the Double VANOS control unit is being replaced, camshaft
timing must be checked. This procedure requires multiple
special tools. Be sure to read the procedures through before
beginning the repair.
- Working inside luggage compartment, disconnect negative
(-) battery cable.
Prior to disconnecting the
batteg read the battery discon-
nection cautions given in
001 General Cautions and
Remove engine cooling fan assembly. See 170 Radiator
and Cooling System.
Remove engine trim covers.
Pry out plastic trim caps (arrows).
Remove cover fasteners, oil filler cap, and covers.
Remove ignition coils:
Disconnect ignition coil electrical harness connectors.
Remove coil mounting fasteners and coils.
NOTE-
Make note of ignition coil ground strap locations.
Remove spark plugs,

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing chain1
- Disconnect negative cable (-) from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Cautions and
Warnings.
4 Removing top and side engine covers:
Press down on locking pins (arrows) to release locks. Lifl
intake manifold cover straight up to remove.
Pry out caps from side covers.
Remove fasteners
and covers.
NOTE-
Some early models use
pry out trim caps and fasteners to
hold the top cover in place.
Disconnect electrical harness connectors at ignition coils
(A).
Remove left and right side ignition coil mounting fasteners
and coils.
NOTE-
Make note of location of ground strap (arrow).
Remove spark plugs.
- Remove posltlve (+) terminal cable from left cylrnder head
cover.
- Unbolt left and right side cable ducts from fuel rail
Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor and intake air tempera-
ture sensor electrical harnesses
(A and B).
Remove air filter housing mounting fastener (arrow)
Loosen intake hose clamp
(C).
Remove air filter housing with mass air sensor and intake
duct from throttle body assembly.

Downloaded from www.Manualslib.com manuals search engine
Battery, Starter, ~iternatorl
The battery is mounted in the right side of the luggage com-
partment, concealed behind a trim panel. Battery capacity is
determined by the amount of current needed to start the vehi-
cle and by the amount of current consumed by the electrical
system. This will vary from model to model.
BMW batteries are rated by
amperelhours (Ah) and cold
cranking amps (CCA) rating, which are listed on the battery.
The Ah rating is determined by the average amount of cur-
rent the battery can deliver over time without dropping below
a specified voltage. The CCA is determined by the battery's
ability to deliver starting current at
On F (-18" C) without drop-
ping below a specified voltage. Always replace the battery
with one having the same or higher ratings.
Battery testing
Battery testing determines the state of battery charge. On
conventional or low-maintenance batteries. the most com-
mon method of testing the battery is that
ofchecking the spe-
cific gravity of the electrolyte using a hydrometer. Before
testing the battery, check that the cables are tight and free of
- corrosion.
Hydrometer testing
Before hydrometertesting, load the battery with 15 amperes
for one minute. If the battery is installed in the vehicle, this can
be done by turning on the headlights without the engine run-
ning. The state of battery charge based on specific gravity
values are given in Table
b. Specific gravity of battery elec-
trolyte at
27" C (80°F).
The hydrometer indicates the specific gravity of the electro-
lyte. The more dense the concentration of sulfuric acid in the
electrolyte, the higher the state of charge
NOTE-
Electrolyte temperature affects hydrometer reading. Checlc
the electrolyte temperature with a thermometer. Add 0.004 to
the hydrometerreading
forevery 6°C (10°F) that the electro-
lyte is above 27°C
(80°F). Subtract 0.004 from the reading
forevery 6°C (10°F) that the electrolyte is below27"C
(80°F).

Downloaded from www.Manualslib.com manuals search engine
Battery, Starter, ~lternatorl
WARNING-
Always wear protective goggles and clothing when perform-
ing a load test.
Table
d. Battery load test - minimum voltage
Ambient temperature Voltage*
27
" C (80" F) 9.6 V
-I 8' C (0"
F) 8.5 V
* Measure
after applying a 200 amp load for 15 seconds.
Closed-circuit current measurement
If the vehicle battery is discharged for an unknown reason,
perform a closed-circuit current measurement as the first test.
For diagnostic purposes, it is important to not disconnect the
battery. Disconnecting the battery may reset a faulty control
unit, preventing proper diagnosis.
The following test is generally completed overnight using a
multimeterwith a closed circuitcurrent measurement adaptor
with a recording function
- Check that battery voltage is 12 volts or higher. If lower,
recharge battery.
- Switch off electrical consumers (interior lights, telephone,
aftermarket equipment, or others).
- Open luggage compartment and remove battery trim panel.
Use screwdriver to lock latch on trunk lid or hatch, simulating
closed luggage compartment. Close other doors.
- Open driver's door, then close it, simulating driver entering
vehicle.
- Switch ignition to RUN position for at least five seconds, then
turn ignition to OFF position. This simulates driving vehicle.
- Open and close driver's door, simulating driver leaving
vehicle.
- Lock car and arm alarm.
- Wait at least 16 minutes for consumer cut-off.