BMW 540i- User Manual

BMW 540i

BMW 540i– User Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 2 – DO YOU NEED TO PERFORM THESE TASKS?
  • Page 3 – vehicle and/or serious injury or worse to your person.
  • Page 4 – REQUIRED PARTS; verify with your parts department when ordering.; Description
  • Page 5 – Total; Optional parts which should be evaluated for replacement; Tool
  • Page 6 – A word about the prices; suspect
  • Page 7 – Main Task; Assembly; TORQUE SPECIFICATIONS
  • Page 8 – be so brittle, so didn't have one on hand prior to beginning work.
  • Page 9 – Disconnect battery positive lead.; Remove Idle Control Valve if so equipped
  • Page 10 – Engine Cover Supports; Fuel Lines
  • Page 11 – Driver’s side electrical harness
  • Page 13 – Accelerator Cables
  • Page 14 – Passenger side electrical harness
  • Page 15 – Vacuum Control Plumbing
  • Page 16 – Engine Vent Tube
  • Page 17 – Intake Manifold
  • Page 19 – VALLEY PAN REMOVAL
  • Page 20 – Valley Pan
  • Page 21 – VALLEY PAN INSTALLATION
  • Page 22 – Water Manifold
  • Page 26 – INTAKE MANIFOLD DISASSEMBLY AND SEAL/GASKET REPLACEMENT; Vacuum Plumbing
  • Page 27 – Rear Manifold Cover
  • Page 28 – Engine Vent Pipe
  • Page 29 – Miscellaneous
  • Page 34 – INTAKE MANIFOLD SUBASSEMBLY; Vent Tube
  • Page 35 – Primary Throttle Body
  • Page 36 – Intake Manifold Seals; - Remove paper towels from intake ports in heads.
  • Page 37 – Vent Tube Installation
  • Page 38 – Vacuum Plumbing Installation
  • Page 40 – Passenger side electrical harness Installation
  • Page 43 – Intake Flex line between MAF and ASC throttle body.
  • Page 44 – Idle Control Valve; Coolant
  • Page 45 – Connect battery positive lead.
Loading the manual



Originally developed and published here by unknown author:

http://members.cox.net/rlacm/IntakeIndex.htm

Recovered and published by BMW-Planet.com – May 2012

BMW 540i (E39, pre-VANOS) Maintenance:

- Intake System Gaskets and seals

- Valley pan

Breathing new life into your M62's leaky intake system, and fixing that nagging
valley pan coolant leak.

BACKGROUND

At around 82k miles my engine was clearly showing signs of minor air leaks in the intake system: rough idle when cold,
occasional miss at idle, periodic extended cranking times during starting, etc. Additionally, a BMW tech pointed out that
my valley pan seal was leaking a small amount of coolant, a common occurence on these motors.

There is some good news here: these two problems, leaky intake seals/gaskets and seeping valley pan, appear to have
nothing in common except, perhaps, for mileage. However, even if you're only trying to fix one, it's an easy task to take
care of the other on a pre-emptive basis while you're in there. In the case of the intake manifold, the only additional work is
R&R of the water manifold/plumbing and the valley pan. Total additional cost is around $50, a little more if you replace
the two hoses that attach to the manifold. Conversely, if you're after the valley pan in the first place, the manifold
gaskets/seals come along "for free."

I reviewed the BMW TIS documents and decided this would be a fairly straightforward procedure: no special tools
required, and less than a day's work. So I headed over to the dealer with parts list in hand.

"Loading the manual" means you need to wait until the file loads and becomes available for online reading. Some manuals are very large, and the time they take to appear depends on your internet speed.

Summary

Page 2 - DO YOU NEED TO PERFORM THESE TASKS?

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Note that a good majority of the required parts had to be special ordered, so plan your time accordingly. The entire job took me just over six ...

Page 3 - vehicle and/or serious injury or worse to your person.

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 momentarily seal it and the RPM will increase for a short time. Note this is not a guaranteed method, and you can make a mess of your paint if ...

Page 4 - REQUIRED PARTS; verify with your parts department when ordering.; Description

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 On this page you'll find all the parts (with prices!) that I replaced during this job. Additionally, I've included lists of special BMW-supplie...

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