Front seat BMW 540i 1997 E39 Service Manual

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I Seat Belts
a
Front seat belt assembly
1. Seat belt buckle
2. Seat belt stop button
3. Seat belt
4. Seat belt height adjuster
5.
6-pillar cross brace
6. Seat belt reel mounting bolt
7. Seat belt anchor mounting bolt
8. Seat belt lock with pyrotechnic
tensioner
9. Tensioner mounting bolt
Front seat belt reel, removing and installing
(sedan and Sport Wagon models)
- Detach battery negative (-) cable in trunk.
~~-~
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Warnings and Cau-
l tions. I
- Remove front seat as described in 520 Seats
4 Gently pry up front and rear plastic door sill protector strips
to remove.

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720-8
I Seat Belts
When Installing automatic reel housing to 5-pillar, slide tab
into locating slot (arrow).
Remainder of installation is reverse of removal
Tightening torques
- -.
Front seat to floor (M10) 42 Nm (31 ft-lb)
Seat belt to seat 48 Nm (35 ft-lb)
Seat belt to height adjuster 31 Nm
(23 it-lb)
Seat belt reel to €3-pillar bottom 31 Nm (23 ft-lb)
Sliding height adjuster to €3-pillar
24 Nm (18 ft-lb)
Rear seat belt assembly
(sedan)
1. Center shoulder belt reel
assembly
(if equipped)
2. Right shoulder belt lock
3. Lap-belt assembly
4. Left shoulder belt lock
5. Bolt MlO
(tighten to 31 Nm, 23 ft-lb)
6. Left shoulder belt reel assembly
7. Center shoulder belt lock
(if equipped)
8. Bolt M12
(tighten to 48 Nm, 35 ft-lb)

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721 -2
l~irba~ System (SRS)
This repair group covers airbag components and replace-
ment.
Airbag system repairand fault diagnosis is not covered.
Diagnostics, component testing, and
airbag system repair
should be carried out by trained BMW service technicians.
Individual
airbag system components can only be tested elec-
tronically when installed in the car. BMW service testers
DIS
or MoDiC or equivalent must be used for diagnostic work.
WARNING-
Special test equipment is required to retrieve airbag fault
codes, diagnose system faults, and
reseffturn off the air-
bag indicator light. The indicator light will remain on until
any problem has been corrected and the fault memory has
been cleared.
Airbags are part of the BMW Multiple Restraint System
(MRS). Three versions of MRS are available in E39 models.
Multiple Restraint Systems
MRS and MRS II include the following restraint components:
311 996-811 997
911
997-311 999
311 999-2002
Driver and passenger front
airbags (MRSIMRS II)
MRS
MRS
II
MRS Ill
Passenger front two-stage airbag (cars manufactured
from
911998).
The seat occupancy sensor (SBE) is used for detection of
a passenger in the right front seat. MRS uses the SBE in-
put to determine seat belt tensioner
and/or front airbag de-
ployment thresholds.
Side impact
airbag for driver and front passenger
(MRSIMRS II)
Leftlright side impact crash sensors (MRSIMRS 11)
Side impact airbag for rear passenger (MRS II) (optional)
Head Protection System (HPS) for driver and front passen-
ger (MRS
II)
Battery Safety Terminal - BST (MRS II)
Hall Sensor seat belt switches (MRS II)
Front pyrotechnic seat belt tensioners
Fuel pump cut off message

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721 -3
Airbag System (SRS)
MRS Ill adds the following features:
MRS
Ill employs "smart" technology. Smart technology re-
fers to the control module's programming for the deploy-
ment of the airbags, in stages depending on the severity of
the impact.
Two-stage a~rbag for ooln drver and passenger Alloivs for
a softer
c~snioning elfecl when the airbags are lr ggered at
lighter impact,
MRS
Ill satellite sensors use 2 wire connectors
Rear side
airbags arrive de-activated from the factory and
can only be activated upon written request from the cus-
tomer.
Rear seat head protection is available when ordered with
optional rear seat side airbags.
E39 Airbags
Driver airbag
Passenger airbag
Head Protection System (HPS)
Inflatable Tubular Structure
(ITS) (MRS
II and MRS Ill)
Front side impact airbag
Rear door side impact airbag
(optional) (MRS I1 and MRS Ill)

