coolant temperature BMW 540i 2000 E39 Workshop Manual

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I General Warnings and Cautions
WARNINGS (continued)
. The air conditioning system is filled with chemical refrigerant,
which is hazardous. The AIC system should be serviced only by
trained technicians using approved refrigerant recoverylrecycling
equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
. Do not expose any part of the AIC system to high temperatures
such as open flame. Excessive heat will increase system pres-
sure and may cause the system to burst.
Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away
from the tire repair area. Inflate and deflate the
tire at least four
times before breaking the bead from the rim.
Completely remove the tire from the rim before attempting any re-
pair.
Cars covered by this manual are equipped with a supplemental
restraint system (SRS), that automatically deploys
airbags and
pyrotechnic seat belt tensioners
In the event oi a frontal or side
impact. These are explosive devices. Handled improperly or with-
out adequate safeguards, they can be accidently activated and
cause serious injury.
- The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals and use extreme care when
working on a car with the engine running or the ignition switched
on.
. Place jack stands only at locations specified by the manufacturer.
The vehicle
illtino iack su~olied with the vehicle is intended fortire -. , . changes only. A heavy duty floor jack should be used lo lift vehicle
before installing
jacl( stands. See 010 General.
- Battery acid (electrolyte) can cause severe burns. Flush contact
area
with water, seek medical attention.
Aerosol cleaners and solvents may contain hazardous or deadly
vapors and are highly flammable. Use only in a well ventilated ar-
ea. Do not use on hot surfaces (engines, brakes, etc.).
Do not remove
coolant reservoir or radiator cap with the engine
hot. Danger of burns and engine damage.
CAUTIONS-
See also WARNINGS
- if you lack the slqills, tools and equipment, or a suitable worl(shop
for any procedure described in this manual, leave such repairs to
an authorized BMW dealer or other qualified shop.
BMW is constantly improving its cars and sometimes these
changes, both in parts and specifications, are made applicable to
earlier models. Therefore, part numbers listed in this manual are
for reference only. Always check with your authorized BMW deal-
er parts department for the latest information.
Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read ail the instructions thorough-
ly, and do not attempt shortcuts. Use tools appropriate to the
work and use only replacement parts meeting BMW specifica-
tions.
Use pneumatic and electric tools only to loosen threaded parts
and fasteners. Never use these tools to tighten fasteners, espe-
cially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque specification listed.
Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the
oil. Do not
pour
oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of waste in accordance with Federal, State and
Local laws.
The control module for the anti-lock brake system
(ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp
in excess of 203" F (95°C) and should not be subjected to tem-
peratures in excess of 185°F
(8S°C) for more than two hours.
- Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative
(-) terminal (ground strap) and
the ABS control module connector.
- Always make sure ignition is off before disconnecting battery.
Label battery cables before disconnecting. On some models, bat-
tery cables are not color coded.
Disconnecting the battery may erase fault code@) stored in control
module memory. Using special BMW diagnoslic equipment, check
lor
iauit codes prior to disconnecting the battery cables. If the mal-
I.mct on ndicator Ignt (MIL) s I. ..minaled. see OBD On-Board
Diaanostics
Tl11s iant is iuenlfted as lne Check Ena~ne oht
(1997-2000 models jor~ervlce Engine Soon light (2061 andlater
models). If any other system iaults have been detected (indicated
by an illuminated warning light), see an authorized BMW dealer.
If a normal
or rapid charger is used to charge battery, the battery
must be disconnected and removed from the vehicle in order to
avoid damaging the vehicle.
- Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the
battery a second time.
* Connect and disconnect a battery charger only with the battery
charger switched off.
- Sealed or "maintenance free" batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the bat-
tery's ampere-hour (Ah)
rating.
. Do not allow battery charging voltage to exceed 16.5 volts. If the
battery begins producing gas or boiling violently, reduce the
charging rate.
Boosting a sulfated battery at a high charging rate
can cause an explosion.

