Automatic BMW 540i 1997 E39 Owner's Manual

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/Fuel injection
Table b. Siemens MS 41.1 ECM pin assignments (continued)
85
86
87
88 CAN-Bus low
CAN-Bus high
Power supply
Diagnostic connector
(TxD)
inputloutput
inpuWoutput
input
input output Automatic transmission control module (AGS)
Automatic transmission control module (AGS)
Battery voltage from main relay terminal 87
Diagnostic TxD signal to pin 17 in data link connector

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130-76
Fuel Injection
Bosch
ME 7.2 ECM pin assignments
Bosch ME 7.2 ECM connectors
X60001
X60002
X60003
X60004
X60005
Table e. Bosch ME 7.2 ECM pin assignments
Connector
X60001
I I I
8 1 lnput [Terminal 87 voltage supply I Fuse F1
9-pin, Black
24-pin, Black
52-pin, Black
40-pin, Black
9-pin,
Blaclc
I I I
9 I NO^ used I
Notes
Ground connector
X6460
Ground connector X6460
Pin 1
2 3
4
5
Connector X60002
Ground connector X6460 6
Pin
/Type I Descriptionlfunction 1 Notes
Type
Ground
Ground
7 llnput l~errninai 30 voltage supply I Fuse F4
Descriptionlfunction
Not used
Not used
Not used
Ground Ground
Ground Ground
1
2
3
4
5
6
7
8
9
10
11
12
13
. . - Ground Input
Input/
output
input/
Output
Ground
Ground
Ground
Ground
Ground
Ground Heated oxygen sensor, heater ground
Back-up
light signal
CAN-BUS Low
CAN-Bus High
Not used Not used
Heated oxygen sensor, heater ground
Heated oxygen sensor ground
Heated oxygen sensor ground
Heated oxygen sensor ground
Heated oxygen sensor ground
Not used
Heated oxvaen sensor, heater
ground
Heated oxygen sensor II behind catalylic converter
Baclcup light switch
Automatic transmission control module (AGS)
Automatic transmission control module (AGS)
Heated oxygen sensor
I behind catalytic converter
Heated oxygen sensor
II behind catalytic converter
Heated oxygen sensor I in front of catalytic converter
Heated oxygen sensor
II in front of catalytic converter
Heated oxygen sensor
I behind catalytic converter
Heated oxygen sensor
Ii in front of catalytic converter

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-
I Radiator and Cooling System
Mechanical thermostat
(M52 engine)
4 The mechanical thermostat relies on coolant temperature to
operate. While coolant is cold, it remains closed, and circu-
lating coolant bypasses the radiator for rapid engine warm
up. At higher coolant temperature, the thermostat progres-
sively opens to allow coolant flow through the radiator, thus
controlling engine temperature. Port
A restricts coolant flow
from radiator, and port
B restricts coolant flow to radiator.
Electrically heated thermostat
4 The electrically heated thermostat is DME map-controlled.
The engine control module (ECM) activates the thermostat to
maintain engine coolant temperature within a narrow range.
In case of failure of the electronics, the mechanical function of
the thermostat acts as a fail-safe.
Radiator and expansion tank
The radiator is a crossflow design. An expansion tank pro-
vides for coolant expansion at higher temperatures and easy
monitoring of the coolant level.
On cars with automatic transmission, ATF is circulated
through an additional heat exchanger (ATF cooler).
Mechanical cooling fan with viscous clutch
The mechanical cooling fan is belt-driven via a viscous fluid
coupling (clutch) attached to the front of the coolant pump.
The fan clutch controls the speed of the fan based on the tem-
perature of the air flowing through the radiator core.
Electric (auxiliary) cooling fan
The electric cooling fan is mounted on the bumper side of the
radiator.
In models manufactured up to
911 998 (M52 or 1997 M62 en-
gine), the electric cooling fan is controlled by a dual tempera-
ture fan switch mounted in the side of the radiator.

