warning BMW 528i 1997 E39 Owner's Manual

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020-24
Maintenance
tions. In general, replacement batteries should always be
rated equal or higher than the original battery.
The battery is held in place by a single hand screw and plate.
A secure battery hold-down is important in order to prevent
vibrations and road shoclt from damaging the battery.
CAUTION-
Prior to disconnecting the baitem read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
NOTE-
Always disconnect the negative (-) cable first, and connect
it last. While changing the battery, clean away any corro-
sion in or around the battery tray
More battery and charging system information is in 121
Battery, Alternator, Starter.
Brake fluid, replacing
Brake fluid absorbs moisture easily, and moisture in the fluid
affects bralte performance and reliability. This is why
BMW
strictly recommends replacing the bralte fluid every two
years. When replacing or adding bralte fluid, use only new
fluid from previously unopened containers. Do not use brake
fluid that has been bled from the system, even
if it is brand
new. Use only DOT
4 brake fluid.
NOTE-
See 340 Brakes for brake fluid flushing procedures.
Brake pad 1 rotor wear, checking
Disc brakes are fitted at all four wheels. Although the brakes
are equipped with a brake pad warning system, the system
only monitors one wheel per axle. Pad thickness should be
checked whenever wheels are off or brake
worlt is being
done.
4 Disc brake pad wear can be checked through opening in
caliper:
Measure distance
(A) of brake pad "eai' to bralte rotor.
See
340 Brakes. Compare to specification below.

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7 Maintenance
< Unbolt caliper from steering arm to properly inspect:
Brake pad thickness
(A)
Brake rotor
Condition of caliper seal
(B)
Condition of caliper slider bolts (C)
NOTE-
Brake caliper removal and installation procedures are given
in
340 Brakes.
Brake pad lining minimum thickness
Dimension
A 3.0 mm (0.12 in)
Brake system, inspecting
Routine maintenance of the brake system includes maintain-
ing the brake fluid in the reservoir,
checking bralte pads for
wear, checking parking brake function, and inspecting the
system for fluid lealts or other damage:
- Check that bralte hoses are correctly routed to avoid chafing
or
Itinking.
- lnspect unions and brake calipers for signs of fluid leaks.
- lnspect rigid lines for corrosion, dents, or other damage.
- Inspect flexible hoses for cracking
- Replace faulty hoses or lines as described in 340 Brakes.
WARNING-
Incorrect installation or overtightening hoses, lines, and
unions may cause chafing
orlealage. This can lead to partial
Parking brake, checking
The parking brake system is independent of the main braking
system and may require periodic adjustment depending on
use. Adjust the parking brake if the brake lever can be pulled
up more than
8 clicks. Check that the cable moves freely. A
description of the parking brake and
parlting bralte adjust-
ment can be found in
340 Brakes.

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.-. -
Maintenance
Drive axle joint
(CV joint) boots, inspecting
CVjoint protective boots must be closely inspected forcracks
and any other damage that will allow contaminants to get into
the joint.
If the rubber boots fail, the water and dirt that enter
the joint will quickly damage it.
NOTE-
Replacement of the CVjoint boots and inspection of the
joints are described
in 331 Final Drive.
Exhaust system, inspecting
Exhaust system life varies widely according to driving habits
and environmental conditions. If short-distance driving pre-
dominates, the moisture and condensation in the system will
not fully dry out. This will lead to early corrosion damage and
more frequent replacement.
Scheduled maintenance of the exhaust system is limited to
inspection:
* Check to see that all the hangers (arrow) are in place and
properly supporting the system and that the system does
not strike the body.
Check for restrictions due to dents or
kinlts,
Check for weakness or perforation due to rust.
NOTE-
Alignment of the system and the location of the hangers are
described in
180 Exhaust System.
Fuel filter, replacing
The fuel filter is located beneath the center of the car, approx-
imately under the driver's seat.
A protective cover must be
removed to access the filter.
4 Fuel filter for M62 engine (arrow)
- Disconnect battery negative (-) cable
CAUTIOI\C
Disconnecting the battery cables may erase fault codes
stored
in engine control module memory.
WARNING -
Fuel will be expelled forcibly when the filter is removed. Do
notsmoke or work near heaters orother fire hazards. Keep a
fire extinguisher handy

