Oil pan BMW 540i 2000 E39 Workshop Manual

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.-
General
4 An adjustable wrench can be a useful addition to a small tool
kit. It can substitute in a pinch if two wrenches of the same
size are needed to remove a nut and bolt. Use extra care with
adjustable wrenches, as they tend to loosen, slip, and dam-
age fasteners.
Jack stands
v
BOOBFNG
4 Strong jack stands are extremely important for any work that
is done under the car. Use only jack stands that are designed
for the purpose.
Blocks of wood, concrete, bricks, etc. are not
safe or suitable substitutes.
A
jaclc should be used only to raise the vehicle, not to support
the car for a long period. Always use
jack stands to support a
Jackstands are available in several styles. The best ones are
:
made of heavy material for strength, have a wide base for sta-
bility, and are equipped to positively lock in their raised posi-
tion. Get the best ones available.
Compared to
a wrench of the correct size, an adjustable
Oil change equipment
wrench is always second best. They should only be used
when the correct size wrench is not available. Choose one of
average size range, about
6 to 8 inches in length.
4 Changing engine oil requires a 17 mm socket or wrench to
loosen and tighten the drain plug and a drain pan (at least
8
quart capacity). A wide, low drain pan will fit more easily un-
der the car. Use a funnel to pour the new oil into the engine.
BMW engines use an oil filter canister with a disposable filter
cartridge insert. A
36 mm socket or wrench is required to re-
move the oil filtercanistercover. See
020 Maintenance foroil
change instructions.

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4 If oil level is low, add oil by removing oil filler cap (arrow) on
top of cylinder head
(6-cylinder oil cap shown, V-8 is sirnilar).
- Add only amount needed to bring oil level to upper mark on
dipstick, using an oil of correct viscosity and grade.
Engine oil and filter, changing
A complete oil change requires new oil, a new filter insert kit,
and a new drain plug sealing washer. The tools needed, a
17
mm drain plug socket or box wrench, a 36 mm socket or
wrench, and a drain pan (8
- 10 US qt. capacity), are de-
scribed in
010 General.
NOTE-
If using a "fast 1ube"service facility for oil changes, make sure
the technician hand-starts and torques the engine oil drain
plug using hand-tools. Power tools can strip the threads of
the plug and the oil pan.
Run engine for afew minutes to warm engine oil. Shut engine
off.
With car on level ground, place drain pan under oil drain plug.
Using a
36 mm socket, loosen and remove oil filter housing
cover (arrow). Remove filter cartridge and discard any
0-
rings (V-8 engine oil filter housing shown, 6-cylinder oil filter
housing is sirnilar).
Using a socket or box wrench, loosen drain plug at oil drain
pan. Remove plug by hand and let oil drain into pan
(V-8 en-
gine oil drain plug shown, 6-cylinder drain plug is similar).
WARNING -
Pull the loose plug away from the hole quicldy to avoid being
scalded by hot oil. It will run out
quiclcly when the plug is re-

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020-1 4
Maintenance
- When oil flow has diminished to an occasional drip, reinstall
drain plug with a new metal sealing washer and torque plug.
Tightening torque Engine oil drain plug to oil pan
25 Nrn (1.8 ft-lb)
6-cylinder oil filter assembly
r------ 1
< Working at oil filter housing (1):
Lubricate and install new oil filter O-rings (3, 4).
Install a new filter cartridge (5).
lnstall and tighten housing cover (2).
6-cylinder oil filter assembly shown, V-8 is similar.
Tightening torque Cover to oil filter housing
25 Nm (1.8 it-lb)
- Refill crankcase with oil. Approximate oil capacity is listed in
Tabled. Engine oil with filter change. Use dipstick to
check correct oil level.
- Start engine and check that oil pressure warning light
immediately goes out.
- Allow engine to run fora few minutes to circulate new oil, then
check for leaks at drain plug and oil filter. Stop engine and re-
check oil level
The section describes other routine maintenance done in the
engine compartment. Information on engine oil service is
giv-
enkar~ier inthis group.
For these procedures, it is not necessary for the car to be
raised and supported off the ground.
Accelerator and linkage
The accelerator and linkage at the throttle housing should be
lubricated periodically. Use ageneral purposeoil on the joints
and bearings of the linkage. Use a multipurpose grease on
the bearing points of the throttle plate.
Air filter, replacing
The specified replacement intervals forthe air filter are based
on normal use. If the car is operated primarily in dusty
conditions, the air filter should be serviced more frequently.

