Gear release BMW 540i 1997 E39 Workshop Manual

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020-26
Maintenance
NOTE-
The parking brake may lose some of its effectiveness if it is
not used frequently This is due to corrosion build-up on the
parking brake drum. To remove corrosion, apply the parking
brake just until it begins to grip, then pull the lever up one
more stop (click). Drive the car approximately 400 meters
(1,300
ft.) and release the brake. To recheck the adjustment
of the parking brake see
340 Brakes.
Clutch fluid, checking
In cars equipped with manual transmission and clutch, the hy-
draulic clutch and the brake system share the same reservoir
and the same bralte fluid. Clutch fluid level and brake fluid lev-
el are checked at the same time.
NOTE-
* See 340 Brakes for more information.
See
210 Clutch for information on the clutch and the
hydraulic clutch operating system.
Differential oil level, checking
The E39 differential is filled with lifetime oil that ordinarily
does not need to be changed.
BMW recommends using only
a specially formulated synthetic gear oil
(SAF-XO) that is
available through an authorized
BM\N dealer parts depart-
ment. For additional information on this lubricant and any
other lubricants that may be compatible, contact an
authorized
BMW dealer service department.
< Check rear differential oil level at filler plug (arrow).
- Check lubricant level with car on a level surface:
Level is correct when fluid just reaches edge of filler hole.
If necessary, top up fluid.
Replace filler plug sealing ring.
Install and tighten oil filler plug when oil level is correct.
NOTE-
Use either a 14 mm or 17 mm Allen socket to remove the
drain plug.
If the car is raised in the air, it should be level when
checking or filling final drive fluid level.
Tightening torque
Filler plug to final drive housing 70 Nrn (52 it-lb)

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I Fuel Injection
Release injector locking clips at each injector and pry injector
wiring duct up off injectors.
Clamp off fuel supply line and fuel return line at end of fuel
rail. Disconnect fuel supply fuel return lines from fuel rail.
WARNING -
Clamp off the fuel lines and then wrap a clean shop towel
around the lines before removing them. Residual
fuelpres-
sure is present in the lines.
Fuel is discharged. Do not disconnect any wires that
could cause electrical
sparks. Do not smoke or work
near heaters or other fire hazards. Keep an approved
I fire extinguisher handy. I
- Remove fuel rail mounting fasteners
- Pull up on fuel rail and remove individual injectors by remov-
ing injector retaining clip and pulling injector from rail.
- Installation is reverse of removal. Fit new O-rings when in-
stalling injectors. For ease of installation, lightly lubricate in-
jector O-ring with
SAE9O gear lube.
Tightening torque Fuel rail to
intake manifold 10 Nm (89 in-lb)
Evaporative emissions, overview
On E39 MS 41 .I cars, the evaporative emissions system is
combined with the tank ventilation system. The evaporative
system is monitored by the ECM for correct purge operation
and leak detection.
The carbon (purge) canister is purged using engine vacuum
via the
purgevalve.The purgevalve (located nextto the mass
airflow sensor) is ECM controlled and regulates the purge
flow into the intake manifold. The valve is powered open and
closed by an internal spring.
If the evaporative emission valve circuit is faulty, a fault code
is set and the MIL is illuminated when OBD
II fault criteria are
exceeded. If the valve is mechanically faulty, poor driveability
may result and a mixture adaptation fault is stored in the
ECM.
The leak diagnosis pump (LDP) is activated by the ECM and
pressurizes the fuel tank and evaporative system as apart of
theOED I1 leakdetection monitor. If the LDP orthe LDP circuit
is defective, afault code is set and the MIL is illuminated when
OBD
I1 fault criteria are exceeded. The LDP is mounted the
left rear wheel well behind the fender liner.

