BMW 540i Specifications download pdf

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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.

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Summary of Contents

Page 1 - - Valley pan

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Page 2

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Page 3

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Page 4 - REQUIRED PARTS

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Page 5 - GENERAL MECHANICS TOOLS

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Page 6 - A word about the prices

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Page 7 - TORQUE SPECIFICATIONS

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Page 8

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Page 9

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Page 10

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Page 11

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Page 12

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Page 13

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Page 14

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Page 15

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Page 16

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Page 17

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Page 18

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Page 19

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Page 20

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Page 21 - VALLEY PAN INSTALLATION

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Page 22

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Page 23

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Page 24

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Page 25

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Page 26

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Page 27

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Page 28 - Engine Vent Pipe

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Page 29 - Miscellaneous

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Page 30

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Page 31

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Page 32

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Page 33

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Page 34 - INTAKE MANIFOLD SUBASSEMBLY

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Page 35

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Page 36 - INTAKE MANIFOLD INSTALLATION

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Page 37

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Page 38

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Page 39

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Page 40

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Page 41

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Page 42

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Page 43

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Page 44

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Page 45

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Page 46 - GOOD LUCK, and HAVE FUN!!!

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