Head BMW 540i 1998 E39 Workshop Manual

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400-1 0
Body-General
Seats
4 Anatomically correct seats are constructed from polyure-
10 way seat adjustment thane foam
containing areas or "zones" of different firmness.
They offer good lateral support without constricting the occu-
pant.
The seats have a passive internal ventilation system: Cylin-
drical cavities within the cushions and backrests generate a
pumping effect as the ride motions cause occupant motion.
This
helps remove moisture and feeds fresh air into the seats.
Other features of the seating system:
The seat bases have steel springs for added support and
strength.
The seat control switches are along the outside edge of
the
seat.
Heated seats are an option in all models
In cars equipped with seat position memory, three different
seat confiaurations can be memorized by the seat control
module(s): Seat memory coordinates with outside mirror
memory. These functions are controlled by the seat mem-
ory
module(s).
* For security reasons, the release lever to fold the rear seat
backrest forward is installed in the trunk.
Sport Wagon models: Rear seat
baclts are split 60140, with
the center armrest on the left seat back.
The center armrest incorporates a non adjustable head-
rest. When folded down, the armrest opens out with
cup-
holders and a storage compartment. See 520 Seats for
more details.
instruments and controls
Everything in the interior passengercompartment essential to
the driver is logically grouped and easy to reach. All instru-
ments and controls have been arranged ergonomically and
are fully integrated into the overall design of the vehicle.
Tilt-telescopic steering wheel has
30 mm (1.2 in) of vertical
and longitudinal adjustment.
Multifunction steering wheel contains two
ltey pads con-
taining controls for the sound system, telephone and
cruise control.
Padded dashboard houses the instrument cluster and the
ventilation and heating system.

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41 0-3
Fenders, Engine ~oodl
Carefully pry front turn signal assembly from fender and dis-
connect electrical harness (arrow).
< Release headlight trim panel locking clip with a screwdrivel
(arrow).
* Working at corner of side trim panel, pull trim panel out
from side of fender to remove.
- Remove front bumper. See 510 Exterior Trim, Bumpers.
Working at rear of
teners (arrows). fender
well, , remove
fender
'mounting fas-
< Remove lower
housing. 'attaching
bolts
(arrow) at rear of wheel

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Fenders, Ensine HOO~I
Hood release cable and spring pins,
adjusting
Before adjusting hood pins, be sure the hood is aligned even-
ly to fenders and front panel.
- Malte sure bowden cable, which connects both hood loclts
together, is seated in lock guide on both left and right loclts.
4 Loosen hood spring pin bolts (A) and retaining hoolt bolts (B)
at hood on left and right sides only enough to allow move-
ment.
- Lower (but do not fully latch) hood several times so pins on
hood center themselves in lower loclts.
NOTE-
Do not let hood lock with latch bolts loose
- Tighten hood spring pin bolts and latch bolts when alignment
is correct.
- Remove one bolt at a time from each side, clean and coat
with
LoctiteB 270 or equivalent, and reinstall. Repeat pro-
cess on all other bolts.
- Adjust rubber stop buffers above headlight assemblies. See
Hood, aligning.
- Test hood for correct closure and opening. If hood does not
spring open, lengthen spring pins.
- To lengthen spring pin, loosen locltnut (arrow) with wrench
inserted through spring, then turn pin counterclocltwise.

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51 0 Exterior Trim. Bumpers
General ........................... .51 0.2 Exterior Trim ...................... 51 0-1 3
Outside Rear View Mirrors
Outside mirror glass. replacing
Outside mirror housing.
removing and installing
......
Outside mirror assemblv .
BMW emblem. removing and installing ... 510-13 .......... .51 0.2
Body side molding. replacing ........... 51 0-13 .......... .51 0.2
Radiator grill. removing and installing .... 51 0-1 4
Headlight housing trim panel.
.......... .51 0.3
removing and installing ............... 510-14 . .
removing and installing ................ .51 0.4
Bumpers ......................... .51 0.5
Front bumper assembly
............... .51 0.6
Front bumper, removing and installing
.... .51 0.7
Front bumper impact absorber. replacing
. .51 0.8
Rear bumper assembly ............... .51 0.9
Rear bumper. removing and installing
... .51 0.10
Rear bumper impact absorber. replacing
. .51 0.1 1
Front bumper height. adjusting
......... .51 0.12

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51 0-8
I Exterior Trim, Bumpers
- Installation is reverse of removal, noting the following:
Carefully slide bumper side panels over mounting brackets
on fenders.
Make sure gap between body and bumper is set to speci-
fications. Adjust height as necessary. See Front bumper
height, adjusting.
If equipped with headlight washers or
park distance control
reconnect hoses and harness.
Tightening torque Bumper to impact absorber
(M10) 41 Nm (30 ft-lb)
Front bumper impact absorber, replacing
To access front bumper mounting bracket and impact absorb-
er mounting hardware remove front bumper cover. See Front
bumper, removing and installing.
4 Remove front bumper impact absorber mounting nuts (A)
and drill out rivets (B).
NOTE-
Install the bumper bracket bolts using thread locking com-
pound.
- Installation is the reverse of removal.
Tightening torques Bumper to impact absorber
41 Nm (30 fl-lb)
Impact absorber to body (6M) 9 Nm (7 ft-lb)
Impact absorber to body (EM) 22 Nm (16 It-lb)