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- Removing left side exhaust manifolds (cylinder bank 5-8):
- Remove heat baffle plate on left side.
Remove oxygen sensor using
BMW special tool 11 7 030
or similar oxygen sensor socket.
Install
BMW special tools 00 0 200,OO 0 201,OO 0 202,OO 0
204, and 00 0 208 or other suitable engine lifting support
above engine and attach to lifting eye on left head.
NOTE-
The supports on special tool 00 0 208 must rest on the
screws on the fenders.
- Remove nut at top of engine support on left side
- Raise engine at front suspension lug a maximum of 25 mm
(I
.O in).
Release clamping bolt and nut
(arrow) and slide universal
joint off steering gear.
4 Remove nuts securing left exhaust manifold to head,
Raise front of manifold as high as possible past end posi-
tion of steering gear and feed out towards bottom.
- Installation is reverse of removal.
Coat exhaust mounting studs with CRC or equivalent
copper paste.
Use new exhaust gaskets and self-locking nuts.
Install new self-locking nuts on engine mount and steering
shaft bolt.

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Tool for bleeding clutch hydraulics (Tool No. 21 5 030)
21 5 030 I
The clutch is hydraulically actuated by the master and slave
cylinders. With the self-adjusting clutch
(SAC), clutch disc
wear is automatically taken up through the self-adjusting
pressure plate springs, making pedal feel consistent through-
out the life of the clutch.
A soft or spongy feel to the clutch pedal, long pedal free-play,
or grinding noises
from the gears while shifting can all indi-
cate problems with the clutch hydraulics. In these circum-
stances it is best to
star? with a clutch fluid flush, followed, if
necessary, by replacement of the hydraulic parts.
NOTE-
The clutch hydraulic system shares the fluid reservoir and flu-
id with the brake hydraulic system.
Clutch hydraulic system,
bleeding and flushing
If the clutchlbralte fluid is murky or muddy, or has not been
changed within the last two years, flush the system and
change the fluid. Flushing the old fluid from the clutch lines is
done using a bralte system pressure bleeder.
- Remove brake fluid reservoir cap. Using a clean syringe, re-
move brake fluid from reservoir. Refill reservoir with clean
DOT
4 bralte fluid.
Worlting inside engine compartment, remove left
interiorven-
tilation filter housing:
Release 3 plastic taps
(A) on duct. Earlier models use a
single release latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Remove filter housing cover.
Release spring lock
(B) on interior ventilation housing and
remove housing.

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Manual Transmission Selector shaft seal, replacing
(transmission installed)
- Put transmission into second gear.
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floorjack is not adequate support
- 6-speed transmission: Remove rear engine splash shield
- Remove exhaust system and heat shields. See 180 Exhaust
System.
- Support transmission with transmission jack.
- Disconnect driveshaft at transmission and tie to side. See
260 Driveshaft.
4 Remove transmission crossmember:
Where applicable, release electrical harnesses from
transmission crossmember.
. Remove transmission mounting bolts (A).
Remove transmission crossmember bolts (B).
Where applicable, remove bolts
(C).
NOTE-
5-speed transmission shown in illustration. 6-speed trans-
mission is similar.
- Tilt down rear of transmission.
CAUTION-
Jilting the engine to lower the transmission can lead to
damaae to various components due to lack of clearance.
-
4 Pry sprlng locking rlng (A) out of groove and press pin
of
sh~fl rod.
Detach
sh~ft rod from selector shafl and tie as~de.
(B) out

