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These cars are noted for getting corrosion in the plugs to the VANOS sensors, but after unplugging it twice, the connection should be fresh and clean. Is the wire intact (not pinched when the valve cover or water pump were being replaced)?
Does your car have the original VANOS O-rings? At 16 years of age and 140k miles, it is due if they have not been replaced.
One of my e36s had a lot of varnish build up in the VANOS that kept it from moving freely. That varnish was extremely difficult to remove. Nothing would dissolve it. It had to be polished off.
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