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I Airbag System (SRS)
Two-stage airbag (MRS Ill)
Beginning with 2000 model year (911 999 production) the front
airbags were changed to a two-stage style airbag. This en-
sures that the force of
airbag inflation is not greater than nec-
essary to provide
protection. The airbags are designed to
Drovide "soit" de~lovment if the acceleration sensor detects a
iow-speed impact, and "hard deployment in higher speed im-
pacts.
NOTE-
A two-stage passenger airbag was used on cars built be-
tween
9/1998 and 3/1999. This pre-smart technology airbag
used two ignition stages. Stage one is designed to ignite first
during an impact. Stage two ignites after a timed period, as
programmed in the MRS
I1 control module.
Airbag indicator light
The MRS control module detects and stores system status
The
airbag indicator light in the instrument cluster displays
the status of the
airbag system when the ignition key is in "ac-
cessory" or
ON positions.
System normal: lndicator light comes on briefly, then goes
out.
- System malfunction: lndicator light fails to come on.
System malfunction: lndicator light comes on briefly, goes
out and lights up again.
The
airbag indicator light also comes on if the seat belt pyro-
technic tensioners have been triggered.

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721-6
I Airbag System (SRS)
MRS
The MRS control module contains the electronic crash sensor
for frontal impact. Sensors mounted on the driver and
pas-
sengerfloor are used for side impacts. The MRS control mod-
ule
is located between the front seat under the center
console.
MRS airbag system
diagram
1. Driver's side airbag
2. Passenger's side airbag
3. Right side impact sensor
4. Seat occupancy sensor pad
5. Right side impact airbag
6. SBE control module (analog to
digital converter)
7. Passenger pyrotechnic seat belt
tensioner and seat belt
mi-
croswitch (Hall sensor MRS Ill)
8. MRS control module
9. Driver pyrotechnic seat belt ten-
sioner and seat belt microswitch
(Hall sensor MRS
Ill)
10. Left side impact airbag
11. Left side impact sensor

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Airbag System (SRS)~
MRS control module, replacing
- Disconnect negative (-) cable from battery and cover nega-
tive terminal with insulating material.
CAUTIOI\C
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in001 General Warnings and
Cau-
tions.
- Remove center console between front seats. See 513 lnteri-
or Trim.
Remove module mounting nuts (arrows) and lift up control
module. Disconnect electrical harness connector.
Installation is reverse of removal.
Be sure that MRS control module ground cable is attached
to the module mounting stud.
Side-impact crash sensor, removing and
installing
- Make sure ignition key is OFF.
- Remove front seat. See 520 Seats.
Remove plastic door sill trim by lifting to release clips at one
end, then sliding off. Fold up carpet towards rear seat floor. If
necessary, remove floor level heater duct.