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250-4
I Gearshift Linkage
Release gearshift lever mounting ring from below using BMW
special spanner 25 1 110. Turn tool 90' ('I, turn)
counterclockwise.
Push shift lever up to remove from shift console,
Raise transmission and temporarily install transmission
crossmember.
Lower vehicle. Working from inside passenger compart-
ment, pull up on shift lever to remove it together with inner
rubber boot and shift lever mounting ring.
Gearshift lever, installing
(manual transmission)
- Clean old grease from shift lever ball and mounting ring.
Also clean shift console bowl. Lubricate with molybdenum
disulfide grease.
- Insert shift lever together with inner boot and mounting ring
into center console.
4 Align shift lever mounting ring locking tabs with slots
(arrows) in shift console bowl. Press down until ring
snaps into place.
NOTE-
lnstall mounting ring witli arrow pointing toward front of car.
4 Pull inner rubber boot over shift console bowl (arrows) to
seal base of shift lever.
NOTE-
lnstall rubber boot witli arrow pointing toward front of car.
- Raise car and support transmission. Remove transmission
crossmember and lower transmission to access base of shift
lever.
CAUTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.

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pearshift Linkage
~UTOMATIC TRANSMISSION
GEARSHIFT
Automatic transmission gearshift mechanism
automatic
5-speed Steptronic (5251,530i)
1. Shift lock solenoid
2. Shifter assembly
3. Shift cable
4. Support bracket
5. Selector lever
Gearshift mechanism, adjusting
(automatic transmission)
- Position gearshift lever in Park.
- Raise vehicle to gain access to shift linkage.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive
lift orjack stands designed for
the purpose.
4 Counterhold bushino A and loosen cable clam~ino nut 6.
Push cable end backward away from engine (arrow 2).
Release pressure on cable.
Tighten clamping nut.
/ CAUTION--
Tightening torque
Shift cable clamping nut
10 Nm (7.5 it-lb)

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-.- .
/ Driveshaft Driveshaft, removing
CAUTION-
. Be sure the wheels are off the ground before removing the
driveshak Set the parl(ing brake before removing the
driveshaft.
Once the driveshaft has been removed, the vehicle can
roll regardless of whether the transmission is in gear or
not.
The driveshaft is mounted to the transmission and final
drive
with self-locliing nuts. These nuts are designed to
be used only once and should be replaced during reas-
sembly.
Remove complete exhaust system. See
180 Exhaust
System.
- Remove exhaust heat shields.
- Support transmission with transmission jack.
< Loosen transmission mount nuts (arrows) on real
transmission support crossmember.
- Release wiring harness retainers from rear transmission
support crossmember.
< Remove mounting bolts (arrows) for rear transmission sup-
port crossmember. Slide crossmember rearward to remove.
- Matchmark front and rear driveshaft halves to corresponding
transmission output and final drive input flanges.
4 Remove nuts securing driveshaft mounting bolts at transmis-
sion output flange. Counterhold bolts (arrows) at transmis-
sion flex-disc. Discard old nuts.
- Hang driveshaft front section from body using stiff wire.

