Oil prop BMW 540i 1998 E39 Owner's Manual

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Radiator and Cooling systeml
Tightening torques
Block drain plug to block 25 Nm
(18
it-lb)
Coolant hose clamp (32 - 48 2.
5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator
2-3Nm(l8-27in-lb)
Thermostat housing to cylinder
head 10 Nm (89 in-lb)
I Coolant thermostat housing assmbly- - I
Thermostat, removing and installing
(M52 TU or M54 engine)
4 The electric map-controlled thermostat is part of the thermo-
stat housing at the front of the cylinder head.
1. Bolts (M6)
2 Bolt (ME)
3. Housing with thermostat
4. Gasket
- If a faulty thermostat is suspected, use appropriate scan tool
to interrogate
ECM for stored fault codes.
- Drain radiator and engine block. See Coolant, draining and
filling (6-cylinder models).
CAUTION-
Allow cooling system to cool before opening or draining the
system.
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Disconnect electrical harness connector from thermostat
housina.
4 Lever out retaining clips (arrows) and pull hose fittings off
thermostat housing.
- Unbolt and remove thermostat housing from front of engine.
Loosen nut at top of engine lifting eye to facilitate removal.
- Installation is reverse of removal, noting the following:
Keep sealing faces free of oil.
* Use new sealing gasket.
When reinstalling hose to thermostat housing, install clip
on hose end fitting, then push hose onto housing until it
clicks into place.
Fill system with coolant. See Coolant, draining and fill-
ing (6-cylinder models).

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Anach pressure brake bleeder to fluid reservoir and pump
bleeder a few times to pressurize hydraulic fluid system.
CAUTION-
* Do not exceed 2 bar (29 psi) pressure at the fluid resenfoil
when bleeding or flushing the hydraulic system.
Brake fluid is poisonous, highly corrosive and danger-
ous to the environment. Wear safety glasses and
rub-
bergloves when working with brake fluid. Do not siphon
brale fluid with your mouth. Immediately clean away
any fluid spilled on painted surfaces and wash with wa-
ter, as brale fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container.
Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the clutch and
brake hydraulic systems, ;nd will also lower the brake
fluid boiling point. Dispose of brale fluid properly.
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor
iack is not adequate support.
- If necessary, remove transmission splash shield.
Hydraulic system, bleeding
Worlting underneath transmission, connect a hose from
clutch slave cylinder bleeder valve
(arrow) to a container.
Open bleeder valve and allow bralte fluid to expel until
clean fluid comes out, free of air bubbles.
Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly operate clutch pedal about
10 times. Fill reservoir
with clean fluid as necessary.
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230-1 8
Manual Transmission
- Unbolt clutch slave cylinder from side of transmission. Do not
disconnect fluid hose. Suspend slave cylinder from chassis
using stiff wire.
CA UTIOG
Unbolt clutch slave cylinder slowly to prevent air being
drawn into hydraulic system.
. Do not operate clutch pedal with slave cylinder re-
moved from transmission.
4 Put BMW special tool 11 7 370 or appropriate sized spacer
between engine oil sump and front axle support. Lower trans-
mission until engine is supported on spacer.
0 V-8 vehicle: Turn front wheels to prevent strain from being
placed on center tie rod.
All vehicles: Tilting the engine to lower the transmission
can lead to damage to various components due to lack
of clearance at rear of engine. Lower transmission
slowly
- Support front of engine with floor jack.
4 Disconnect shift rod from selector shaft coupling
- Disconnect shift console from top of transmission. See 250
Gearshift Linkage.
6-cylinder: Remove transrnisslon mounting Torx-head bolts
(arrows). Note length and locatlon of bolts.
Remove
transrnlssion by pulling backward untll transmls-
sion Input shaft clears clutch d~sc spl~nes, then pull down-
wards. Lower
transmlsslon jack to remove transrnlsslon. -
- - -
-

