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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 06-13-2007, 08:39 PM
tgriffin tgriffin is offline
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How in the hell do you replace a 540i water pump?

My water pump fell apart on my 2003 540i. I've taken the thermostat off, along with all the hoses, fan shroud, and such. The water pump is finally off... my wife had to get the bottom screw off because I couldn't get my fingers back there. My question is how do I get the water pump past that steel bar in front? Does the steel bar come out? The water pump is trapped behind it. Any tips would be greatly appreciated!!!
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  #2  
Old 06-13-2007, 09:17 PM
applecran applecran is offline
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you might have to take the crank shaft pulley off... that is the big one on the bottom, there are a bunch of bolts in there, take them all off and it will come off... hold on to it, it has a bit of weight - not heavy, but will fall down)... once that is off you should be able tot get it past that silver bar that is in the way...

That helped me anyway.

Good luck.
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  #3  
Old 06-13-2007, 10:39 PM
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if you lived closer, i would give you a hand. i can replace a pump in 90 minutes, start to finish and that included burping the system.
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  #4  
Old 06-14-2007, 05:43 AM
tgriffin tgriffin is offline
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Thanks for the tip about removing the crankshaft pulley. It's the one thing I have taken off yet. Taking that off should allow access to put this thing back together again.


I'm proud of the other guy who can complete the job in 90 minutes. His comments don't really offer any help though, do they?
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  #5  
Old 06-14-2007, 06:46 AM
KTrostel KTrostel is offline
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Quote:
Originally Posted by tgriffin View Post
I'm proud of the other guy who can complete the job in 90 minutes. His comments don't really offer any help though, do they?
I would take Chivas' comments to indicate the difficulty level of the project - 90 min ie not that difficult.

When I swapped out my w pump Bimmerd00d (I think) suggested that I use a 10mm ratching head box end wrench to extract the bolt hidden behind the crankshaft pulley. This way it is not necessary to remove the pulley. You will not be able to apply the exact torque to this bolt but a light coat of form a gasket and a good guess on the torque has worked quite well for my 540i.
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  #6  
Old 06-14-2007, 06:50 AM
cn90 cn90 is offline
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Some Info for DIY

Last year I wrote the Cooling Overhaul Tips for Inline 6 (1998 528i):
http://www.bimmerboard.com/forums/posts/199986

For V8:
http://bimmerboard.com/forums/posts/361164
As from the picture, there is a trick to remove the WP WITHOUT removing the Crank pulley.

HTH.....
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  #7  
Old 06-14-2007, 07:33 AM
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bimmerd00d bimmerd00d is offline
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Quote:
Originally Posted by KTrostel View Post
I would take Chivas' comments to indicate the difficulty level of the project - 90 min ie not that difficult.

When I swapped out my w pump Bimmerd00d (I think) suggested that I use a 10mm ratching head box end wrench to extract the bolt hidden behind the crankshaft pulley. This way it is not necessary to remove the pulley. You will not be able to apply the exact torque to this bolt but a light coat of form a gasket and a good guess on the torque has worked quite well for my 540i.
Yep, 10mm ratchet box-end wrench makes that one bolt a LOT easier. I would recommend removing the crank pulley now, as my bolts on the pulley backed thmselves out. R&R the crank pulley would allow them to be re-tightened. Definitely remove it, it's 6 10mm bolts.
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  #8  
Old 06-14-2007, 08:31 AM
KTrostel KTrostel is offline
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Quote:
Originally Posted by bimmerd00d View Post
Yep, 10mm ratchet box-end wrench makes that one bolt a LOT easier. I would recommend removing the crank pulley now, as my bolts on the pulley backed thmselves out. R&R the crank pulley would allow them to be re-tightened. Definitely remove it, it's 6 10mm bolts.
Did you use any loctite on the crank pulley bolts? Blue, Red...
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  #9  
Old 06-14-2007, 01:47 PM
gb1k gb1k is offline
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Quote:
Originally Posted by tgriffin View Post
My water pump fell apart on my 2003 540i. I've taken the thermostat off, along with all the hoses, fan shroud, and such. The water pump is finally off... my wife had to get the bottom screw off because I couldn't get my fingers back there. My question is how do I get the water pump past that steel bar in front? Does the steel bar come out? The water pump is trapped behind it. Any tips would be greatly appreciated!!!