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Gaskets and seals 01
0-9
Gearshift automatic transmission
adjusting
250-7
shift interiock. checkino function " 250-9
shiftloclc. checicino function 250-8 - manual transmission
gearshift lever, removingiinstalling
250-5
steptronic 250-7
General module (GM Ill)
600-8
see also Central locking
Generator see Battery, starter, alternator
Glass see Door window
Glove compartment
513-16
see also
Global positioning system
(GPS)
620-9
Grill
see Exterior trim
Grounds
100-5
Guide link
see Rear suspension, suspension
arms
Halogen headlight
630-5
Hand brake
see Brakes, pariring brake
Handle, door
see Door
locks
Hatch seeTailgate
Hazard warning switch
see Switches Headlight
housing trim
see Exterior trim
washer611-17 see also Lights
Headlight spray
nozzle
611-17
Headlight switch
see Switches
Heater core
see Heating
Heater valve
see Heating
Heating lieater core, replacing
640-18
lheater core temperature sensor,
removingiinstalling
640-12 heater valve, replacing 640-17
IHKA housing, removinglinstallin~
640-21
see also NC
Hood
410-6
Hood latch and release
410-10
Hydraulic valve lifters
see Cylinder head and valvetrain
IAT
(lntalce air temperature) sensor
see 130
under appropriate fuel
injection system
idle speed control valve
see 130
under appropriate fuel injection system
Idle stabilizer
see 130
under appropriate fuel
injection system, idie speed controi
valve
idler arm
320-30
lgnition coll
see lgnition system
lgnition interlock
320-13
lgnition lock cylinder
removingiinstalling
320-1 1. 612-4
lgnition switch
seeSwifches
Ignition system
diagnosis checking for
spark 120-10
disabling ignition system 120-10 misfire detection 120-6
oscilioscope diagrams 120.6
troubleshooting 120-6
camshaft position sensors 120-14 coils 120.10
crankshaft speed sensor 120-12 firing order 120-9
knoclc sensors 120-16
IHKA
see NC
IHKR see NC
Injector
see 130 under appropriate
fuel
injection system, luel injector
Input shaft
oil seal
see Manual transmission, oil seals
Inspection
see Maintenance
Instruments GPS see Global positioning system
(GPSI layout 6202
removingiinstalling 620-8 self-testing 620-6
Intake air temperature sensor (IAT)
see 130 under appropriate fuel
injection system
Intake manifold
removingiinstalling
6-cvlinder enoine 110-10. 113-8. 113-22 -
V-8 engine (M62) 113-56
Integral link
see Rear suspension, suspension
arms
lnterior lights
see Lights
lnterior protection
(FISIUIS) 515-25
lnterior trim
513-13
lnterior ventilation microfilter see
NC, ventilation microfiller

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Steering description 300-10
liuid see Maintenance
gearbox
320-25
idler arm 320-30
lock 320-12
pitman arm 320-28 power steering pump 320-17
rack & pinion 320-19
steering column 320-10 motors 320-16
removinglinstalling 320-14
trim 320-10
steerino wheei 320-7 tie rods-
6-cvlinder, reelacinq 320-22
V- center tie' rod, replacing 320-32
variations 310-5
Steering box
see Steering, gearbox
Steering column switches
see Switches
Steering column
see Steering
Steering lock
see Steering
Steering
wheei switches
see Switches
Stepper motor
see
AIC
Steptronic transmission
see Gearshift
Strut see Front suspension
see also Rear suspension
Subframe see Rear suspension
Sunroof initializing
540-2
adiustinq 540-5 . . cornponents, removingiinstailing
540-9
emergency closing 540-4
Suspension, front
see Front suspension
see also
Aluminum suspension
cornponents
Suspension, rear
see Rear suspension
see also Aluminum suspension
cornponents
Swing arm
see Rear suspension, suspension
arms
Switches
ASCIDSC 612-12 back-ue
manual transmission 230-8
automatic transmission, see
Automatic transmission, range
switch
center console switches
612-11
central ioci(ing 612-1 1
hazard 612-1 I headlight 612-9
ignition cylinder 320-1 1. 612-6
outside mirror 612-11
pedal cluster switches 612-8 seat heater 612.12
steering column positioning 612-7
steering column switches 612-6 steering wheel switches 612-2
turn signaliheadlight dimmer 612-6
window 612-1 1
wipers 612-6
Tailgate
412-6 emergency release 400-4,412-6,
515-21
taiigatelrear window
loclring 515-14 see also Trunldtaiioate ioclr - see also Central ioclcing
Taillights
see Lights
Tape player
650-3
TCM (transmission control module)
see Automatic transmission
Tension strut
see Front suspension
Thermostat see Cooling system
see also Electrically heated
thermostat
Throttie body
see 130 under appropriate
fuel injection system
Throttie
cable
130-38
Throttie position sensor
see 130 under appropriate luel
injection system
Throw-out bearing
see Clutch, mechanical
Thrust arm
see Front suspension
Tie rod
see Steering
Tightening fasteners
010-8
Tilt sensor 515-24
Timing chain
see
Camshaft timing chain
Tire, changing
010-18
Tires
300-1 1
see also Maintenance
Toe
320-34
Tools
010-13