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020-1 6
Maintenance
loose, hose is damaged, or connection is dirty or corroded.
Dried coolant has achalky appearance. Hoses should be firm
and springy. Replace any hose that is cracked, has become
soft and limp, or has been contaminated by oil.
4 As a preventive measure, replacement of the cooling system
hoses every four years is recommended. The illustration
shows examples of damage to coolant hoses. Any of these
conditions is cause for replacement (illustration courtesy of
/ Abrasion Damaged Hose Heat Damaged Hose 1 Gates Rubber Company, I~c.).
Engine drive belt, replacing
Drive belts and pulleys transfer power from the engine crank-
shaft to various accessories.
E39 models use two polyribbed
(serpentine) belts:
The outer belt turns the
NC compressor.
0 The inner, longer belt turns the alternator (generator), cool-
ant pump and power steering pump.
Inspect drive belts with the engine off. If the belt shows signs
of wear, cracking, glazing, or missing sections, it should be
replaced
immediately. To reduce the chance of belt failure
while driving, replacement of the belts every four years is
recommended.
WARNING -
Observe care when replacing belts. Personal injury could
result if a tensioner springs back into position uncontrolled.
CA UTIOI\C
Mark drive belt rotation direction if removing and reusing an
old belt.
NOTE-
When belts are replaced with new ones, store the old set in
the trunk for emergency use.
All models, use
BMW special tools 11 5 030 and 11 5 040 to
loosen and remove cooling fan and clutch from coolant
pump.
NOTE-
32 mm cooling fan nut has left-hand threads
If necessary, remove fan cowl from radiator.

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11 0-20
Engine Removal and Installation
Working at right side of transmission bellhousing, disconnect
electrical harness connections (arrows) from starter. Re-
move starter retaining bolts and remove starter from trans-
mission mount.
M62 TU engine: Disconnect electrical harness connector
for right oxygen sensor from retaining clip and remove re-
taining clip from transmission.
- Working underneath engine compartment at left side:
Unclip positive battery cable from oil pan.
. Remove alternator cooling duct.
4 M62 engine: Remove fastener A and plug connector B from
alternator.
- M62 TU engine: Remove electrical harness connectors from
front of water cooled alternator.
- Remove exhaust system and transmission. See 180 Ex-
haust System and 230 Manual Transmission or 240 Auto-
matic Transmission.
- Working at front of engine:
Remove upper and lower hoses from radiator.
D~sconnect expansion tank hose from coolant pump.
- Remove belt-driven cooling fan:
Counterhold fan with special tool
11 5 050.
Turn fan mounting nut (32 mm) clockwise (left hand
threads) to loosen.
Rotate fan clockwise to remove.
Remove cooling fan shroud:
Disconnect electrical connectors from coolant level sensor
(B) and coolant temperature sensor (C).
. Remove expansion rivets (A) from each side of shroud
Remove coolant hose
(D).
Slide fan shroud with expansion tank up. Remove radiator
overflow tube from spout of expansion tank. Remove radi-
ator fan shroud with expansion tank.
Remove radiator. See
170 Radiator and Cooling System.

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11 3-69
Cylinder Head Removal and Installation
4 Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Boss for special tool 11 3 200 located at rear of engine oil
pan.
4 Working at left cylinder head (driver's side) fit primary sprock-
et and chain to camshaft flange, centering threaded bores.
Insert bolts (arrows) and hand tighten.
?-I I 4 Install BMW special tool 11 3 390 into right timing case cover.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
I - Tighten sprocket retaining bolts in the following order:
All bolts on left cylinder head exhaust camshaft
3 accessible bolts on right cylinder head exhaust camshaft
All bolts on left cylinder head
intake camshaft
3 accessible bolts on right cylinder head intake camshaft r"".."..7n
Tightening torques
Sprocltet bolts to camshait flange
15 Nm (11 ft-lb)
- Remove camshaft and crankshaft locking tools from engine.
- Using crankshaft center bolt, turn engine clockwise to access
remaining sprocket retaining bolts of right cylinder head cam-
shafts. Tighten remaining bolts.
Tightening torques Sprocket bolts to camshaft flange 15 Nm
(11 ft-lb)

