BMW 540i 1998 E39 Workshop Manual

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Fuel Tank and Fuel Pump
Fuel pressure gauge, installing
(V-8 models)
Remove engine cover by pressing down on pins (arrows) to
release cover locks.
4 Disconnect and remove fuel supply line from lefl side of fuel
rail by sliding
loclting collar in (arrows) and pulling lines
apart.
NOTE-
* ME2 TU and MS43 vehicles (1999 and later models) use a
non-return fuel line with only one line to the fuel
rafl.
BMW uses three styles of fuellfne connections; a one-use
clamp, a locking fitting that uses
BMWspeclal tool 16 1 050
to release, and a quick release sleeve (above) that discon-
nects the line when depressed.
WARNING -
* Fuel In fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any
lealiing fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before workina on the tank or lines.
< Install inline fuel pressure gauge.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from coming loose underpressure.
NOTE-
The fuel pressure gauge should have a minimum range of 0
to 5 bar (0 to 75 psi).

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Fuel Tank and Fuel Pump
Fuel delivery,
testing
Checitino fuel delive~ is a fundamental oart of troubleshoot- .. ing and diagnosing thk DME system. ~ukl pressure directly
influences
fuel delivery. An accurate fuel pressure gauge will
be needed to make the tests.
There are two significant fuel deliveryvalues to be measured:
* System pressure - created by fuel pump and maintained
by pressure regulator
Residual pressure
- pressure maintained in closed sys-
tem after engine and fuel pump are shut off
if proper system pressure and residual pressure are present,
also check for problems in fuel delivery volume, which can be
affected by restrictions such as clogged fuel filter or fuel pick-
up port in the fuel tank.
System pressure, testing
1. Fuel pressure regulator outer seal
4 System pressure is created by the fuel pump and maintained
2. Vacuum line connection.
3. Fuel pressure regulator Inner seal.
4. Fuel flow back to fuel tank.
5. Fuel flow from fuel pump.
Fuel pressure
regulator
Fuel pressure regulator locations
M52 In fuel injector rail, in engine
compartment
M52 TU In 312 way valve, below vehicle under
driver seat
by the pressure
regulator. System pressure is not adjustable.
M54 In fuel filter
M62 to 9/97 In fuel injector rail, in engine
compartment
M62 from 9/97 to 9/98 In 312 way valve, below vehicle under
driver seat
M62 TU from 9/98 In fuel filter, below vehicle under driver
seat

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Fuel Tank and Fuel Pump
4 Relieve system pressure and attach a fuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
WARNING-
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or
worlc near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any
leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before
working on the tank or lines.
- Operate fuel pump as described in Operating fuel pump for
tests. Compare fuel pressure to specifications in accompa-
nying table.
Fuel pressure specification
All E39 vehicles 3.5 +0.2 bar (50.76 i2.9 psi)
- If pressure is low, repeat test while gradually pinching off re-
turn hose to fuel tank. Pressure should rise rapidly. If not, fuel
pump is most likely faulty. If pressure rises, the fuel pressure
regulator is most
likely faulty.
- If pressure is too high, checlc return line from pressure regu-
lator to tank. Check for
ltinks in hose. If no faults can be
found, pressure regulator is most likely faulty.
CAUTION-
The fuel pump is capable of developing a higher pressure
than that regulated by the pressure regulator. In the event the
fuel pump checlc valve is faulty (stuck closed), male sure the
I fuel pressure does not rise above 6.0 bar (87psi). Damage
to the fuel lines or fuel system components could result.
- Reassemble engine, noting the following:
Remove fuel pressure gauge and fittings.
Replace schraeder valve, if removed
Replace fuel pump relay.
Replace fuel filler cap.
Residual pressure, testing
For quick restarts and to avoid vapor lock when the engine is
hot, the fuel injection system retains fuel pressure after the
engine is shut off. This residual pressure is primarily
rnain-
tained by the fuel pressure regulator and a checlc valve at the
fuel pump
outlet.

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. .
I Fuel Tank and Fuel Pump I
4 Relieve system pressure and attach afuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines
- Start engine allow it to run for approximately one minute.
Note fuel pressure reading.
- Observe fuel pressure reading after approximately 20 mln-
utes. The pressure should not drop more than 0.5 bar from
system pressure listed in fuel pressure specifications in ac-
companying table.
Fuel pressure specification
Ail
E39 vehicles 3.5 i-0.2 bar (50.76 i2.9 psi)
- When finished, disconnect pressure gauge and fitting, and
replace schraeder valve, if removed.
- If fuel system does not maintain pressure:
Visually check for leaks in fuel lines and unions,
Check for leaking
injector(s).
Check for faulty fuel pump check valve.
- To test fuel pump check valve:
Repeat residual pressure test.
Immediately aftershutting off engine, pinch off fuel delivery
line using a fuel hose pinch clamp (BMW
13 3 010 or
equivalent).
If pressure is now maintained, fault is most likely at fuel
pump check valve.
If pressure again drops below specifications, fault is most
likely in fuel pressure regulator.

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.-
err- .- Fuel Tank and Fuel Pump
FUELPUMP AND FUELLEVELSENDER
E39 models use a two-lobed fuel tank. Each lobe of the tank
has its own fuel level sending unit. Each sender has a float
connected to a variable resistance wipercontact. To equalize
fuel level between the two
tank lobes, a siphon pump is in-
stalled in the left lobe.
When replacing asender or fuel pump, always replace hose
clamps,
gasltets and O-rings.
WARNING
-
When removing the fuel level sender or the fuel pump, the
fuel tank should be drained to
1/4 capacity or below as de-
scribed later in this repair group.
NOTE-
The compensating siphon pump maintains the fuel level be-
tween the right and left tank lobes. If fuel level sender resis-
tances are not approximately the same on left and right,
remove the senders and visually inspect the level in each
lobe. If the levels are different, check the siphon pump.
Fuel level sender resistances
Float position
l~est results (Q
Down (empty) 150- 70
Up (full) 1401 -415
Fuel level sender (right side) and fuel
pump, removing
and installing
- Drain fuel from tank as described later.
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- To access top of fuel tank, remove rear seat lower cushion by
lifting front edge
off catches.

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I Fuel Tank and Fuel Pump
- Expose right side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover insu-
lation.
Peel back insulation at
perforations to expose fuel tank ac-
cess cover.
Remove right side cover to expose electrical harness con-
nector.
WARNING -
Fuel may be spilled. Do not smolce or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
Remove
tank sending unit:
Release electrical harness by sliding lock back, then lifting
off connector.
a Disconnect hose (arrow).
Unscrew threaded collar from fuel
pumpifuel level sender.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may re-
sult if the special tool is not used.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CAUTION-
Do not bend fuel level sender arm.
To remove fuel pump, press locking tabs (arrows) towards
pump body.
Lifl out pump, using care not to damage hoses.

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.- .
Fuel Tank and Fuel Pump
- To reinstall:
Use new sealing ring at tank collar.
* Align tab of sending unit with matching recess in opening
of tank.
Be sure that fuel line connections point in same direction
as they came out.
Reconnect harness connector and hose.
Fill tank and check for leaks by running engine.
Install access cover and its mounting fasteners.
CAUTIOI\C
After finishing repairs but before starting engine, be sure
there is at least
5 liters (1.5 gallons) of fuel in the tank. The
NOTE-
It is common practice to replace the fuel filter when the fuel
pump
unit is replaced. See 020 Maintenance.
Tightening torque
Tank collar locking ring to tank 35 Nm (26 lb-ft)
Fuel level sender (left side),
removing and installing
The procedure for removing and replacing the left side fuel
level sender is
simllar to that used for the r~ght side. There is
no fuel pump on the left side.
- Remove rear seat lower cushion by lifting off catches at front.
- Expose left side access cover:
- Peel forward lip of carpet.
Release rubber grommet from center of access cover
insulation.
Peel back insulation at
perforations to expose fuel tank
access cover.
Remove cover to expose electrical harness connector.
WARNING-
Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.

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/ ~uel Tank and Fuel Pump
4 Remove tank sending unit:
Disconnect electrical harness connector.
Disconnect hose (arrow).
- Unscrew threaded collar from fuel level sender.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may
result if the special tool is not used.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CA UTIOW-
Do not bend fuel level sender arm.
4 Once level sensor unit has been lifted partially out of tank,
disconnect tank siphon hose by pressing tabs (arrows).
- Installation is reverse of removal
Attach tank siphon hose to sender unit firmly.
Use new sealing ring at tank collar.
. Be sure that fuel sender float points in same direction as
during removal.
- Reconnect harness connector.
Fill tank and
check for leaks by running engine.
CAUTION-
After finishing repairs but before starting engine, be sure
there is at least
5 liters (1.5gallons) of fuel in tan/(. The fuel
pump will be damaged if run without fuel.
Tightening
torque
Tank collar loclting rlng to tanlt 35 Nm (26 lb-ft) -

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7 .- A Fuel Tank and Fuel Pump
Siphon pump, removing and installing
The fuel compensating siphon pump equalizes fuel level
between the two fuel tank lobes.
- Drain fuel tank as described later,
WARNING -
Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.
- Remove left and right fuel level sensors and fuel pump as
described earlier.
4 Once left side level sensor unit has been lifted partially out
of tank, disconnect tank siphon hose by pressing tabs
(arrows).
- The tank lobe siphon pump is held to baffle in bottom of right
tank lobe. Release retainer and lift out pump.
- Installation is reverse of removal.
Attach siphon pump to right side baffle.
Attach tank siphon hose to left sender unit firmly.
Use new sealing ring at tank collars
Be sure that fuel sender floats point in same direction as
during removal.
Reconnect harness connectors.
. Before starting engine, fill fuel tank with at least 5 liters
(1.5 gallons) of fuel.
Check for
leaks by running engine.
Afler finishing repairs but before starting engine, be sure

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--
I Fuel Tank and Fuel Pump
The plastic fuel tank is mounted underneath the center of the
car (underneath the rear seat). Mounted in the fuel tank are
the fuel pump and fuel level sending units. Connecting lines
for the evaporative emission control system and expansion
tank are also attached to the tank.
Fuel
tank capacity for E39 models
Tank capacity
70 liters (18.5 gal)
Reserve capacity
8 liters (2.1 gal)
Fuel tank, draining
Drain fuel tank into a safe storage unit using an approved fuel
pumping device.
WARNING-
# Before removing tank, be sure that all hot components,
such as the exhaust system, are completely cooled down.
Fuel may be spilled. Do not smoke or
work near heat-
ers or other fire hazards.
- Start engine and allow to run 10 - 15 seconds to fill fuel com-
pensating siphon assembly. This will allow both lobes of fuel
tank to he drawn off through fuel filler pipe,
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given
in 001 General Warnings and Cau-
tions.
- Remove fuel tank filler cap
- Slide suction hose into filler neck about 130 cm (51 in.), twist-
ing as necessary. Withdraw fuel into storage unit.
- Monitor fuel level reduction in both lobes:
- Remove rear seat cushion and access both fuel tank send-
er harness connectors.
Use multimeter to measure resistance at both senders,
Resistance should drop as fuel level drops.
- If siphoning mechanism is faulty, drain left tank lobe sepa-
rately by removing sender cover and pumping fuel directly
out of left lobe.