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INDEX 'tl
WARNING
Your common sense, good
judgemenl, and general alertness are
crucial to sale and successiul service
worlr. Belore attempting any work on
your
BMM be sure lo read 001
General Warnings and Cautions
and the
copyriglll page at the front 01
the manual. Review these warnings
and
caulions each lime you prepare
lo work on your BMW. Please also
read any warnings and cautions that
accompany
tile procedures in the
manual.
312-way valve (running losses)
see Fuel tank
Abbreviations, commonly used 600-14
ABS (antilock brake system)
see
Bral(es
A/C air distribution motors
see stepper motors (below)
blower final stage (resistor pack),
replacing
640-16
blower, removinglinslalling
640-1 5
compressor, replacing
640-24 condenser, replacing 64045
control panellmodule, removing1
installing
640-1 1
evaporakr, removinglinstalling 640-29
evaporator temperature sensor
640-12 expansion valve, removinglinstailing
640-27
IHKA/ IHKR system description 640-5
receiveridrier, replacing 640-26
stepper motors 640-1 3 ventilation microiilter, replacing
020-22. 640-17
see also Heating
Accelerator
iinlcage
see Maintenance
Activated carbon canister
see Fuel tank
ADS (auxiliary throttle valve)
130-57
Air compressor
330-44
Air conditioning
see
AIC
Air distribution (flap) motors
seeNC, stepper motors
Air filter see Maintenance
Air spring
300-6, 330-12
Airbag system (SRS)
2-stage
airbag 721-4
control module, replacing 721-7 driver airbag, removinglinstalling
721-8
iiead protection airbag 721-12 components 721-1 1
indicator
lighl721-4
passenger airbag, removinglinstalling
721-9 side-impact airbags crash sensor,
replacing
721-7
Airflow sensor see 130 under appropriate
fuel
injection system
Air pump
see 130 under appropriate fuel
injection system, secondary air
injection system
Air suspension
see Electronic height control
(EHC)
Alarm
see Anti-theft alarm
Alignment see
Wheei alignment
Aluminum suspension components
300-2
Antenna 650-6
Alternator see Battery, starter, alte rnator
Amplifier
650-4
Anti-theft alarm (DWA)
515-24 emergency disarming 515-31
Antifreeze (engine coolant)
see Maintenance
see also Cooling system
Antilock brake system (ABS) see Brakes
ASC see Brakes
ATF (automatic transmission fluid)
see Automatic transmission
see also Cooling systern
Automatic headlight adjustmenl
(LWR) see Lights
Automatic seat belt tensioner
720-4
Automatic shiftloclc
see
Gearshift
Automatic transmission
applications
200-3, 240-4
ATF 020-10, 200-4
capacity 240-8 checking 240-6
drainingifilling 240-7
heat exchanger 170-5
fluid pan and strainer 240-9 gearshift
see Gearshift
ID tag
200-3 range switch 610-6
removaliinstallation 240-10
steptronic see Gearshift
Auxiliary cooling fan
see
Coollng system, electric Ian
Auxiliary throttle valve (ADS)
130-57
Axle joint
see Drive axle
Back-up light switch
automatic transmission see Automatic transmission. range switch
- .~.~~~
manual transmission 230-8 -
- I

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INDEX 7
WARNING
Your common sense, good
judgement, and general alertness are
crucial to safe and successful service
work. Before
attempting any work on
your BMW, be sure to read 001
General Warnings and Cautions
and the copyright page at the front of
the manual. Review these warnings
and cautions each time you prepare
to
work on your BMW. Please also
read any warnings and
caulions that
accompany
/he procedures in the
manual.
Jack stands
010-16
Jump starting 010-19
Keys
515-1 1
Knock sensor
see Ignition system
Leak detection,
fuel tanlr
see Fuel tank, leak detection unit
Leather upholstery
see Maintenance, leather
upholstery and trim
LDP
(leak detection pump)
see Fuel
tanir, leal( detection unit
Level sender
see Fuel tank
see also Fuel pump
License
plate iight
630-1 1
Lifters see Cylinder head and vaivetrain
Lifting the car
010-5 Lights
bulb applications
630-2
control module (LCM) 630-3
foglights 630-8 headiighls 630-4
automatic headlight adjustment
(LWR)
630-7
vertical aim system 630-8 interior lights 630-12
bulb applications 630-13
side turn signal 630-9
taillight 630.10 trunk light bulb 630-14
turn signals, taillights 630-12
LOClCS see Central loci(ing
see also Door loclrs
Lubrication system
oil
level warning switch, replacing
119-20
oil pan, removinglinstalling
6-cylinder 119-10
V-E lower 119-13 V-8 upper 119-15
oil pressure
checiring 11
9-4
warning system, testing 119-5 warning switch, replacing 119-20
oil pressure
reliel valve
6-cylinder 119-26
V-8 11 9-27
oil pump, removinglinstalling
6-cylinder
119-22
V-8 1 19-4
troubieshooting 119-3
Luggage compartment
seeTrunk
MAF (mass air flow) sensor
see 130 under appropriate fuel
injection system Maintenance
accelerator linkage
020-14 air filter 020-14
automatic transmission 020-29
battery 020-22
body lubrication 020-31 body and interior 020-31
braire fluid 020-24
brake padlrotor wear 020-24
brake system 020-25 clutch fluid 020-26
cooling system 020-15
CV ioint boots 020-27
differential oil level 020-26
drive bells 020-16 engine comparlmenl 020-14
engine cooling system 020-16
engine oil 020-1 1 exhaust system 020-27
exterior washing 020-31
fluid and lubricant specifications 020-9
fuel lilter 020-27 fuel lanir and fuel lines 20-28
idle speed 020-19
inspection 020-5
interior care 020-31
lealher upholslery and trim 020-31
maintenance tables 020-6
manual transmission oil 020-30
microiilter 020-22 oxygen sensors 130-72, 180-8
parlcing brake 020-25
power steering fluid level 020-20
seat belts
020-32 service indicator 020-3
spark plugs 020-20
special cleaning 020-32 suspension, front 020-29
suspension, rear 020-29
tires 020-29
washing
020-32
waxing 020-32 windshield wiper blade 020-33
wheels, aligning 020-30
Malfunction indicator iight (MIL)
OED-2
Manifold, exhaust
see Exhaust system
Manifold,
intake
see Intake maniiold

