warning BMW 540i 1998 E39 Repair Manual

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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.

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< 6-cylinder models: Remove intake manifold to access oil
pressure switch
(arrow).
V-8 models: Oil pressure warning switch (arrow) is located
under oil filter housing mounted to left inner fender panel.
NOTE-
Any time the oilpressure warning switch is removed, be sure
to replace the sealing washer.
Tightening torque Oil
~ressure switch to oil filter housins 27 Nrn (20 ft-lb)
Oil level warning switch, replacing
(6-cylinder and
V-8)
4 Oil level warning switch is located at bottom of the engine oil
pan.
Drain engine oil before attempting to remove level warning
switch.
Be sure to refill engine and check for leaks after work is
completed.
NOTE-
Any time the oil level warning switch is removed, be sure to
replace the sealing O-ring between switch and oil pan.

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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)

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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

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120 lgnition System
...................... General
Special tools ...................
Warnings and cautions ...........
Engine management .............
................. lgnition system
Ignition system. troubleshooting
....
... Oscilloscope diagnostic diagrams
................ Misfire detection
............. Ignition System Service 120-9
.................... Ignition firing order 120-9
.............. Disabling ignition system 120-10
................... Checking for spark 120-1 0
lgnition coil assembly.
................. testing and replacing 120-1 0
.............. Crankshaftspeedsensor 120-12
............. Camshaft position sensors 120-1 4
...................... Knocksensors 120-16

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120-3
Ignition System
Warnings and cautions
The ignition system produces dangerous high voltage. In ad-
dition the sensitive electronic components can be damaged
if
proper precautions are not adhered to.
WARNING-
* Do not touch or disconnect any cables from the coils while
the engine is running or being
cranked by the starter.
The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when working on a car with the ignition
switched on or the engine running.
- Connect and disconnect tlie DME system wiring and
test equipment leads only when the ignition is
OFF:
Before operating the starter without starting the engine
(for example when
making a compression test) always
disable the ignition.
CA
U TIOW-
Do not attempt to disable the ignition by removing the coils
from the spark plugs.
Connect or disconnect ignition system wires, multiple
wire connectors, and ignition test equipment leads only
while the ignition is
off Switch multimeter functions or
measurement ranges only with the test probes discon-
nected.
* Do not disconnect the battery while the engine is run-
ning.
A high impedance digital multimeter should be used for
all voltage and resistance tests. An LED test light
should be used in place of an incandescent-type test
lamp.
In general, make test connections only as specified by
BMW as described in this manual, or as described by
the instrument manufacturer.
Engine management
BMW €39 engines use an advanced engine management
system known as Digital Motor Electronics (DME). DME in-
corporates on-board diagnostics, fuel injection, ignition and
other engine control functions. DME variants are listed in
Table a. Engine management systems.
Second generation On-Board Diagnostics
(OED II) is incor-
porated into the engine management systems used on the
cars covered by this manual. Use a BMW-specific electronic
scan tool, or a "Generic"
OED II scan tool to access Diagnos-
tic Trouble Codes (DTCs). DTCs can help pinpoint ignition
ine management problems.

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Lnition switch
4 The positive (+) power supply to the ignition coils comes to
the ignition switch via an unloader relay. When the ignition
switch is turned on, the relay closes, to provide voltage to the
ignition coils. The coils are then actuated at the negative side
by the engine control module.
NOTE-
Schematic diagrams shown are for illustrative purposes only.
See ELE Electrical Wiring Diagrams for engine manage-
ment specific wiring information.
WARNING- Do not touch or disconnect any cables from the coils while
the engine is running or being cranked by the starter:
The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when
working on a car with the ignition
switched on or the engine running.
* Connect and disconnect the DME system wiring and
test equipment leads only when the ignition is
OFF
Before operating the starter without starting the engine
(for example when
making a compression test), always
disable the ignition.
4 Knock sensors (arrows) monitor the combustion chamber for
engine-damaging knock. Six-cylinder models (shown) use
two sensors with each sensor monitoring three cylinders.
V-
8 models use four sensors, each monitoring two cylinders. If
engine
knock is detected, the ignition point is retarded by the
ECM.
I Ignition advance Ignition timing is electronically mapped and not adjustable.
The ECM uses engine load, engine speed, coolant tempera-
ture, knock detection, and intake air temperature as the basic
inputs for timing control.
A three dimensional map similar to
the one shown is digitally stored in the ECM.
- The initial ignition point is determined by the crankshaft
speed sensor during cranking. Once the engine is running.
timing is continually adjusted based on operating conditions.