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Exterior Trim, Bumpers 1
Radiator grill, removing and installing
- Open hood
4 Carefully pry out tab on lefl or right side of grill trim ring (A),
as well as tabs on bottom.
- Push grill out through opening. Be careful of hood lever on
passengers side of grill.
- Once grill is removed, pry remaining tabs (B) to separate in-
ner grill from chrome trim ring.
- Before installation, assemble chrome trim ring and grill insert
securely. Replace components
if tabs or catches are brolten
or missing.
- Install grill and trim ring in appropriate location in hood. Press
on trim ring until grill snaps into place.
Headlight housing trim panel, removing
and installing
4 Open hood
- Remove spray nozzle of vehicles equipped with headlight
cleaning systems. See
611 Wipers and Washers.
Release inner tab (arrow) support.
Swing trim out to release outer hook
point. from fender mounting
Installation is reverse of removal

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513-12
Interior Trim
< Remove steering column trim panel by releasing clips (ar-
rows).
< Remove left side mounting fasteners (arrows).
Lilt dash panel upwards and remove through passenger
door.
- Installation is the reverse of removal.
Window and door post trim panels,
removing and installing
Windshield post trim (A pillar), removing and Installing
- On 1998 and later cars, disconnect battery negative (-) cable
I
WARNING-
On 1998 and later models, front Head Protection System
(HPS)
airbags are installed in the driver and passenger side
windshieldpost
trim (A-pillar). See 721 Airbag System
(SRS) for warnings and cautions regarding airbags.
< Remove A-p~llar trim panel fastener cap (arrow)

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51 3-1 4
llnterior Trim
Carefully pry bottom of upper trim panel away from door post
to release clips.
Pull upper trim panel straight down (arrow) to remove.
Installation is reverse of removal.
If necessary replace defective or
broken mounting clips.
Rear window pillartrim (C-pillar), removing and installing
(models without rear
HPS airbags)
1 I
WARNING-
On 1998 and later models, rear Head Protection System
(HPS)
airbags may be installed (optional equipment) in the
driver and passenger side C-pillar area.
The procedure given
below does not cover models with rear HPS airbags. See
721 Airbag System (SRS).
4 Carefully pry interior light out of C-pillar trim panel and dis-
connect wiring harness.
Carefully pry trim panel out at top to release clips,
- Pull trim panel straight up to remove.
- lnstallation is reverse of removal.
If necessary replace defective or broken mounting clips.

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51 3-1 5
I Interior Trim
Dash panel support, removing and
installing
- Remove lower dash panel. See Lower dash panel assem-
bly, removing and installing.
- Remove upper dash panel. See Upper dash assembly, re-
moving and installing.
- Remove upper steering column fasteners. See 320 Steering
and Wheel Alignment.
4 Remove dash support fasteners (arrows).
Remove wire ties as necessary and remove support.
- Installation is reverse of removal.
Rear parcel shelf, removing and installing
(models without rear
HPS airbags)
WARNING-
On 1998 and later models, rear Head Protection System
(HPS)
airbags may be installed (optional equipment). The
procedure given below does not covermodels with rear HPS
airbags. See721
Airbag System (SRS).
- Remove C-pillar trim panels. See Rear window pillar trim
panel (C-pillar), removing and installing.
- Remove rear seat backrest. See 520 Seats.
- Rear parcel shelf removing:
Remove center headrest fasteners.
Remove
seatbelt floor mounting fasteners.
Carefully pry out safety belt trim panels and feed
seatbelt
through slots.
. . . - -. . . . . . . . . Remove expansion rivets and slide pane fonvard to re-
move.
< Remove expanson r:vets (arrows).
Remove vent panels (A).
Remove speafter pane s (B).
Remove center head rest s-pporl fasteners (C).
Slioe parcel shelf forward lo remove.
- lnsta lation s reverse of removal.

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51 5-24
l~entral Locking and Anti-Theft
ANTI-THEFT SYSTEM (DWA)
When the anti-then system (DWA) is armed, the doors, hood,
windows, trunk lid or tailgate are monitored against forcible
entry by switches and sensors. The vehicle is protected
against being jacked up or towed away by a tilt sensor.
The control electronics for DWA are integrated in the General
Module (GM). In addition to the control electronics, the sys-
tem includes the following components.
* DWA horn
DWA LED indicator
- Tilt sensor
- Monitoring switches and sensors
The system can be armed or disarmed from the driver's door
lock,
trunklid lock, tailgate lockorthe remote transmitter (FZV
Itey). When armed, the alarm horn
soundsfor30seconds and
the low beam headlights and turn signals flash for
5 minutes.
The electronic immobilizer (EWS) is also activated when
DWA is activated.
The alarm is switched off immediately if key is inserted in door
loclt or FZV key button is used.
DWA LED Status
The DWA status LED is located in the rear view mirror (ar-
row). When DWA is armed, the LED flashes slowly to indi-
cate armed status.
The LED and exterior lights flash once and the alarm horn
sounds when the system is successfully armed ordisarmed.
The LED will continue to flash slowly denoting the armed sta-
tus. If any monitored input is not closed when the system is
armed, the LED will flash rapidly for
10 seconds to indicate
the fault.
Tilt sensor
-
4 The tilt sensor, located on the left side of trunlt or cargo com- -
partment, consists of a conductive liquid chamber, a proces-
sor board and metal probes. The probes are submersed in
the liquid and produce a resistance value dependent on the
tilt of the sensor (angle of the vehicle). This resistance be-
comes the reference value when the DWA system is armed.
.-