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--- -
Maintenance
Table c. Inspection II Service
Additional
New parts Warm engine Dealer service repair
Tools required required required recommended information
Engine compartment maintenance
Replace air filter element. (Note: reduce
replacement intervals in dusty operating
conditions).
Replace brake
fluid every 2 years (time
interval begins from vehicle production
date).
Cooling system service
Spark plug service
Brake
system maintenance
:j:
*
Replace coolant every 3 years (time
interval begins from vehicle production
date).
Replace oxygen sensor every 160,000
itm
(1 00,000 miles).
020
FLUID AND LUBRICANT
SPECIFICATIONS
:I:
Oxygen sensor service
*
x:
Spark plugs:
M52
1 M62 engine:
Replace every 60,000 itm (48.000 miles).
M52
TU I M54 1 M62 TU engine:
Replace every 160,000
ltm (100.000
miles).
< Engine oil viscosity (SAE grade) vs. operating temperature
range for the BMW engines covered in this manual.
Fluid and lubricant capacities and specifications are listed be-
low. See
Fluids and lubricants.
:I:
*
*
*
WARNING -
The use of fluids that do not meet BMW" specifications may
impair performance and
reliabilitl: and may void warranty
coverage.
340
170
180
* 020

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020-1 1
Maintenance
Table g. Differential oil
(Lifetime fluid; no fluid change required)
Differential
/Approximate. capaclty (in~t~al fill) I Spec~f~cat~on , , .
G 1.6 liter
(1.7 US
at) I
188 Compact I .O liter BMW SAF-XO
(1 .I US ql) synthetic oil
1.4
liler 220 1215 Compact US qt) I
Table h. Engine Coolant
Year, model
latent heater:
V-8 13.5 liter
1997:
6-cylinder
V-8
Table
i. Brake fluid
Bralte system fiuld BMW hlgh
performance, DOT 4
Approximate
capacity
9.9 liter (10.5 US qt)
11.4 liter (12.0 US qt)
With the introduction of synthetic oil and extended oil change
intervals, a new oil filterwith improved filter paper design was
introduced. The new filter paper resists deterioration caused
by high oil temperatures over an extended time.
Specification
Use BMW specified oil to top off the engine oil level between
oil changes.
BMW recommends the following engine oils:
Table
j. Engine Oil Specification
Years
IOii description I BMW part no.
1999 and later mineral
oil
BMW
HP 5W-30
svnthetic oil 07
51 0 017 866

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11 0-20
Engine Removal and Installation
Working at right side of transmission bellhousing, disconnect
electrical harness connections (arrows) from starter. Re-
move starter retaining bolts and remove starter from trans-
mission mount.
M62 TU engine: Disconnect electrical harness connector
for right oxygen sensor from retaining clip and remove re-
taining clip from transmission.
- Working underneath engine compartment at left side:
Unclip positive battery cable from oil pan.
. Remove alternator cooling duct.
4 M62 engine: Remove fastener A and plug connector B from
alternator.
- M62 TU engine: Remove electrical harness connectors from
front of water cooled alternator.
- Remove exhaust system and transmission. See 180 Ex-
haust System and 230 Manual Transmission or 240 Auto-
matic Transmission.
- Working at front of engine:
Remove upper and lower hoses from radiator.
D~sconnect expansion tank hose from coolant pump.
- Remove belt-driven cooling fan:
Counterhold fan with special tool
11 5 050.
Turn fan mounting nut (32 mm) clockwise (left hand
threads) to loosen.
Rotate fan clockwise to remove.
Remove cooling fan shroud:
Disconnect electrical connectors from coolant level sensor
(B) and coolant temperature sensor (C).
. Remove expansion rivets (A) from each side of shroud
Remove coolant hose
(D).
Slide fan shroud with expansion tank up. Remove radiator
overflow tube from spout of expansion tank. Remove radi-
ator fan shroud with expansion tank.
Remove radiator. See
170 Radiator and Cooling System.