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Automatic Transmission
4 Remove transmission cooler line clamp mounting nut (ar-
row) from transmission bell housing. Disconnect cooler lines
from transmission.
- Disconnect both transmission cooler fluid lines from trans-
mission.
CAUTION-
Place a pan under transmission fluid lines to catch dripping
fluid.
4 Remove access plug in cover plate below engine oil pan
(V-8 models) or left side of bellhousing (6-cylinder models).
Remove torque converter bolts. Turn
cranltshaft to access
bolts.
V-8 models: Place BMW special tool 23 3 030 between
engine oil pan and front
subframe (arrows).
- 6-cylinder models: Place BMW special tool 11 7 370
between engine oil pan and front subframe.
- Support transmission with transmission jack.
4 Remove transmission crossmember bolts A, B and C and re-
move transmission support crossmember
(V-8 model shown,
6-cylinder models are similar).
- Remove bellhousing-to-engine mounting bolts.
- Use appropriate selection of BMW special tools 24 4 130 to
hold torque converter in place during transmission removal.
CAUTION-
Do not allow the torque converter to fall off the transmission
input shaft
- Remove transmlsslon by pull~ng back and down. Lower jack
to allow transmiss~on to clear vehicle.
rrs corn-hi8 Rniiti Riranrd

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331-17
Final ~rivel
4 Remove staked collar nut and press output shaft out of wheel
hub with special
BMW tool 33 2 11 111 161117.
- Remove drive axle
- Installation is reverse of removal, noting the following:
* Use a new collar nut.
- Apply a light coating of oil to contact face of collar nut and
install it loosely.
Install road wheel and lower car to ground.
* With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening
torques
Drive axle collar nut to drive flange M24
300 Nrn (221 ft-lb)
Drive axle collar nut to drive flange M27
300 Nrn (221 ft-lb)
Drive axle to differential flange
M10x20 rnrn blaclc Torx bolt 83 Nrn (61 it-lb)
- M10x20 rnrn silver Torx bolt loo Nrn (74 ft-lb)
Road wheel to hub
120 Nrn+lO (89tt-lbi-7)
CV joint boots
NOTE-
When replacing a CVjoint boot, use a complete CVjoint
boot repair kit. The lit will include a new boot, clamping
bands, special lubricant, and a new inner CV joint circlip.
The lit is available from an authorized
BMW dealerparts
department.
The outer CVjoint cannot be removed from the axle
shaft
In order to replace the outer CV boot, it is necessary to re-
move the inner joint and boot first.
If the
CVjoints are worn or defective, a complete rebuilt
axle shaft is available from an authorized
BMW dealer
parts department.
- Remove appropriate axle shaft. See Drive axle, removing
and installing (sedan), or Drive axle, removing and in-
stalling (Sport Wagon).
- Working with axle shaft at bench, cut off old boot clamps and
remove boot. Clean old grease off joint and shaft. Use new
grease from CV joint boot kit.
4 Remove dust cover from CV joint and remove circlip (arrow)
retaining joint inner hub to axle shaft.

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340-6
1 Brakes
Brake system troubleshooting
/symptom I Probable cause 1 Repairs
Brake squeal
Pedal goes to floor when
bralting
Low pedal after system bleeding
Pedal spongy or brakes work
only when pedal is pumped
Excessive braking effort
Brakes pulsate, chatter or grab
Uneven
bralting, car pulls to one
side, rear braltes
loclt
Brakes drag, bind or overheat Brake
pad carriers dirty or corroded or
pads loose (poor fit) in pad carrier
Braite pads heat-glazed or oil-soaked
Wheel bearings worn (noise most
pronounced when turning)
Incorrectly Installed brake pads,
parking bralte shoes, or bralte parts
Brake fluid loss due to system leaks
Master cylinder or traction control
system faulty
Master cylinder faulty
Air in braite fluid
Master cylinder or traction control
system faulty
Brake pads wet
Brake pads
heat-glazedorfluid-soalted
Vacuum booster or vacuum hose
connections to booster faulty
--- Warped brake rotors
Brake pads worn
Brake pads heat-glazed or oil-soaked Remove
brake pads and clean calipers. Use original
equipment pads for proper fit and use BMW anti-squeal
compound during installation,
Replace brake pads. Ciean rotors. Replace leaking caliper:
as required.
Replace worn bearings. See 310 Front Suspension
or33C
Rear Suspension.
Check component installation. Checldreplace anti-rattle
springs.
Checlt fluid level and inspect for signs of leakage.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Replace master cylinder.
Bleed system using factory or compatible diagnostic tool.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Use light pedal pressure to dry pads while driving.
Replace
bralte pads and rotors. Replace leaking calipers.
lnspect vacuum lines. Test vacuum booster and replace as
required. Test vacuum non-return valve for one-way flow.
Resurface or replace rotors.
Replace brake pads.
Clean rotors. Replace leaiting calipers.
Incorrect tire pressures or worn tires
Brake pads on one side of car heat-
glazed or fluid-soaked
Caliper or brake pads binding
Worn suspension components
Brake caliper or brake pads binding
Master cylinder or traction control
system faulty lnspect
tire condition. Checlt and correct tire pressures.
Replace brake pads. Clean rotors. Replace leaking
calipers.
Clean and recondition brakes.
Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Ciean or replace caliper.
Replace master cylinder. Diagnose traction control system
using faclory or compatible diagnostic tool.