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020-28
1 Maintenance
- When replacing fuel filter:
Use appropriate hose clamping device to clamp off filter
inlet and outlet hoses to lessen fuel spillage.
Loosen center clamping bracket and hose clamps on
either end of filter.
Note arrow or markings indicating direction of flow on
new filter.
Install new filter using new hose clamps
- Drain fuel filter from inlet side into a container and inspect
drained fuel.
Checlc for rust, moisture and contamination.
I - I < If fuel filter is equipped with fuel pressure regulator:
I 2 / Remove vacuum hose (1)
Pull out locking clip (2).
- Remove fuel pressure regulator (3).
Install pressure regulator in new filter.
Clean thoroughly around the filler connections before
removing them.
After assembly, check filter connections carefully for
I
I lealcs before installing cover.
NOTE- ~-
Additional informarion about the fuel filler assembly is in 160
Fuel Tank and Fuel Pump.
Fuel tank and fuel lines, inspecting
lnspectthe fuel tank, fuel lines, and fuel system fordamage or
lealts. Checlc for fuel lealts in the engine compartment or fuel
odors in the passenger compartment. Check for any evapora-
tive emissions hoses that may have become disconnected,
checking carefully at charcoal canister and evaporative emis-
sions purge system. See
130 Fuel Injection and 160 Fuel
Tankand Fuel Pump for component locations and additional
information.
WARNING-
When checlcing for fuel leal(s, the engine must be cold. A hot
exhaust manifold or exhaust system could cause the fuel to
ignite or explode causing serious personal injury Ventilate
the work area and clean up spilled fuel immediately.

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Maintenance
Suspension, front, inspecting
Inspection of the front suspension and steering includes a
check of all moving parts
forwear and excessive play. Inspect
ball joint and tie-rod rubber seals and boots for cracks
ortears
that could allow the entry of dirt, water, and other
contaminants. See
310 Front Suspension.
Suspension, rear, inspecting
Differential and rear drive axle service consists of checking
and changing the gear oil, inspecting for leaks, and checking
the drive axle
CV joint boots for damage.
The areas where
lealts are most likely to occurare around the
drive shaft and drive axle mounting flanges. For more infor-
mation on identifying oil leaks and theircauses, see
330 Rear
Suspension and
331 Final Drive.
Tires, checking inflation pressure
Correct tire pressures are important to handling and stability,
fuel economy, and tire wear. Tire pressures change with tem-
perature. Pressures should be
checked oRen during season-
al temperature changes. Correct inflation pressures can be
found on the driver's door pillar and in the owner's manual.
Note that tire pressures should be higher when the car is
more heavily loaded.
WARNING-
Do not inflate any tire to a pressure higher than the tire's max-
imum inflation pressure listedon the sidewall. Use care when
adding air to warm tires. Warm tire pressures can increase as
much as
4 psi (0.3 bar) over their coldpressures.
Tires, rotating
BMW does not recommend tire rotation. Due to the car's sus-
pension design, the front tires begin to wear first at the outer
shoulder and the reartires begin to wearfirst at the middle of
the tread or inner shoulder. Rotating the tires may adversely
affect road handling and tire grip.
Transmission service, automatic
The automatic transmissions installed in E39 models are
filled with special automatic transmission fluid. The transmis-
sion lubricant type can be found on the "type-plate" on the
side of the transmission. The recommended lubricants are
listed earlier in this repair group. See Fluids and lubricants.
If in doubt, consult an authorized BMW dealer for alternate

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020-32
Maintenance
using a soft cloth. Regular use of a good quality leather condi-
tioner will reduce drying and cracking of the leather.
Polishing
Use paint polish only if the finish assumes a dull loolc afler
long service. Polish can be used to remove tar spots and tar-
nish, but
afleiwards a coat of waxshould be applied to protect
the clean finish. Do not use abrasive polish or cleaners on
aluminum trim or accessories.
Seat belts
Dirt and other abrasive particles will damage seat belt web-
bing. If it is necessary to clean seat belts, use a mild soap so-
lution. Bleach and other strong cleaning agents may weaken
the belt webbing and should be avoided.
WARNING-
Do not clean the seat belt webbing using dry cleaning or oth-
er chemicals. Allow wet belts to
dry before allowing them to
retract.
-
The condition of the belt webbing and the function of the re-
tractor mechanisms should be inspected. See
720 Seat Belts
for seat belt inspection information.
Speciai cieaning
Tarspots can be removed with a bug and tar remover. Never
use gasoline,
lterosene, nail polish remover, or other unsuit-
able solvents. Insect spots also respond to tar remover.
A bit
of baking soda dissolved in the wash water will facilitate their
removal. This method can also be used to remove tree sap
spots.
Washing chassis
Periodic washing of the underside of the car, especially in
winter, will help prevent accumulation of road salt and rust.
The best time to wash the underside is just afler the car has
been driven in wet conditions. Spray the chassis with a pow-
erful jet of water. Commercial or self-service carwashes may
not be bestforthis, as they may recycle the salt-contaminated
water.
Waxing
For a long-lasting, protective, and glossy finish, apply a hard
wax after the car has been washed and dried. Use carnauba
or synthetic based products. Waxing is not needed after
every washing. You can tell when waxing is required by
look-

