BMW 540i Specifications download pdf (Page 19)

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm

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

At this point, inspect the area around the valley pan - that black plate is a plastic heat shield which snaps to the pan.

The retainer clips will undoubtedly break when unsnapped, so plan on replacing the shield if you replace the pan. If you

see any trace of (dried) coolant in this area, replace the valley pan. In fact, given that the plate and heat shield only cost

about $50, you should replace them as a preventative measure while the manifold is off. The seal on my original pan

was a traditional flat gasket while the new one uses an o-ring (apparently this is a common failure mode and has been

addressed with an updated part).

VALLEY PAN REMOVAL

Water Manifold

- Heater hoses. There are two heater hoses (A) which must be disconnected at the

manifold. Now would be a perfect time to replace these hoses, depending on the

condition of yours. The long one historically fails with a pinhole right at the top of the

first bend. Remove both hoses from the manifold (coolant will escape when these

hoses are removed).

- The manifold (B) is bolted to the block via six (three per side) 10mm bolts. These

bolts run straight forward into the rear face of the block. Using a combination of

deep and standard 1/4" drive sockets, along with a short (1") extension on the

passenger side, remove all six bolts. More coolant will escape once the manifold

seal is broken.

- The two water pipes which run between the water pump and the manifold (C) use

o-ring seals at each end. Work the pipes off the manifold, and remove the manifold

from the vehicle: set aside.

- Work the two pipes out of the water pump housing: set aside.

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BMW 540i Specifications Page 19