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Brakes
Warnings and cautions
WARNING-
. E39 cars require special BMWsen/ice equipment toprop-
erly bleed the brake hydraulic system. See Bleeding
Brakes for additional information.
Semi-metallic and metallic brake friction materials in
brake pads or shoes may produce dangerous dust.
Brake fluid is poisonous, corrosive and dangerous to
the environment. Wear safety glasses and rubber
gloves when worliing with
bralie fluid. Do not siphon
brake fluid with your mouth. Dispose of brake fluid
properly
Do not reuse self-locking nuts, bolts or fasteners. They
are designed to be used only once and may fail if re-
used. Always replace them with new self-locliing fas-
teners.
CAUTlOI\C
Immediately clean bralie fluid spilled on painted surfaces
and wash with water, as
bralie fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container.
Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the
braking sys-
tem, and will also lower the fluid boiling point.
. Plug open lines and brake fluid ports to prevent con-
tamination.
Only tighten brake hoses on front wheels
with wheels
in straight ahead position.
If carrying out electric welding
worlc, be sure to discon-
nect electrical harness connector from electronic con-
trol module.
Do not expose electronic control modules to high sus-
tained heat, such as in a paint drying booth. Maximum
heat exposure:-95°C (203
OF) for short periods of time-
85'C (185°F) for Ions periods of time (approx. 2 hours)

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WARNING
Your common sense, good
judgement, and general alertness are
crucial lo sale and
successlul service
work. Belore attempling any work on
your BMW, be sure to read 001
General Warnings and Cautions
and lhe copyright page
a1 llle Iron1 01
the manual. Review lliese warnings
and cautions each time you prepare
lo work on your
BMW Please also
read any warnings and
caulions lhal
accompany the procedures In !he
manual.
Component locations
see Electrical system
Compression test
113-5
Compressor see
AlC
Condenser see
AlC
Constant velocity (CV) joint
see Maintenance
see also
Driveshall
see also Drive axles
Consumer cutoff
600-10
Control arm see Front suspension
see also Rear suspension,
suspension arms
Coolant (antifreeze) see Maintenance
see also Cooling system
Coolant pump
see Cooling system Cooling system
coolant bleeding
170-14 6-cylinder engine, draininglfilling
170-10
V-8 engine, draininglfilling 170-12
coolant pump 170-3
6-cyiinder engine, replacing 170-1 9
V-8 engine, replacing 170-20 cooling fan 170-4
viscous ciutch fan, removingi
installing 170-14
electric fan, removlngiinstailing 170-1 5
expansion tank, removinglinstalling
170-22
electrically heated (ciiaracterislic
map) therrnostat 170-4
radiator, removinglinstaliing 170-22
service
see Maintenance
therrnostat 170-16
transmission fluid heat exchanger
170-5 troubleshooting 170-7
combuslion leal( test 170-10
pressure test
170-9
Crankshaft oil seals
iront
117-6
rear 11 9-6
Crankshaft speed sensor
see Ignition syslem
Crash sensor
see
Airbag system (SRS), side-impact
airbag crasii sensor
Cruise control clutch switch 612-9
CV joint
see Maintenance
see also Driveshalt
see also Drive axles
CV joint boot
see Maintenance
see also Drive axles
Cylinder head removinglinslaliing
M52 engine 113-8
M52 TU / M54 engine 113-22
M62 engine 113-56
Cylinder head and valvetrain
hydraulic lifters, checking and
replacing
116-7 leak test 116-5 valves 11 6-56
see
alsocylinder head Dashboard
513-7
Deck
lid
seeTrunk lid
Diagnostic monitors
OED-4
Diagnostic trouble codes
(DTCs)
080-7
Digital multimetel
010-17
Differential see Final drive
DLC (data
link connector) 020-4, OED-4
DME (digital motor electronics)
see
130 under appropriate fuel
injection system
see also ignition system
DM-TL (detection module-tank leak)
see
Fuel lank, leak deteclion unit
Drive
belts
see Maintenance
Dome light
seeLighls, interior lights
Door
door
check, replacing 411-4
hinge adjustment 41 1-5
loci(
see Door lock see also Central locking
removinglinslaliing 41
1-2
panel, removinglinstaliing 41 1-7 window
see Door window
Door
check
see Door
Door
handle
see Door lock
Door glass
see Door window
Door
lock
handles and loci(s 515-16
see also Central locking
Door
molding
510-13
Door panel see Door