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170-5
Radiator and Cooling System
Fan switch calibration (M52, M62 engine)
coniprairoi OUt rlgnal
Auto. ciimilte ~ontioi inpuls via CAN bus
Electric fan activation:
Low speed
91°C (196°F)
High speed 104' C (21 9' F)
< In models manufactured after 911998 (M52 TU engine, M54
engine.
M62 TU engine), the electric cooling fan is controlled
by the engine control module (ECM) via the output final
stage.
The output final stage is mounted on the fan housing, next to
the fan motor. The fan is operated using a pulse width modu-
lated signal. Fan circuit wiring is protected by a 50-amp fuse.
Electric fan activation is based on the following inputs to the
ECM:
Radiator outlet temperature
Calculated catalytic converter temperature
Vehicle speed
* Battery voltage
Calculated
A/C pressure
When the vehicle is first started, the ECM activates the elec-
tric fan briefly at 20% of its maximum speed, then switches
off. This is for diagnostic monitoring. The voltage generated
by the fan when it slows down (acting as a generator) must
match the stored rpm values in the fan output stage toconfirm
that the fan is operating correctly.
NOTE-
If the ECM fault memory indicates a cooling fan fault, check
that the fan is not seized and that it spins freely.
When
A/C is switched ON, the electric fan is not immedi-
ately turned on.
After the engine is switched
OFF the fan may continue to
run at varying speeds for up to 10 minutes, based on cal-
culated catalyst temperature.
Transmission fluid heat exchanger
Automatic transmission fluid lines circulate transmission fluid
(ATF) to and from a heat exchanger at the radiator.
All 6-cylinder
models andV-8 models produced to 911998 are
equipped with a transmission cooler located in a cooling cas-
sette in front of the radiator.

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200 Transmission-Genera!
General ........................... .20 0.2 Automatic Transmission
Drivetrain .......................... .20 0.2 Transmission Lubricants
Manual Transmission
.............. .20 0.2

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This repair group covers general application information for
the clutch, manual and automatic transmissions, shift linkag-
es and driveshaft.
Drivetrain
I ZF manual transmission I
BMW E39 models are equipped with a longitudinal drivetrain.
The transmission is bolted directly to the rear of the engine.
A
driveshaft connects the output shaft of the transmission to the
rear final drive. Individual drive axles with integrated constant
velocity joints transfer rotational power from the final drive
unit to the rear wheels.
4 Due to different power characteristics and performance re-
quirements, various manual transmissions are used in mod-
els covered by this manual. Manual transmission
applications are given in the table below.
For manual transmission specifications or repair procedures,
refer to
230 Manual Transmission.
Manual transmission models use a single disc clutch with
dual-mass flywheel. For further information, see
210 Clutch.
The manual transmission metal ID plate is mounted on side of
transmission. Do not rely on numbers cast on transmission
case for identification.
Manual transmission applications
Model Year Engine Transmission
5251 2001 - 2002 M52TU, M54 Getrag S5D 250G
528i 1997-2002 M52 ZF S5D 3202

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Different automatic transmissions are used, depending on
model and model year
and/orproduction date. All of the auto-
matic transmissions are electrohydraulically controlled with
five forward speeds. Automatic transmission applications are
given in the table below.
Automatic transmission applications Model Year Engine Transmission
526 from 911 999 M52 TU ASS 360R
5251 from 312001 M54 ASS 3252
5301 to 312001 M54 ASS 390R
530i from 312001 M54 ASS 3252
540i
from 111 997 M62 TU ASS 4402
Automatic transmission identification metal ID plate is mount-
ed to body of transmission.
4 GM transmission ID tag (arrow) is on left side of transmission
housing, behind transmission selector cable, just above
transmission pan.
< ZF transmission ID tag (arrow) is on left rear of transmission,
just above transmission pan.

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The lubricant used varies, depending on transmission and
model year. Fluid application information is clearly marked on
a label on transmission.
On manual transmission, either ATF (orange label reads
ATF-Oil) or a special BMW lubricant (yellow label reads MTF-
LT
I) is used. See 230 Manual Transmission.
Automatic transmission is filled with either Dexron
Ill ATF
(black transmission ID plate reads ATF-Oil), or special life-
time oil (green transmission ID plate reads Life-Time Oil). See
240 Automatic Transmission.
CAUTION--
If in doubt as to the type of fluid installed in a particular trans-
mission, consult an authorized
BMW dealer service depari-
ment for the latest in operating fluids.

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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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240 Automatic Transmission
General . . . . . . . . . . . . . . . . . . . . . .
Special tools . . . . . . . . . . . . . . . . . . .
Automatic transmission applications
. . . . . ,240-2 ATF, draining and filling . . . . . . . . . . . . . . . . 240-7
. . . . . ,240-2 Automatic transmission fluid
. . . . . ,240-4 pan and strainer. . . . . . . . . . . . . . . . . . . . . . 240-9
Troubleshooting . . . . . . . . . . . . . . . . . . .240-4 Transmission Removal
and Installation
. . . . . . . . . . . . . . . . . . . 240-10 Automatic Transmission Fluid Transmission, removing and installing . . . 240-10 (ATF) Service . . . . . . . . . . . . . . . . . . . . . ,240-6
Automatic transmission fluid (ATF) . . . . . . . ,240-6
ATF level, checking . . . . . . . . . . . . . . . . . . ,240-6