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-8" ."
Cylinder Head Removal and Installation --
Using crankshaft center bolt, rotate engine clockwise from
the
45" before TDC up to TDC position (OIT aligns with cast-
ing mark on cylinder block).
< Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
NOTE-
Special tool boss located at the rear of upper engine oil pan.
- Working at right cylinder head (cylinder 5-8) fit primary
sprocltet and chain to camshaft flange.
!
I
4 Press timing chain tensioner rail against timing chain (white
arrow) to check that fastener holes are centered in sprocket
slots (black arrows).
NOTE-
If necessary, remove sprocl Fit sensor gear with mark pointing up (arrow).
Insert bolts and hand tighten.

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Camshaft Timing Chain Timing chains, removing
(M52 engine)
Camshaft timing chain removal on M52 engines requires en-
gine oil pan removal.
Special
BMW sewice tools are needed for timing chain re-
moval and installation procedures. The special tools assure
propertiming of thevalvetrain. Precise marks to
setthe timing
on the camshafts are not provided for reassembly. Read the
procedures through before beginning the job.
NOTE-
If the camshafts are not properly timed, the pistons can con-
tact the valves.
- Remove VANOS control unit. See VANOS control unit, re-
moving (M52 engine).
- Remove radiator cooling fan and shroud. See 170 Radiator
and Cooling System.
- Drain cooling system. See 170 Radiator and Cooling Sys-
tem.
- Remove coolant hoses from thermostat housing and remove
thermostat housing from front of cylinder head.
- Loosen bolts for coolant pump pulley.
- Remove drive belts for alternator and AIC compressor. See
020 Maintenance.
- Remove coolant pump pulley.
Remove drive belt tensioner mounting bolts (arrows) and re-
move tensioner from front of engine.
- Remove engine speed sensor from lower timing chain cover.

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4 With crankshaft at TDC position, remove vibration damper
bolts (arrows) and remove vibration damper.
< Mount crankshaft holding tool (BMW special tool 11 2 150
and
11 2 410) to crankshaft hub. Counter hold crankshaft and
loosen crankshaft hub retaining bolt.
Crankshaft hub retaining bolt is torqued to
410 Nm (300 ft-lb).
Do not use flywheel
locliing tool to hold cranl(shait stationary
to loosen or tighten crankshaft hub center bolt. Use only the
special tools specified, or equivalent hub holding tool.
- Remove crankshaft hub.
- Remove cylinder cover mounting fasteners and remove cyl-
inder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original positions. Make
note of their arrangement during removal.
- Drain engine oil, remove oil pan. See 119 Lubrication Sys-
tem.
Remove primary timing chain tensioner (arrow).
CAUTION-
Timing chain tensioner is under spring tension. I
- Remove VANOS control unit. See VANOS control unit, re-
moving
(M52 engine).
- Remove fasteners from intake and exhaust camshaft
sprocket.

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Camshaft Timing chain1
Tap locating dowels into cover until they protrude 2 to 3 mm
from sealing surface.
- Using new gaskets, install lower timing chain cover:
Tap cover into position to engage dowels.
Install timing chain cover fasteners and tighten to
5 Nm (44
in-lb).
Drive dowels in flush to front of cover.
. Tighten cover mounting bolts alternately and in stages.
Install cylinder head to timing chain cover fasteners and
tighten.
Tightening torques Lower timing chain cover to block
M7 15 Nm (1 1 ft-lb)
ME 20 Nm (15 it-lb)
- Replace front crankshaft radial seal. See Crankshaft oil
seal, front, replacing
(M52 engine).
Install engine oil pan using
a new gasket. See 119 Lubrica-
tion System.
Mount primary timing chain sprocket to primary
cha~n so that
arrow on sprocket faces up. Mount sprocket to camshafl so
that tapped holes in camshaft are on left side of elongated
holes in sprocket.
4 Install adjustable timing chain tensioner (BMW special tool
11 4 220). Thread tool in finger tight until slack is removed
from chain.
NOTE-
BMW special tool 11 4 220 is an adjustable timing chain ten-
sioner that simulates the function of the hydraulic tensioner.
- Check that elongated holes in primary sprocket are centered
to bolt holes in camshafl and chain is free of slack.
- Install secondary timing chain guide and secondary chain
tensioner. Tighten mounting bolts (tensioner remains
locited
down).
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