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..
Cylinder Head Removal and Installation 1
< Remove intake throttle valve and ASC throttle assemblies:
Disconnect ASC throttle cable
(A).
- Remove ASC throttle housing mounting fasteners (B).
NOTE-
It is not necessary to disconnect coolant hoses (C) 01
bowden cables (D).
Remove intake throttle housing mounting hardware, pull
throttle housing off
intake manifold, and set aside.
- Working under intake manifold, disconnect the following:
Engine oil dipstick tube support.
Oil separator return line from dipstick tube.
Intake air temperature sensor electrical harness connector
(underside of intake manifold near throttle body).
* Fuel tank vent line and electrical harness at canister vent
valve.
Remove lower intake manifold supports (arrows).
- Disconnect coolant line retaining bracket at cylinder block.
4 Remove manifold mounting hardware (arrows).
- Remove intake manifold from cylinder head while carefully
checking for electrical connections or hoses.
NOTE-
Fuel rail is removed with intake manifold,
CAUTIOI\C
Stuff clean rags into open intake ports to prevent any parts
from falling into
Nie engine intake.
- Drain cooling system (engine block and radiator), then re-
move radiator cooling fan and fan shroud. See
170 Radiator
and Cooling System.
- Disconnect coolant hoses from thermostat housing.

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- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Install intake camshaft cover and cylinder
head cover.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in 020 Mainte-
nance.
If necessary, adjust accelerator cable.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl

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Cylinder Head Removal and Installation
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Tightening torque Exhaust
maniiold to cylinder head (M7)
20 Nm (15 ft-lb)
- Install electrical harness connectors for oil pressure sender
and coolant temperature sensor before installing
intalte man-
ifold.
7 Install intake manifold:
1. Manifold mounting nuts: tighten to 15 Nm (1 1 ft-lb)
2. Fuel pipe bracltet
3. Fuel pipe bracltet
4. Vacuum pump bracltet
5. Manifold mounting bracltet
6.
Tank venting valve bracltet
7. Mounting bracket to manifold bolt (M6)
8. Mounting bracket to cylinder block nut (MIO), tighten to
47 Nm (33 fi-lb)
Intake manifold installation is reverse of removal, noting the
following:
* Use new fuel injector seals.
Carefully
check intake manifold gasket and replace if nec-
essary.
Inspect O-ring seal between mass air flow sensor and air
filter housing. To facilitate reassembly, coat seal with
acid-
free grease.
Use new fuel injector seals.
Carefully check intake manifold gasket and replace if
necessary.
CA UTIOPI-
When reattaching throttle assembly harness connector, con-
nector is fully tightened when arrows on connector
andplug
line up.
Tightening torque
lntalte manifold to cylinder
head (M7)
15 Nm (1 1 it-lb) ~ ~- Mounting bracket to cylinder bloclt (M10) 47 Nm (33 ft-lb)
Mounting bracket to intake manifold (MI?) 10 Nm (89 in-lb)

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1 17-34
1 Camshaft Timing Chain
DOUBLE VAMOS SYSTEM
(M52 TU AND M54 ENGINES)
Double VANOS system function
The M52TU and M54 6-cylinder engines are equipped with a
Double VANOS system that varies intake and exhaust cam-
shaft timing.
The main components of the Double VANOS system are:
lntalte and exhaust camshafts with helical spline inserts.
Camshaft sprockets with adjustable gears.
VANOS actuators (two position piston housing with
inter-
nallexternal helical spline cup).
Three-way solenoid switching valves.
Camshaft position impulse wheels.
Hall effect camshaft position sensors.
Camshaft position
IS varied based on engine rpm, throttle po-
sition signal, intake air and coolant temperature.

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Lnition switch
4 The positive (+) power supply to the ignition coils comes to
the ignition switch via an unloader relay. When the ignition
switch is turned on, the relay closes, to provide voltage to the
ignition coils. The coils are then actuated at the negative side
by the engine control module.
NOTE-
Schematic diagrams shown are for illustrative purposes only.
See ELE Electrical Wiring Diagrams for engine manage-
ment specific wiring information.
WARNING- Do not touch or disconnect any cables from the coils while
the engine is running or being cranked by the starter:
The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when
working on a car with the ignition
switched on or the engine running.
* Connect and disconnect the DME system wiring and
test equipment leads only when the ignition is
OFF
Before operating the starter without starting the engine
(for example when
making a compression test), always
disable the ignition.
4 Knock sensors (arrows) monitor the combustion chamber for
engine-damaging knock. Six-cylinder models (shown) use
two sensors with each sensor monitoring three cylinders.
V-
8 models use four sensors, each monitoring two cylinders. If
engine
knock is detected, the ignition point is retarded by the
ECM.
I Ignition advance Ignition timing is electronically mapped and not adjustable.
The ECM uses engine load, engine speed, coolant tempera-
ture, knock detection, and intake air temperature as the basic
inputs for timing control.
A three dimensional map similar to
the one shown is digitally stored in the ECM.
- The initial ignition point is determined by the crankshaft
speed sensor during cranking. Once the engine is running.
timing is continually adjusted based on operating conditions.

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130-1
130 Fuel injection
General ........................... .I3 0.2
Tools and test equipment .............. .I3 0.3
Warnings and cautions ................ .I3 0.5
Fuel Supply ....................... .I3 0.6
Relieving system fuel pressure .......... .I3 0.6
Siemens MS 41 . 1. ................... 1 30-7
ECM relay. testing .................... .I3 0.7
Mass air flow (MAF) sensor.
checking and replacing
................ .I3 0.9
Engine coolant temperature (ECT) sensor.
testing and replacing
.................. 130-10
Intake air temperature (IAT) sensor.
testing and replacing
................. .I3 0.1 1
Throttle position sensor (TPS).
testing and replacing
.................. 130-1 2
ldle speed control valve.
checking and replacing
............... .I3 0.1 3
Fuel injectors. checking and replacing .... 130-15
Evaporative emissions. overview ....... .I3 0.1 6
Secondary air injection. overview ....... .I3 0-17
Engine control module (ECM).
removing and installing
................ 130-18
Siemens MS 41.1 ECM pin assignments . .I3 0.19
Siemens MS 42.0 and MS 43.0. ..... .I3 0.23
ECM relay. testing ................... .I3 0.27
Mass air flow (MAF) sensor.
checking and replacing
............... .I3 0.28
Engine coolant temperature (ECT) sensor.
testing and replacing
................. .I3 0.30
Intake air temperature (IAT) sensor.
testing and replacing
................. .I3 0.31
MS 42.0 throttle valve assembly. replacing . 130-32
MS 43.0 throttle valve assembly. replacing . 130-35
Throttle cable. adjusting (MS 42.0) ...... .I3 0.38
ldle speed control valve. checking
and replacing
....................... .I3 0.38
Evaporative emissions control diagrams . . 130- 39
Evaporative emissions control.
(MS
42.0 and MS 43.0). .............. .I3 0.39
Engine control module (ECM).
removing and installing
................ 130-40
Siemens MS 42.0 and MS 43.0
ECM pin assignments ................. 130-41
Bosch M5.2 (M62 up to 911997)
BOSC~ M5.2.1 (M62 911997 to 911998) 130-46
M5.2 system features ................. 130-47
M5.2.1 system features ............... 130-47
ECM relay. testing ................... 130-49
Oxygen sensors. checking ............. 130-51
Fuel injectors. checking and replacing .... 130-52
Mass air flow (MAF) sensor. replacing .... 130-53
ldle speed control valve. testing
and replacing
....................... 130-54
Throttle position sensor (TPS).
testing and replacing
................. 130-55
Engine coolant temperature (ECT) sensor.
testing and replacing
................. 130-55
Intake air temperature (IAT) sensor.
testing and replacing
................. 130-57
Auxiliary throttle valve (ADS) (M62 and
M62 TU engine). replacing ..... 130-57
Evaporative system pressure
leak diagnosis. overview
(5.2.1 only) ..... 130-58
Bosch 5.2 ECM pin assignments
(M62 UP to 911 997) ................... 130-59
~osch 5.2.1 ECM pin assignments
(M62 911 997 to 911 998) ............... 130-62
BOSC~ ME 7.2 ..................... 1 30-66
ME 7.2 system overview ............... 130-67
EDK adaptation ..................... 130-69
ECM relay. checking .................. 130-69
Engine coolant temperature
(ECT) sensor. testing
................. 130-71
Engine coolant temperature
(ECT) sensor. replacing
............... 130-71
Oxygen sensors. replacing ............. 130-72
Fuel injectors. removing and installing .... 130-72
Mass air flow (MAF) sensor.
removing and installing
................ 130-73
Evaporative system pressure
leak diagnosis. overview
............... 130-74
Secondary air injection. overview ........ 130-75
Bosch ME 7.2 ECM pin assignments .... 130-76