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4 INDEX
Door window anti-trap
512-4 convenience openinglclosing 512.4
regulator and motor 512-1 1
service
512-5 switches 512-3
see also Switches
Double
VANOS see VANOS
Drive
axle
CV joint 331-15 CV joint boot 331-15
rernovinglinstalling 331-14
Drive belt
see Maintenance
Driveabiiity troubleshooting
100-4
Driveaway protection
see EWS (eiectronic immobilization)
Driveshaft aligning
260-7
center bearing, replacing 260-12 CV joint, replacing 260-14
itex-disc, replacing 260-1 1
iront centering guide, replacing 260-13
rernovinglinstailing 260-6
lroubleshooting 260-3
U-joint 260-3
DSC
see Braires
DTC (diagnostic trouble code)
OBD-8
DWA
see Anti-theft alarm
ECM (engine control module)
see 130 under appropriate
iuei
injection system
ECT (engine coolant temperature)
sensor see 130 under appropriate
iuei
injection system
EDK adaptation
130-69
MS 43.0 130-35
EHC see Electronic iieigiit control (EHC)
Electric cooling fan
see Cooling system, cooling
fan
see also Cooiing system, eiectric fan
Electrical switches
see Switches
Electrical system abbreviations
600-14 bus System 600-4
component location table 610-3
components
photos
610-36
Sport Wagon 610-81 engine 121-2
troubleshooting 600-15
voltage and polarily 600-5 wire color codes 600-12
wiring diagrams 600-12
Electrical wiring diagrams
ELE-1
Eiectricaliy heated thermostat
(characteristic map)
170-4
Eiectronic height control (EHC)
300-8, 330-44
Eiectronic immobilization
see EWS (electronic immobilization)
Eiectronics box
(E-box)
610-37
Emergencies
010-18
Emergency brake see
BraBes, parking brake Engine
see also Cylinder head and valvetrain
applications
100-2
compression, testing 113-5
cooling see Cooiing system
crankshaft front oil seai
see Crankshaft oil seals
cyiinder leak-down test 113-8
diagnostic testing 113-1
drive belts
see Maintenance
driveability troubleshooting
100-4
engine management systems 100-2
see also Ignition
see also Fuel injection
fuel supply
130-6
ground connections 100-5
see also 61 0 identilying ieatures 100-3
lubrication svstem
see
~ubricetion system
mount
on-board diagnostics
OBD-I
oxygensensor
see Fuel injection
see also Exhaust system
Dreventive maintenance
see Maintenance
removal/installation
Engine control module (ECM)
see 130 under appropriate iuel
injection system
Engine cooiant temperature (ECT)
sensor see 130 under appropriate iuel
injection
system
Engine cooling fan
see Cooiing system, electric fan
Engine hood
41
0-6 raising to service position 410-6
Engine troubleshooting
see Engine, driveability troubleshooting
EVa~oratiVe control svstem
160-3 see also 130 under aDDroDriate iuel
injection system
Evaporator see
NC
Evaporator temperature sensor see
NC

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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan