check oil BMW 540i 1998 E39 Manual PDF

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.-- -
/ Fuel Tank and Fuel Pump - .. -. -- 1
Fuel pump fuse and relay
Troubleshooting of any fuel pump fault should begin with
checking the fuel pump fuse and the fuel pump relay. The
DME main relay should also be checked. The fuel pump relay
is located behind right side luggage compartment interior
panel.
I Fuel pump relay
BLU =blue ERN = blo$,m GRN =groan GRY = grsy ORG =orange PNI< =pink RED =red VIO =violel WHT = wlilte
rk-; I I 1 ECM
I I I 31 8 ,._--___.I
NOTE-
Special tools are required for some of the tests described
here.
4 Fuel pump circu~t is fuse-protected.
0 6-cylinder models with Siemens DME MS41 .I, MS42, V-8
models with Bosch DME M5.2, M5.2.1 englne manage-
ment: Fuse
F54,15A (luggage compartment fuse panel)
6-cylinder models with Siemens DME MS43 engine man-
agement: Fuse
F22,25A (glove compartment fuse panel)
V-8 models with Bosch DME M7.2: Fuse F54,25A (lug-
gage compartment fuse panel)
- Fuse 31 in glove compartment fuse panel supplies power to
coil side of fuel pump relay. Engine control module (ECM)
supplies switched ground to relay. During starting, fuel pump
runs as long as ignition switch is in START position and con-
tinues to run once engine starts. If electrical system fault in-
terrupts power to fuel pump, engine will not run.
. .
Operating fuel pump for tests
- To operate fuel pump for testing purposes without having to
run engine, bypass fuel pump relay to power pump directly.
< To run fuel pump, open luggage compartment and release
right side trim panel.

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Warnings and cautions
Obse~e the following warnings and cautions when worlting
on the cooling system.
WARNING -
. At normal operating temperature the cooling system is
pressurized. Allow the system to cool as long as possible
before opening (a minimum of one hour), then release the
cap slowly to allow safe release ofpressure.
a Releasing the coolant system pressure lowers the cool-
ant boilingpoint and the coolant may boil suddenly. Use
1 heavy and wear eye and face protection to
guard against scalding.
Use extreme care when draining and disposing of en-
gine coolant. Coolant is poisonous and lethal to hu-
mans andpets. Pets are attracted to coolant because
of its sweet smell and taste. Seek medical attention im-
mediately if coolant is ingested.
CAUTIOG
Avoid adding cold water to the coolant while the engine is
hot or overheated. If it is necessary to add coolant to a
hol
system, do so only with the engine running and coolanl
pump turning.
To avoid excess silicate gel precipitation in the cooling
system and loss of cooling capacity, use BMW coolant
or equivalent low silicate antifreeze.
a If oil enters the cooling system, the radiator, expansion
tank and heating circuit must be flushed with cleaning
agent. BMW recommends removal of the radiator and
expansion
tank to flush.
When
worlcing on the cooling system, cover the alter-
nator to protect it against coolant drips.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in
001 General Warnings
and Cautions.
Begin the diagnosis of cooling system problems with a thor-
ough visual inspection.
If no visual faults are found, it is rec-
ommend that the engine control module (ECM) fault memory
be checked for stored diagnostic trouble codes
(DTCs) using
BMW scan tool
DlSplus or equivalent.

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170-8
I Radiator and Cooling System
Common cooling system faults can be grouped into one of 4
categories:
Cooling system
lealts
Poor coolant circulation
Radiator cooling fan faults
Electrical/electronic faults
Cooling system inspection
- Check that coolant pump drive belt tensioner is functioning
properly and that belt tension is correct. Belt tensioner sys-
tems for the different models are shown in
020 Maintenance.
- Check condition of coolant pump drive belt.
- Checlc coolant hoses for cracks or softness. Checlc clamps
for looseness. Check coolant level and check for evidence of
coolant
lealts from engine.
- Check that radiator fins are not blocked with dirt or debris.
Clean radiator using low-pressure water or compressed air.
Blow outward, from engine side out.
- To check coolant pump:
Remove mechanical cooling fan. See Mechanical
(vis.
cous clutch) cooling fan, removing and installing.
Remove drive belt from coolant pump pulley. See
020
Maintenance.
Firmly grasp opposite sides of pulley and check for play in
all directions.
Spin pulley and check that shaft runs smoothly without
play.
NOTE-
The coolant provides lubrication for the pump shaft, so an oc-
casional drop of coolant
lealing from the pump is acceptable.
If coolant drips steadily from the vent hole, replace the pump.
- At normal engine operating temperature, cooling system is
pressurized. This raises boiling point of coolant.
Leaks may
prevent system from becoming pressurized. If visual evi-
dence is inconclusive, pressure test cooling system as de-
scribed later to help pinpoint hard-to-find leaks.
- If cooling system is full of coolant and holds pressure:
- Use an appropriate scan tool to interrogate engine control
module (ECM) for radiator fan or DME control circuit faults.
Checlc for loose or worn drive belt.
0 Test for failed thermostat or coolant pump impeller. Some
pumps may be fitted with plastic impellers.

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- Raise and safely support vehicle
WARNING-
Make sure the car is stable and well supporied at all times.
Use a professional automotive /iff orjack stands designed for
the
ournose. A floor jack is not adeouate suooort.
- If necessary, remove transmission splash shield.
- Disconnect fluid line from slave cylinder on lefl side of trans-
mission. Place pan under hose to catch dripping fluid.
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder.
- Installation is reverse of removal, noting the following:
Check for wear on slave cylinder. Any wear except on tip is
caused by misalignment of clutch components.
Lightly coat
pushrod tip with molybdenum disulfide grease
(MolyltoteIB Longterm or equivalent).
. During installation be sure pushrod tip engages recess in
clutch release lever.
Fill fluid reservoir with clean fluid.
. Bleed clutch hydraulics as described earlier.
Tightening
toraues - -.
Clutch slave cylinder to transmission 22 Nm (16 R-lb)
Fluid line to slave cylinder 17 Nm (13 ft-lb)
The transmission must be removed from the engine to access
the clutch mechanical components. It is recommended that
the clutch disc, pressure plate and release bearing be re-
placed during a clutch overhaul.
Besure tocheck the bottom of the bellhousing foroil. If engine
oil is found, check for a faulty rear crankshaft main oil seal.
See
119 Lubrication for rear main seal replacement.
Clutch variations
Two versions of the clutch are used:
1997 528i (6 cylinder) uses traditional clutch components.
All
540i (V-8) and 1998 and later 6 cylinder models from
use a self-adjusting clutch (SAC).

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210-1 4
1 Clutch
Dowel sleeve I
Check flywheel location
and correct installation. dowel sleeve
(arrow)
for . damage
< When installing dual-rnass flywheel, position dowel sleeve
next to two locating notches (arrows).
- Lightly oil flywheel mounting bolt threads and torque to
specification.
Tightening torque
Flywheel to crankshaft 105 Nm (77 ft-lb)
CAUTIOI\C
Do not reinstall flywheel bolls with LoctiteCTJ or similar thread
locl~ing compound.
- Install transm~ssion as descr~bed in 230 Manual Transmis-
sion.
4 If flywheel was replaced, check pulse sensor (arrow) for cor.
rect installation depth.
- Remove pulse sensor.

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230-6
Manual Transmission
Manual transmissions installed in the 5 Series are normally
filled with a "Lifetime" manual transmission fluid
(BMW MTF
LT-I) and do not require periodic fluid changes. Transmis-
sions filled with MTF LT-I lifetime oil are identified with a yel-
low label near the transmission fill plug labeled "Lifetime Oil
MTF-LT-1".
Transmission fluid level, checking
- Drive vehicle for a few miles to warm transmission.
- Raise and safely support vehicle to access transmission
filler plug.
CAUTION-
Make sure the car is stable and well supporfedat all times.
4 Remove side filler plug (B). Insert finger into hole to check
fluid level. If fluid level is up to bottom of filler hole (finger is
wetted by transmission fluid), level is correct.
NOTE-
* Check and fill transmission with car on level surface.
5-speed transmission shown in illustration. 6-speed trans-
mission is similar.
- Install and torque filler plug.
Tightening torque
Transmission drain or fill
plug
to transmission case SO Nm (37 it-lb)
Transmission fluid, replacing
- Drive vehicle for a few miles to warm transmission.
- Raise and safely support vehicle to access drain plug.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed
for the purpose.
A floor jack is not adequate support.
Check that the
fill plug is not seizedprior to draining
transmission fluid.

