Rpm BMW 540i 1997 E39 Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
113-5
Cylinder Head Removal and Installation I
< Fuel line plugs
(Tool No.
BMW 13 5 281113 5 282)
4 Fuel line removal tool for quick-disconnect fittings
(Tool No.
BMW 16 1 050)
< Tensioning bracket (V-8)
(Tool No. BMW 11 7 380)
Compressed air fitting for testing VANOS operation
((Tool No.
BMW 11 3 450)
< Upper timing cover installation tool set, V-8
(Tool No. BMW 11 1 41 0)
Cylinder compression, checking
A compression gauge is needed to make a compression test.
For accurate test, the battery and starter must be capable of
cranking the engine at least
300 rpm, and the engine should
be at normal operating temperature.
NOTE-
Performing a compression test may cause a fault to set in the
ECM and may illuminate the Malfunction
Indicator Light
(MIL). The light can only be turned out using either
BMW
special service scan tools or an equivalent aftermarket scan
tool. Disconnecting the battery will not erase the fault memo-
ry or turn out the light. See OBD On-Board Diagnostics.

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
-- . - .. . - Lubrication system]
- Remainder of installation is reverse of removal.
Replace self-locking nuts when reinstalling front suspen-
sion components.
Use new oil dipstick tube sealing O-ring.
After adding engine oil, start and run engine. Raise engine
speed to 2,500 rpm until oil pressure warning light goes out
(about 5 seconds).
NOTE-
BMW does not specify a front end alignment following this
procedure.
Tightening torques Front subfrarne to body rail
(M12, use new bolts)
8.8 grade
10.9 grade
12.9 grade 77 Nrn
(57 ft-lb)
105 Nrn (77 ft-lb)
110 Nrn (81 ft-lb)
Stabilizer bar link to stabilizer bar
65 Nrn (48 ft-lb)
Steering shaft universal joint clamping bolt
(use new bolt)
19 Nrn (14 it-lb)
Lower oil pan, removing and installing (V-8)
- The V-8 engine is equipped with a 2-piece oil pan. The fas-
teners in
V-8 engine oil pump assembly, including the
sprocket retaining nut, are known to loosen and fall off into
the oil pan. Be sure to install these fasteners with Loctite
O
or equivalent thread locking product and torque to specifica-
tions.
CAUTION-
It is recommended that the oil pump retaining bolts and oil
pump drive sprocket retaining nut tightening torque be
checkedany time the
oilpan is removed.
- Raise car and place securely on jack stands.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
- Remove splash shield from under engine.
- Drain engine oil
- On cars with automatic transmission, remove ATF cooler line
brackets from oil pan.

Downloaded from www.Manualslib.com manuals search engine
.
[Lubrication System
< Disconnect electrical harness connector (arrow) at oil level
sensor.
< Remove lower oil pan mounting bolts (arrows)
CAUTIOI\C
If the lowerpan does not separate easily from upperpan, a
few taps with a rubber mallet should break it free. Do
notpry
the oil pan loose.
- When installing oil pan:
Thoroughly clean all old
gasltet material from mating sur-
faces and use a new gasket.
4 Install threaded guide studs at locations marked by arrows
to guide new oil pan
gasltet and oil pan into position and to
prevent damage to sealing lip.
- Install new oil pan mounting bolts (threads coated with
sealer).
Remove guide studs and install remainder of oil pan bolts.
- Remainder of reassembly is reverse of disassembly
- After adding engine oil, start and run engine. Raise engine
speed to 2,500 rpm until oil pressure warning light goes out
(about 5 seconds).
Tightening torques Lower oil pan to upper
oil pan
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (10.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Oil drain plug to oil pan (M12) 25 Nm (18 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
Lubr~cat~on System r- -
Working at lower rear of engine, remove oil pan retaining
bolts
(arrows).
- If necessary, remove oil cooler bracket from oil pan.
- Remove remaining oil pan bolts. Slide upper section of oil
pan forward to remove.
- Installation is reverse of removal, noting the following:
Clean sealing surfaces of debris.
- Coat joints with Three Bond 1209 O sealant.
Use new gaskets.
Install all oil pan bolts first, installing bolts at transmission
end without preload.
Tighten oil pan bolts at front end, then tighten bolts at rear
of engine.
Be sure to reinstall all oil
pump fasteners, including the
sprocl - After adding engine oil, start and run engine. Raise engine
speed to
2,500 rpm until oil pressure warning light goes out
(about
5 seconds).
Tightening torques
AIC drive belt tensloner
M6 10 Nm (7.5 it-lb)
M8 24 Nm (18 ft-lb)
Front axle
subframe to chassis
(Use new fasteners) 77 Nm (57 ft-lb)
Oil drain
line to upper oil pan 30 Nm (22 ft-lb)
Oil pump to crankcase 34 Nm (25 ft-lb)
Oil pan fasteners
(upperllower)
M6 8.8 10 Nm (7.5 ft-lb)
M6 10.9 (replace)
I2 Nm (9 ft-lb)
M8 8.8 22 Nm (16 ft-lb)
Steering column universal joint to
steering box (replace) 19 Nm (14 ft-lb)
Oil pressure warning switch, replacing
(&cylinder and V-8)
- In all models, the oil pressure warning switch is located at the
base of the oil filter housing.

Downloaded from www.Manualslib.com manuals search engine
Lubrication System
- Lower front suspension and remove oil pan, as described
earlier, to gain access to oil pump.
Remove oil pump
sprocket mounting nut (left-hand thread)
(arrow). Lift sprocket off together with drive chain.
Engines produced to 9/98: Remove oil pump with pick-up
tube. Pick-up tube is bolted to side of oil pump.
Engines produced from 9/98 to 01/00: Remove pick-up
tube, scraper tray and oil pump as a unit.
Engines produced from 01/00: Remove oil pump pick-up
tube bolts and remove pick-up tube before removing pump.
Remove mounting bolts from oil pump. Withdraw pump.
NOTE-
Record location of any spacers between pump and engine
bloclc Note positions of locating dowels.
- Remove cover from oil pump and check for wear or scoring.
Spin oil pump shaft and
check that gears turn smoothly. Re-
place pump if gears spin with difficulty
orany wear is present.
- Inspect oil pressure relief valve as described later.
- Installation is reverse of removal, noting the following:
Replace pick-up tube O-ring (if applicable).
- Align sprocket splines to oil pump shaft spl~nes before
tightening sprocket nut.
- After adding engine oil, start and run engine. Raise engine
speed to 2,500 rpm until oil pressure warning light goes out
(about 5 seconds).
Tightening torques Oil drain plug to oil pan 25
Nm (18 ft-lb)
Oil pan to engine
bloclc
M6 (8.8 grade)
M6 (10.9 grade)
M8 (8.8 grade)
10 Nm (89 in-lb)
12
Nrn (9 ft-lb)
22 Nm (16 ft-lb)
Oil pump sprocket to oil pump shait
(M10 x 1) (left hand thread)
25 Nm (1 8 it-lb)
Oil pump to crankcase (ME) 22 Nm (1 6 it-lb)
Oil pump pickup tube to cranltcase (M6) 10 Nm (89 in-lb)

Downloaded from www.Manualslib.com manuals search engine
11 9-26
/Lubrication System
< Use Allen wrench to adjust chain slaclc (B) by turning thread-
ed spacer
(A).
Oil pump chain adjustment
Slack
10 52 mrn (0.394i0.079 in)
- Coat remaining oil pump mounting fastener with Loctite 03. In-
stall and tighten.
- Remainder of assembly is reverse of disassembly.
- After adding engine oil, start and run engine. Raise engine
speed to
2,500 rpm until oil pressure warning light goes out
(about
5 seconds).
Tightening torques
Lower oil pan to upper oil pan
M6 (8.8 grade) 10
Nm (89 in-ib)
M6 (10.9 grade) 12
Nm (9 ft-lb)
M8 (8.8 grade) 22
Nrn (1 6 ft-lb)
Oil drain plug to oil pan (M12) 25 Nm (I8 ft-lb)
Oil pump cover to oil pump
(M6) 10 Nrn (89 in-lb)
Oilpump sprocket to shaft TKO) 45 Nm (33 it-lb)
Oil pump to engine bloclc
M8 (8.8 grade) 22 Nrn (16 ft-lb)
Oil pressure relief valve (&cylinder)
Remove oil
pump as described earlier. The oil pump pressure
relief valve is held in the side of the
oil pump with a circlip.
< Inspect oil pump relief valve components and bore for scor-
4. Sleeve
5. Circlip
- Install using a new circlip.
Oil
pressure relief valve assembly
,- ..., !~. -.-~. - ~- -~!~~-% h. .- .,, /to-cy~~noer engrnej ing or other damage.
1. Control plunger
2. Spring
3. Sealing O-ring