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INDEX 9
WARNING
Your common sense, good judgemenl, and general alerlness are
crucial lo seie end successful service
ivork. Beiore attempting any work on
your
BMW be sure to read 001
General Warnings and Cautions and llle copyright page at lhe iron1 of
the manual. Review Niese warnings
and caulions each lime you prepare
lo work on your BMW Please also
read any warnings and caulions lllal accompany the procedures in the
manual.
Rear suspension
ball joints
330-19
bushings 330-13
control arms
seesuspension arms, below
description
300-5
electronic height control (EHC)
330-44
ride height 300-14 ride height sensor 330-46
shoclr absorbers end springs 330-9
stabilizer bar 330-42
struts and springs 330-5 subframe 330.13
suspension arms 330-13
variations 330-4 wheel bearing, replacing 330-32
see also Maintenance
see also Drive axles
see also Final drive
Rear window (Sport Wagon)
see
Tailgate
Rear window defroster 610-17
Receiverldrter
see NC
Relay positions
see Electrical component tocations
table 610-3
Remote entry (FZV)
see Central locking
Reversing light switch
see
Baclc-up light switch
Ride height
300-14
Ride height sensor
see Rear suspension
Ring antenna
see EWS (electronic immobilizalion)
Rotor
see Brakes
Roundel see Exterior trim
Running tosses
(312-way) valve
see Fuel
tenlr
SCA (soft close)
seeTailgate, soft close
see also Trunk lid. soft close
Scan tools
OED-3
Seals gaskets and 010-9
see also Crankshaft seals
Seat front,
removing/instelling 520-10
memory system 520-4 rear 520-13
see also Seat belt
Seat beit front 720-4
rear 720-8
troubleshooting 7202
see also Maintenance
Secondary air injection
see 130 under appropriate
iuel
injection system
Selector shaft seat
see Manual transmission, oil
Seals
Self-adjusting ctulch (SAC)
see Clutch, variations
Service indicator see Maintenance
Shift interlock see Gearshift
Shift lever
see
Gearshift
Shift linkage see Gearshift
Shiftlock see Gearshilt
Shack absorber see Rear suspension
/ Side turn signal assembly
see Lights
Sill trim panel
411-10
Slave cylinder
see Clutch, lhydraulic
Steep mode
600-1 1
Soft close
(SCA) see Tailgate
see also
Trunk lid
Solenoid 121-23
Sound system
650-2
Spare parts kit
010-21
Spark plugs
see Maintenance
Speakers
650-4
Specifications, fluid
020-4
Sport wagon
400-4
Springs
see Front suspension
see also Rear suspension
SRS (supplemental restraint system)
see
Airbag system (SRS)
Stabilizer bar see Front suspension
see also Rear suspension
Starter see Battery, starter, alternator