120 BMW 540i 1997 E39 Service Manual

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120-1 6
Ignition System
Remove camshaft sensor (arrow) from front of right cylinder
head.
Disconnect camshaft sensor harness from cable duct above
right cylinder head.
Installation is reverse of removal, noting the following:
Use new O-ring when installing sensor.
Be sure wiring is rerouted in same orientation.
Use scan tool to read out and clear ECM fault memory.
Tightening torque Intake camshaft sensor to timing chain 5 Nm
(3.5 ft-lb)
cover
Knock sensors
Knock sensors, replacing (M52, M52 TU and M54
engines)
The knock sensors are bolted to the left side of the cylinder
block under the intake manifold.
- Remove intalte manifold as described in 113 Cylinder Head
Removal and Installation.
D~sconnect knock sensor electrical harness connector (A) on
left side of engine cylinder block.
Remove knock sensor
mount~ng bolts (arrows) on side of
cyllnder block. Remove sensors.
Note the installed angle of the
lnocl~ sensor on the bloc/( be-
fore removing it. Reinstall the sensor
in the same position. Be
sure to use a torque wrench when tightening the sensor
mounting bolt.
< Clean lknock sensor contact surface on engine bloclc and
sensor (arrows) before installing
ltnock sensor.
Tightening torque
Knock sensor to head 20 Nm (15 ft-lb)
- Use scan tool to read out and clear ECM fault memory.
Knock sensors, replacing
(M62 and M62 TU engines)
The
knock sensors are bolted to the side of the cylinder block
under the
intake manifold.

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.
Battery, Starter, Alternator
Table b. Specific gravity of battery electrolyte at 27°C (80°F)
Specific gravity State of charge
1.265 Fully charged
1.225 75% charged
1.190 50% charged
1.155 25% charged
1.120 Fully discharged
if the specific gravity is at
orabove 1.225, butthe battery lacks
Dower for
startinq, determine the battew's service condition
with a load volta& test. if the average specific gravity of the
six cells is below 1.225, remove the battery from the luggage
compartment and recharge.
Battery open-circuit voltage test
Before testing, load battery with 15 amperes for one minute
with battery load-tester or turn on headlights for about one
minute without engine running. Connect digital voltmeter
across battery terminals. Open-circuit voltage levels are giv-
en in Table
c. Open-circuit voltage and battery charge.
If open-circuit voltage is
OK but battery still lacks power for
starting, perform a load voltage test.
If open-circuit voltage is
below 12.4 volts, recharge battery
and retest.
Table c. Open-circuit voltage and battery charge
Open-circuit voltage State of charge
12.6 V or more
12.4 V
12.2v
12.0 v
Fully charged
75% charged
50% charged
25% charged
11.7Vorless Fully discharged
Battery load voltage test
A battery load tester is required for a load voltage test. The
test is made by applying a high resistive load to the battery
terminals and then measuring battery voltage. The battery
should be
fully charged forthe most accurate results. The bat-
tery cables must be disconnected before
malting the test. Re-
place the battery if the voltage is below that listed in Table d.
Battery load test
- minimum voltage.

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121-10
I Battery, Starter, Alternator
- Strip approximately 15 rnm (0.6 in) of insulation from cable
end.
terminal harness
Shrink insulation
Terminal connector
4 Push terminal connector of new cable over stripped end of
old cable. Tighten clamp.
- Slip shrink-fit insulation over positive cable. Attach new safe-
ty harness to end of positive cable. Shrink insulation with hot
air blower.
- Reinstall cable in cable bracket and attach to battery.
- Reattach negative battery cable. Reinstall luggage cornpart-
rnent trim pieces.
- Use BMW scan tool DlSplus or equivalent to read out airbag
control module fault memory. Correct faults, then clear mem-
ory.
1 1 4 Various versions of alternators have been used in E39
vehicles. See Table e.
Table e. Alternator application chart
Model Alternator type
Air cooled, 90 amp or 120 amp
Air cooled, with multi-function control
(MFR), 120 amp or 140 amp
Air cooled with multi-function control
(MFR), 120 amp or 140 amp
540i 1997 Air
cooled. 120
amp or 140amp sazrz~orsl 1998 ~~~ ~ .~ . ...~ ~ ~-~~~~ Air cooled; with integrated mu~ii-
function control (MFR). 120 amp 140
amp 1999-2002 Water
cooled, with integrated multi-
function control (MFR), 90-150 amp
(variable output)