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230-9
Manual ~ransmissionl
Carefully pry out selector shaft oil seal with BMW special tool
23
0 210, or with a narrow seal remover or small screwdriver.
Coat new selector shaft seal with transmission fluid. Drive
new seal in flush with housing. Use
BMW special seal instal-
lation tool
23 0 220 or equivalent and a soft-faced (plastic)
hammer.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new
loclc nuts.
Check transmission oil level, topping up as necessary.
Tightening torques Aluminum driveshaft to flex-disc
. MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft CV joint to final drive flange
MI 0 (Torx bolt) 70
Nm (51 ft-lb)
M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
MI0 (8.8 grade) 48 Nm (35 ft-lb)
MI0 (10.9 grade) 60
Nm (44 it-lb)
MI2 (8.8 grade) 81
Nm (60 ft-lb)
MI2 (10.9 grade) lo0 Nm (74 ft-lb)
- MI4 140 Nm (103 ft-lb)
Transmission crossmember
to transmission (ME) 21 Nm (15 ft-lb)
. to chassis (M10) 42 Nm (30 ft-lb)

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240-6
I Automatic Transmission Automatic transmission fluid (ATF)
The E39 automatic transmission is filled with either Dexron Ill
ATF or Texaco 80728, a life time oil.
CA UTIOI\C
Use only the transmission fluid that is approved for use by
BMW All other fluids will cause non warrantable transmis-
I sion damage.
Mixing different types of transmission fluids will lead to
transmission failure.
NOTE-
The type of transmission lubricant used can be found on a
stickeron the transmission pan. Dexron
111ATF (blacksticker)
reads "ATF-Oil': Special life time oil (green sticker) reads
'Life-Time Oil': If in doubt, consult an authorized
BMW dealer
for alternate fluid use and current information regarding
transmission operating fluids.
ATF level, checking
Check ATF level if there is evidence of a leak, a complaint re-
lated to fluid level or afler transmission repairs.
The automatic transmission is not equipped with a dipstick.
Checking the ATF level requires that the transmission be at
operating temperature during the checking procedure.
NOTE-
Vehicle must be level throughout tests
- Drive vehicle to warm up ATF to operating temperature.
- Connect BMW diagnostic scan tool DiSplus, MoDiC, GTI or
equivalent to determine transmission oil temperature.
ATF level checking
Fluid temperature
30' - 50°C (85' - 120" F)
- With engine running, switch on air conditioning to increase
engine idle speed.
- Apply parking brake.
- While applying foot brake firmly move gear shift selector
lever through
all gear positions, pausing in each gear briefly.

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240-1 3
Automatic ~ransmissionl
- Blow out oil cooler lines with low-pressure compressed air
and flush cooler with clean ATF twice before reattaching lines
to transmission.
CA UTIOG
Wear safety glasses when worling with compressed air:
@ Do not reuse ATF used for flushing.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Reinstall driveshafl using new nuts.
Install new sealing washers on transmission cooling line
banjo bolts.
Install new O-rings on transmission cooler lines, where
applicable.
Inspect engine drive plate (flywheel) for cracks or elongat-
ed holes. Replace
if necessary.
Be sure bellhousing alignment dowel sleeves are located
correctly. Replace damaged sleeves.
Checlc to be sure torque converter is seated correctly in
transmission during final installation.
Use
BMW special tool 24 2 300 to align three mounting
tabs on torque converter with indentations on drive plate
(flywheel).
Fill transmission with clean ATF until oil level is even with
fill hole. Then check fluid level as described earlier.
Adjust gearshift mechanism. See
250 Gearshift Linkage.
NOTE-
In order to avoid difficulties in transmission removal at a fu-
ture time, use washers with Torx-head mounting bolts.

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31 0-1 0
Front Suspension
4 Clamp spring compressor (BMW special tool 31 3 340 or
equivalent) in shop vise.
WARNING-
* Do not attempt to disassemble the strut assembly without
a spring compressor designed specifically for this job.
Prior to each use,
checlc special tool for functionality.
Do not use a damaged tool.
Do not make any modifications to tool. Use correct size spring retainers when compressing
coil spring.
I When assembling BMW spring compressor (special
tool
31 3 340), make sure spring retainerplates are felt
and heard snapping into place. Check seating of spring
retainers carefully.
Position coil spring between spring holders so that
3 coils lie
between spring holders
(arrows). Compress spring.
WARNING -
When tensioned, the spring coils must rest completely in
the spring holder recess.
Never tighten or loosen spring compressor with an im-
pact tool.
Only tighten down the coil springs until stress on the
thrust bearing is relieved.
a Only loosen strut nut if spring coils are completely in-
serted in the spring holder grooves. If
necessarx loos-
en compressor, reposition and recompress.
Use
BMW special tool 31 2 21 0 or equivalent to remove strut
nut. Counterhold strut shaft using
6 mm Allen wrench.
CAUTION-
Do not remove strut nut with impact tool.
Remove upper strut bearing and related components.
If a new coil spring is being installed, relieve tension on
spring compressor and remove coil spring.
Check strut dust boot, rubber stop and spring pads. Replace
as necessary.
Replace strut, upper strut mount or spring, as needed