Downloaded from www.Manualslib.com manuals search engine
- -
/Battery, Starter, Alternator -- - -. - --I
< Check for battery voltage at alternator terminal 30 (B+) (ar-
row):
Pull back rubber insulating cover at terminal 30 at rear of
alternator.
Connect voltmeter between terminal 30 and ground and
check for battery voltage.
If voltage is not present, check
wiring for faults.
NOTE-
On V-8 engines, access to the rear of the alternator is limited.
Check for battery voltage between the jump start post on the
left cylinder head and ground.
r Disconnect harness connector from alternator. Turn ianition
on and check for battery voltage between terminal
lgand
ground. If voltage is not present, check wiring and fuses for
faults.
Reconnect connector to alternator.
Locate the blue wire coming from terminal
61E of the alter-
nator connector. Carefully connect the positive
(+) test lead
to the wire using a piercing test lead end.
Turn ignition key on and check for voltage. Voltage should be
less than 1.5 VDC and charge indicator lamp should light.
- Making sure all test equipment and tools are clear, start en-
gine. Voltage should increase to
8.0 VDC or higher. The
charge indicator light should go out.
If voltage does not increase and system is not charging,
the fault is in alternator.
- If voltage does not increase, but system is charging, inter- - roaate svstem for faults usina an appropriate BMW scan - .. . tool and'reset fault memory.
- If a load tester is not available, a quick alternator output test
can be done by running engine at about 2000 rpm and turn-
- -
ing on electrical loads (fans, lights, rear window defroster, -
- and wipers). With all accessories on, battery voltage should
be above 12.6
V.

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection I
Mass air flow (MAF) sensor,
checking and replacing
4 The hot film mass air flow (MAF) sensor (arrow) sends a
varying voltage (approx.
0.5 - 4.5 vdc) to the ECM represent-
ing the measured intake air. The air mass input signal is pro-
duced electronically by the
MAFsensorusing a heated metal
film in the air flow stream.
The ECM relay provides the operating voltage to the MAF
sensor. As air flows through the MAF sensor, the film is
-
cooled. To maintain the film at a constant temperature, addi-
tional heating current is necessary. It is this additional current
that is the basis for the input signal.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using throttle position and engine rpm in-
puts. A faulty MAF sensor illuminates the MIL.
A faulty MAF sensor can produce the following problems:
Difficult to restart when engine is hot.
Engine starts then stalls.
Engine starts and runs only with accelerator pedal de-
pressed.
Disconnect electrical harness connector from MAF sensor
(arrow).
- Turn ignition on and check for voltage and ground at connec-
tor.
There should be ground at pin
1 and battery voltage at pin
3.
If any faults are found, check for wiring breaks between
MAF sensor and ECM and between MAF sensor and ECM
relay.
NOTE-
Visually inspect the sensor for damage, missing or blocked
screens. The screens affect air flow calibration. Also inspect
the sealing O-rings where the sensor inserts into the air
filter
housing and intake boot. Ensure the pin connections are
clean and tight.
4 Connect a BMW-compatible scan tool or an OBD II generic
scan tool. Check air mass signal (load signal) with the engine
at idle. Raise idle speed and check that load signal changes
with rpm.
CA UTIOI\C
Be sure ignition is OFFbefore disconnecting or reconnecting r
1 DME svstem components. 1

Downloaded from www.Manualslib.com manuals search engine
130-1 2
Fuel Injection
- Disconnect intake air boot from throttle housing. Unbolt throt-
tle housing and lay aside. It is not necessary to disconnect
throttle cable or electrical harness connectors from throttle housing.
- Remove electrical harness connector from IAT sensor.
- Unclip temperature sensor and remove from intake manifold.
- Installation is reverse of removal. Use a new gasket at throttle
housing.
Throttle position sensor (TPS),
testing and replacing
4 The throttle position sensor (arrow) is located on top of the
throttle valve housing and provides the ECM with a voltage
value that represents throttle position (angle) and rate of
movement.
TheTPS is non-adjustable. If the throttle position sensor is re-
placed, the previous 'learned' TPS settings must be cleared
from the ECM using a BMW-compatible scan tool.
If the throttle position sensor signal is defective, afault code is
stored and the
MILis illuminated when OBD II fault criteria are
exceeded. The ECM still operates the engine using the mass
air flow
(MAF) sensor and engine rpm inputs.
- Check throttle position sensor function by disconnecting har-
ness connector and checking continuity across terminals. If
test results are incorrect,
replace throttle position sensor. The
sensor is non-adjustable.
Throttle
~osition sensor testina values -
Terminals Test
values
1 and ground in harness 5 vdc (approx.)
connector, ltey on
1 and 3 at sensor 4.0 itR(appr0x.)
1 and 2 at sensor Throttle
plate rotated from idle to
lull throttle, continuously variable
from 1.0
- 4.0 1tR
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME svstem components. r