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130-2
/Fuel Injection
This repair group covers service and repair of the Bosch and
Siemens engine management systems used on
1997
through 2002 E39 models. Additional engine management
service and repair information may also be found in the fol-
lowing repair groups:
0 020 Maintenance
120 Ignition System
160 Fuel Tank and Fuel Pump
610 Electrical Component Locations
OBD On Board Diagnostics
NOTE-
Camshaft position sensor, crankshaft speed sensor and
knoclc sensors are covered in 120 Ignition System.
Table a. Engine management system applications
- - ~ ~
1 ~odellmodel year / Engine IDME system I - I
5281, 1997-1 998 IM52. 2.8 liter ISiemens MS 41 .I I 1
528i. 1999ZO00 1~52 TU, 2.8 liter ]siemens MS 42.0 I I
5251, 2001-2002 1~54, 2.5 liter 1 Siemens MS 43.0 I I
530i, 2001-2002 1~54, 3.0 liter ISiemens MS 43.0
5401 1999-2001 1~62 TU, 4.4 liter l~osch ME 7.2
I
OBI) II software and hardware is incorporated in the engine
management control systems. The
OED II system monitors
components that influence exhaust and evaporative emis-
sions. If a problem is detected, the
OED I1 system stores the
associated fault code and condition.
540i. 1997
4 If vehicle emission levels exceed 1.5 times Federally mandat-
ed criteria, the
OED II system illuminates a malfunction indi-
cator light
(MIL) in the instrument cluster.
For the
E39 cars covered by this manual, three different
MIL symbols were used, depending on year and model.
See illustration.
When faults arise, or if the malfunction indicator lamp (MIL) is
illuminated, begin troubleshooting by connecting BMW ser-
vice tester
DISplus, MoDiC, GTl or equivalent scan tool. The
capabilities of OBD
II software has the potential to save hours
540i. 1998 IM62, 4.4 liter /Bosch M5.2.1
M62, 4.4 liter Bosch M5.2

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Fuel Tank and Fuel Pump
Warnings and cautions
Observe the following warnings and cautions when servicing
the fuel system.
WARNING-
* The fuel system is designed to retain pressure even when
the ignition is off. When working with the fuelsystem, loos-
en the fuel lines slowly to allow residual
fuel pressure to
dissipate. Avoid spraying fuel. Use shop rags to capture
leaking fuel.
Before beginning any work on the fuel system, place a
fire extinguisher in the vicinity of the work area.
Fuel is highly flammable. When working around fuel, do
not disconnect any wires that could cause electrical
sparks. Do not smoke or worknearheaters or other fire
hazards.
* Always unscrew the fuel tank cap to release pressure
in the
tanlc before working on the tank or lines.
When disconnecting a fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
Do not use a work light with an incandescent bulb near
any fuel. Fuel may spray on the hot bulb causing a fire.
0 Make sure the worlc area is properly ventilated.
CAUTION-
- Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions an4
Warnings.
Before
making any electrical tests with the ignition
turned on, disable the ignition system as described in
120 Ignition System. Be sure the battery is discon-
nected when replacing components.
To prevent damage to the ignition system or other DME
components, including the engine control module
(ECM), always connect and disconnect wires and test
equipment with the ignition off.
Cleanliness is essential when
worl~ing with the fuel sys-
tem. Thoroughly clean the fuel line unions before dis-
connecting any of the lines.
Use only clean tools. Keep removed parts clean and
sealed or covered with a clean, lint-free cloth, especial-
ly if completion of the repair is delayed.
Do not move the car while the fuel system is open.
Avoid using high pressure compressed air to blow out
lines and components. High pressure can rupture inter-
nal seals and gaskets.
Always replace seals, O-rings and hose clamps.