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100-4
I Engine-General
The M62 90" V8 engine uses four valves per cylinder, double
overhead camshafts and light alloy cylinder head and cylin-
der
bloclc engine construction.
On 1997 and 1998 540i models, Bosch engine management
systems are utilized. Table a lists engine management sys-
tem applications.
4 For the 1999 model year, the M62 TU VANOS engine was in-
troduced to the 540i models. This engine is primarily a carry-
over from the earlier M62 engine, but contains many unique
identifying components and technology:
Variable camshaft timing (VANOS) for the intake valves.
Bosch ME 7.2 engine management system with electronic
throttle control. There is no accelerator cable connecting
the throttle pedal to the throttle housing in these cars.
Compact water-cooled generator (alternator).
E39 vehicles are equipped with sophisticated self-diagnostic
engine management systems. These systems monitor and
store diagnostic fault information. If the malfunction indicator
lamp (MIL) illuminates, the first diagnostic test should be to
connect a dedicated scan tool for BMW automobiles and in-
terrogate the fault memory.
If the malfunction indicator light (MIL) comes on orflashes, it
indicates that an emissions-related fault has occurred and
that fault information is stored in memory within the ECM.
4 The MIL in E39 cars displays one of these warning graphics
in the instrument cluster.
The diagnostic capabilities of these systems have the poten-
tial to save hours of diagnostic time and prevent incorrect
5 placement. See OBD On-Board Diagnostics.

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110-3
Engine Removal and lnstallationl
Q Fuel line plugs
(Tool No.
BMW 13 5 281 / 13 5 282)
4 Fuel line removal tool
(Tool No.
BMW 16 1 050)
CAUTION-
Disconnecting the battery may erase fault code@) storedin
memoiy Check for fault codes prior to disconnecting the
battery cables.
If the MIL (Malfunction Indicator Light, also may be
called "Check Engine" or "Service Engine Soon" light)
is illuminated, see
OBD On-Board Diagnostics for
DME fault code information.
It orhersysrem faults have been detected, as indicated I
by an ~llum~nated ABS, SRS orASC/DSC ~arning light,
see the appropriate repair group in this manual or an
authorized BMW dealer for more information on fault
codes.
NOTE- Engine removal procedures are similar for all 6-cylinder
models. When differences
exist, they are noted at the be-
ginning of each step. Engine are referred to by engine
code. See
100 Engine-General for engine code and appli-
cation information.
@ Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse
gaskets, O-rings or seals during reassembly.
The
intake manifold must be removed on &cylinder mod-
els before the engine can be removed.
WARNING-
Due to risk of personal injury, be sure the engine is cold be-
fore beginning the removal procedure.

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11 0-4
/Engine Removal and Installation
- Disconnect negative (-) cable from battery.
CAUTION- Prior to disconnecting the
batteg read the battery discon-
nection cautions
in 001 General Cautions and Warnings.
- Remove engine hood, or place in service position. See 410
Fenders, Engine Hood.
4 Remove left and right interior ventilation ducts (lefl side
shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic loclting tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclocltwise to
unloclt from bulkhead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring
loclt (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel:
Remove rubber sealing gasket (arrow).
- Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift off panel.
Remove complete air filter housing:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intalte duct
(6) and (where applicable) disconnect idle speed control
valve electrical harness connector.
Disconnect harness connector (C) from mass air flow sen-
sor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

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. .- -
I Engine Removal and Installation I
4 Where applicable, remove schraedervalve cap (arrow) from
air connection on fuel rail. Using a tire chuck, blow fuel back
through feed line using a brief burst of compressed air
(rnax-
imum of 3 bar or 43.5 psi).
WARNING -
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) andmay be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap
a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Alwavs unscrew the Fuel tank cao to release
oressure
I in the tank before working on the tank or lines. I
- Raise car and support in a safe manner.
WARNING-
Male sure the car is stable and we/ supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor jack is not adequate support
- Working underneath car, remove protective engine splash
guard.
4 Disconnect fuel lines by sliding locking collar in (arrows) and
pulling line apart.