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120-6
lgnition System
lgnition system, troubleshooting
Troubleshooting ignition system faults should begin with an
interrogation of the On-Board Diagnostics (OBD
II) system.
The OBD
II system detects ignition system misfire and other
related faults. When faults are detected, the OBD
II system
stores a Diagnostic Trouble Code (DTC) in the Engine Con-
trol Module (ECM) along with other pertinent fault information.
4 In addition, the Malfunction Indicator Light (MIL) will come on
if an emissions related fault is detected. Additional OBD
II in-
formation, including a DTC lookup table, can be found in
OED On-Board Diagnostics.
NOTE-
BMWmodels covered in this manual were equipped with one
of three versions of
MIL warning lights (as shown).
Misfire detection
Engine m~sfire in one or more cylinders, may be caused by a
var~ety of malfunctions in various subsystems. The OBD II
system ~ncorporated into the engine management systems is
des~gned to detect and warn of misfire faults during englne
operat~on. See OED On Board Diagnostics.
WARNING -
lgnition misfires can cause high hydrocarbon exhaust emis-
sions andcatalytic converter damage. For this reason, if a se-
vere misfire is detected, the fuel injector
will be turned off to
the specific cylinder and the
MIL will be illuminated. A misfire
may also produce an overheated catalytic converter, which
can be a fire hazard.
Oscilloscope diagnostic diagrams
One way to diagnose a faulty coil is to use an oscilloscope to
analyze spark quality with the engine running.
See Table b. lgnition secondary voltage diagnostics for
list of common ignition
coil voltage faults and related causes.

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120-1 2
ignition System
Crankshaftspeedsensor
Crankshaft speed sensor, replacing (M52, M52 TU and
M54 engines)
4 Crankshaft speed sensor for 6-cylinder engine is mounted in
the left rear side of the cylinder block below the starter (ar-
row). The sensor reads a toothed pulse wheel mounted to
the end of the crankshaft.
- if the Engine Control Module (ECM) does not receive a signal
from the crankshaft speed sensor during cranking, the en-
gine will not start.
- If the OBD II svstem misfire detection ~rotocol detects a cat- - - ~~
alysr oarnagin; faLlt oJe to a ma I-nclion in crandshafi speeo
sensor components. Ine Check Engine
lignr (Malfuncrion In-
dicator Light or MIL) will be illuminated.
NOTE-
If the crankshaft speed sensor pulse wheel is damaged, the
engine will have to be disassembled down to the crankshaft
to
reolace the wheel.
- Make certain ignition has been turned off.
- Raise car and support in a safe manner.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjacltstands designed for
the ouroose.
A floor iaclc is not adequate support.
- Remove under engine splash guard
4 Working underneath starter:
Cut off wire tie securing crankshaft speed sensor harness
connector (arrow) to sensor.
* Disconnect harness connector.
4 Remove sensor mounting fastener (arrow) and remove sen-
sor from cylinder block.
- Installation is reverse of removal, noting the following:
Use a new O-ring when installing sensor.
Be sure wiring is routed in same orientation.
Secure sensor using new wire ties.
Use scan tool to read out and clear ECM fault memory.

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121-1
121 Battery. Starter. Alternator
General ........................... .I2 1.2
Special tools ........................ .I2 1.2
Engine electrical system ............... .I2 1.2
Battery Safety Terminal ............... .I2 1.3
Warnings and cautions ................. 121 -4
Battery ............................ 121-5
Battery testing ...................... .I2 1.5
Hydrometer testing ................... .I2 1.5
Battery open-circuit voltage test ......... .I2 1.6
Battery load voltage test ................ 121 -6
Closed-circuit current measurement ..... .I2 1.7
Battery charging ...................... 121 -9
Battery safety terminal, replacing ......... 121-9
Alternator (generator) ............. .I2 1.10
Alternator. basic .................... .I2 1.11
Alternator with multi-function
control (MFR)
...................... .I2 1.11
Water-cooled alternator ............... 121 -12
Charging System Troubleshooting . 121-12
Charging system quick-check .......... 121-13
Charging system. checking ............ 121-13
Alternator. removing and installing
(6-cylinder engine)
.................. 121 -1 5
Alternator. removing and installing
(M62 engine. air cooled)
.............. 121-16
Alternator. removing and installing
(M62 TU engine. water cooled) ......... 121-1 8
Starter ........................... 121 -1 9
Starter troubleshooting ............... 121 -1 9
Starter. removing and installing
(6-cylinder engine)
.................. 121-20
Starter. removing and installing
(V-8 engine)
........................ 121 -21
Solenoid switch. removing and installing . . 121-23