10mm bolt deep inside the the front of the head, look where the pipes go inside the head, you will see the securing bolt.
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  #10  
Old 06-14-2007, 06:21 PM
tgriffin tgriffin is offline
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I could pull the water pump after removing the pulley. Thanks for all the suggestions!
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  #11  
Old 08-13-2011, 08:42 AM
mad12.1964 mad12.1964 is offline
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What is the trick to remvoe the WP WITHOUT removing the Crank pulley?
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  #12  
Old 08-13-2011, 09:19 PM
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540indiana 540indiana is offline
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Quote:
Originally Posted by mad12.1964 View Post
What is the trick to remvoe the WP WITHOUT removing the Crank pulley?
There is no trick. You dont need to remove the crank pulley to remove the water pump.
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  #13  
Old 08-14-2011, 02:30 AM
JimLev JimLev is offline
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Quote:
Originally Posted by tgriffin View Post
My water pump fell apart on my 2003 540i. I've taken the thermostat off, along with all the hoses, fan shroud, and such. The water pump is finally off... my wife had to get the bottom screw off because I couldn't get my fingers back there. My question is how do I get the water pump past that steel bar in front? Does the steel bar come out? The water pump is trapped behind it. Any tips would be greatly appreciated!!!
Don't bother taking off the pulley.
Remove the 10mm hex head bolt at each end of the tube, a 2 minute job.
There is a small flange welded to each end of the tube, the bolt holds the flange to the head. Get a mirror and look at it.
The secondary air tube will pull straight out.
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  #14  
Old 08-14-2011, 11:15 AM
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bluebee bluebee is offline
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Quote:
Originally Posted by JimLev View Post
Don't bother taking off the pulley
So that others can find this easier in the future, I added this to the bestlinks:
- How to remove the BMW E39 540i V8 waterpump without removing the crankshaft pulley (1) (2)


As always, if you know of better links, let me know.
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  #15  
Old 08-14-2011, 04:39 PM
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chivas chivas is offline
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Quote:
Originally Posted by JimLev View Post
Don't bother taking off the pulley.
Remove the 10mm hex head bolt at each end of the tube, a 2 minute job.
There is a small flange welded to each end of the tube, the bolt holds the flange to the head. Get a mirror and look at it.
The secondary air tube will pull straight out.
OMG!! Hi Jim!!! Glad to see you here. How are things?
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  #16  
Old 08-15-2011, 05:35 AM
mad12.1964 mad12.1964 is offline
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Thank you for your reply.... One more question.... from the procedure Cerber posted (#1), he cautioned about the two aluminum tubes sandwiched between the WP and back of the engine. I am concern when I pull the water pump out, I will remove the two tubes. Is there a correct way to remove the WP without disturbing the two tubes?
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  #17  
Old 08-15-2011, 05:52 AM
mad12.1964 mad12.1964 is offline
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Link #1 showes the procuedure by CNN-090 for 528i and the second links show a picture of V8 (but no insturctions)..... Did I miss a link or instruction for the 540i in these two posting?
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  #18  
Old 05-26-2012, 11:16 AM
Columbian Columbian is offline
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Air Tube Photo

Quote:
Originally Posted by JimLev View Post
Don't bother taking off the pulley.
Remove the 10mm hex head bolt at each end of the tube, a 2 minute job.
There is a small flange welded to each end of the tube, the bolt holds the flange to the head. Get a mirror and look at it.
The secondary air tube will pull straight out.
Thanks for the tip.
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  #19  
Old 01-01-2013, 06:08 PM
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bin01123 bin01123 is offline
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working on this in a few days and I'm thinking about removing the pulley. That piping has gaskets and if I went that route I would like to replace those while I was there.
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  #20  
Old 01-01-2013, 06:47 PM
nsogiba nsogiba is offline
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i removed the secondary air injection pipe as described above when i did my water pump, and did not replace the o-rings on the pipe. did not leak and no problems.
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  #21  
Old 01-01-2013, 07:03 PM
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Topaz540i Topaz540i is offline
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this link is for a more indepth project but it covers alot of the same dissassembly as the water pump is removed so the pics and bolt location hints should help alot.

http://www.beisansystems.com/procedu..._procedure.htm
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  #22  
Old 01-01-2013, 07:27 PM
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Thanks for the input. I'll work on this tomorrow when I get back from work

Sent from my HTC VLE_U using Bimmer App
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  #23  
Old 01-02-2013, 07:12 PM
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Thanks guys. Removing the injection pipe was the way to go. It came off pretty easy.
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