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BMW E39 Engine Covers Removal
 
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Pelican Technical Article:

BMW E39 Engine Covers Removal

Kerry Jonsson

Time:

1 hour1 hr

Tab:

$0

Talent:

***

Tools:

Socket (10mm), flathead screwdriver

Applicable Models:

BMW 525i Sedan/Wagon (2001-03)
BMW 528i Sedan/Wagon (1997-00)
BMW 530i Sedan (2001-03)
BMW 540i Sedan/Wagon (1997-03)

Parts Required:

Cover fasteners

Hot Tip:

Work with a cool engine.

Performance Gain:

Access to engine

Complementary Modification:

Replace mounting insulators

When servicing the engine on a BMW E39, you may have to remove the cabin microfilter housing and engine covers to access specific components. In this article, I will show you how to remove the covers, providing easy access to the top and rear of engine.

When removing the microfilter housings and ducts, you may have to remove the upper engine cover on 8-cylinder models. On 6-cylinder models you can leave the engine cover in place. Now this all depends on what repair you are performing. You will have to decide what covers have to be removed due to the repair you are performing. For example: bleeding the brakes, you will only have to remove the left side microfilter housing. Spark plugs, you will have to remove all the engine covers, including the microfilter housings.

Remove cabin microfilters. See our tech article on Cabin microfilter replacing.

With both microfilters removed, you can now remove the microfilter housing.
Figure 1

With both microfilters removed, you can now remove the microfilter housing. First you will have to unhook the clamp for the HVAC intake duct. (green arrow)

Then, push the rubber ducts off the cabin microfilter housing.
Figure 2

Then, push the rubber ducts off the cabin microfilter housing.

Working at the front of the left side housing, unplug the hood switch electrical connector (green arrow) by pressing the release tab and pulling is straight off.
Figure 3

Working at the front of the left side housing, unplug the hood switch electrical connector (green arrow) by pressing the release tab and pulling is straight off.

Next, pull the weather stripping (green arrows) off the cowl and housings.
Figure 4

Next, pull the weather stripping (green arrows) off the cowl and housings. Inspect it, if it is worn or dry rotted, replace it. The yellow arrow points to some damage on the weather strip, this will need to be replaced.

Now the lower housing can be removed.
Figure 5

Now the lower housing can be removed. Squeeze the locking spring (green arrow) while pulling up on housing. With housing removed, you can now access the brake master cylinder (left side) and the E-box (right side). Repeat these steps to remove the right side cover, left side shown in photos.

Models with 6-cylinder engine:
6-cylinder models have two engine covers.
Figure 6

6-cylinder models have two engine covers. You can remove each one independently although for certain repairs you will have to remove both, for example: Ignition coils you remove only the cover on cylinder head. Valve cover gasket, you would remove both covers. Green arrow points to intake manifold engine cover. Yellow arrow points to cylinder head engine cover.

To remove intake manifold side engine cover: using a small flathead screwdriver, pry out trim covers, remove 10mm fasteners (green arrows), then remove trim cover from engine.
Figure 7

To remove intake manifold side engine cover: using a small flathead screwdriver, pry out trim covers, remove 10mm fasteners (green arrows), then remove trim cover from engine.

To remove cylinder head engine cover: Remove engine oil cap.
Figure 8

To remove cylinder head engine cover: Remove engine oil cap. Then, using a small flathead screwdriver, pry out trim covers, remove 10mm nuts (green arrows), then remove trim cover from engine.

With cover removed, inspect mounting insulators, there are two and only used on cylinder head engine cover.
Figure 9

With cover removed, inspect mounting insulators, there are two and only used on cylinder head engine cover. (green arrow) If insulators are worn, replace.

Models with 8-cylinder engine:
Remove center engine cover first, press each cover release button (green arrows) while pulling up on the cover.
Figure 10

Remove center engine cover first, press each cover release button (green arrows) while pulling up on the cover.

Once all buttons release, remove cover from engine.
Figure 11

Once all buttons release, remove cover from engine.

With center engine cover removed, you can now remove the cylinder head trim covers.
Figure 12

With center engine cover removed, you can now remove the cylinder head trim covers. Use a small flathead screwdriver and lever out the trim caps. Then use a 10mm socket to remove the trim cover fasteners. (green arrows). Then remove covers from engine.

Once you have the cylinder head engine covers removed, inspect the sealing profile gasket (green arrow).
Figure 13

Once you have the cylinder head engine covers removed, inspect the sealing profile gasket (green arrow). It can become swollen over time and not seal properly. If there is any doubt in its shape, replace it. When reinstalling, be sure it is properly aligned and installed onto cylinder head.

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Page last updated: Wed 12/7/2016 02:05:46 AM