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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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Checlc flywheel location dowel
and correct installation. sleeve (arrow) for
damage
4 When installing dual-mass flywheel, position dowel sleeve
next to two locating notches
(arrows).
- Install flywheel using new self-locking bolts,
Tightening torque Flywheel to cranltshaft
(use new self-locking bolts)
120 Nm (89 ft-lb)
Use new self-lock~ng bolls lo rnslall llylvheel Do not reuse llle
old slrelch-lype bolls Do nor rnsrall bolls wrlh Loct~lo@ or srm-
I ilar thread licking compound. 1
Flywheel, removing and installing
(V-8 engine)
- Inspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. Replace flywheel if any faults are found.
4 Loclcflywheel with BMW special tool 11 2 070. Remove pres-
sure plate and clutch disc as described earlier.
- Use BMW special tool 11 4 180 (Ton. T60) to loosen and re-
move flywheel mounting bolts. Remove flywheel.
- Clean flywheel bolt threads in crankshaft

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230-1 1
Manual ~ransmissionl
Coat new seal with transmission fluid. Use seal installation
drift (see table below) to drive seal into position until it is flush
with housing.
Output seal drives
Transmission
BMW special tool
Getrag S5D 250G 240110
ZF S5D 3202 23 2 300
inspect sealing surface on output flange. Replace if flange
surface is worn or damaged.
Heat output flange to about 176"
F (80" C) to aid in installa-
tion. This can be done by placing flange in hot water. Rein-
stall output flange to output shaft.
- Coat flange nut with LoctiteB243 and reinstall. Torque in two
stages.
Tightening torques Output flange to output shaft
Stage I 190 Nm (140 ft-lb)
Stage II (after loosening) 120
Nm (89 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Check transmission fluid level, topping up as necessary
Tightening torques Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
. MI0 (Torx bolt) 70
Nm (51 ft-lb)
. M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
- MI0 (8.8 grade) 48
Nm (35 ft-lb)
- MI0 (10.9 grade) 60
Nm (44 It-lb)
. MI2 (8.8 grade) 81 Nm (60 ft-lb)
. MI2 (10.9 grade) I00 Nm (74 It-lb)
M14 140 Nm (103 It-lb)
Transmission crossmember
- to transmission (ME) 21 Nm (15 It-lb)
- to chassis (M10) 42 Nm (30 It-lb)

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230-14
I Manual Transmission
If installing new output flange: Recalculate thickness of
shims based on difference in height between output shaft
surface and collar nut support surface. Shims must be within
the output flange preload specification below the collar nut
support surface.
Output flange preload Difference between heights of shaft and output 0.05
- 0.22 mm
flange sealing
suriace MINUS thickness of shims (0.002 - 0.009 in)
NOTE-
Shims are available in increasing sizes of 0.1 mm from
1.4 mm to 2.1 mm (0.055 in to 0.083 in) from BMWparts.
- Install shims. Install and torque flange collar nut.
Tightening torques Output flange to out put shaft
. Stage I 190 Nm (140 ft-lb)
. Stage II (after loosening) 120 Nm (89 it-lb)
- Use BMW special tool 23 2 470 to install flange nut retaining
plate.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Checlc transmission fluid level, topping up as necessary.
Tightening torques
Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
MI0 (Tom bolt)
70 Nm (51 ft-lb)
M8 (compression nut) 32 Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
* MI0 (8.8 grade) 48 Nm (35 ft-lb)
- MI0 (10.9 grade) 60 Nm (44 ft-lb)
. MI2 (8.8 grade)
81 Nm (60 ft-lb)
MI2 (10.9 grade) 100 Nm (74 ft-lb)
- MI4 140 Nm (1 03 ft-lb)
Transmission
crossmembe~
to transmission (ME)
to chassis (M10)
21 Nm (15 ft-lb)
42 Nm (30 it-lb)

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Automatic Transmission
Automatic transmission applications
Automatic transmissions are identified by code letters found
on a data plate located on the side or rear of the transmission
case. See table below for application information.
Automatic transmission applications
Model Year Engine Transmission
5281 to 911999 M52 A4S 310R
5281 from 911999
M52 TU A5S 360R
5251 to 312001 M54 A5S 390R
5251 from 312001 M54 ASS 3252
530i to 312001 M54
ASS 390R
530i from 312001 M54
A5S 3252
540i from 111997 M62
TU A5S 4402
Automatic transmission basic components
The automatic transmission fitted to BMW 5 Series models is
comprised of
3 main elements:
0 Torque converter capable of torque multiplication at an
infinitely variable ratio
Electrohydraulically controlled valve body
0 Gearbox containing 5 forward speeds and reverse