Obd BMW 540i 1998 E39 Workshop Manual

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YOU are now in Volume I
I
Foreword ................... .. ........................................................................\
.......... v
Index
........................ .. ................................................................ rear of manual
General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder
Maintenance OiO 020 Maintenance
Engine
100 Engine-General 110 Engine Removal and Installation
113 Cylinder Head Removal and
Installation
116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain
119 Lubrication System
200 Transmission-General
2 Transmission 210 clutch 230 ManualTransmission
I20 Ignition System
121 Battery, Starter, Alternator
130 Fuel Injection
160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System
180 Exhaust System
240 Automatic Transmission
250 Gearshift Linkage 260 Driveshaft
Suspension, 300 Suspension, Steering and 330 Rear Suspension
Brakes-General 331 Final Drive
Steering and No Front Suspension 340 Brakes
320 Steering and Wheel Alignment
400 Body-General
410 Fenders, Engine Hood 411 Doors
412 Trunk Lid, Tailgate
510 Exterior Trim, Bumpers 512 Door Windows
Equipment 513 Interior Trim
7
Equipment and 720 seat Belts
Accessories 721 Airbag System (SRS)
OBD On-Board Diagnostics
. ............ ..
515 Central Lociting and
Anti-Theft
520 Seats 540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rear of manual
Electrical
6 system
600 Electrical System-General 620 Instruments
610 Electrical Comoonent Locations 630 Liohts
611 wipers and washers 612 Switches eati in^ and Air Conditioning
Radio
. ........... ........ .........................
Electrical Wiring Diagrams

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I General Warnings and Cautions
WARNINGS (continued)
. The air conditioning system is filled with chemical refrigerant,
which is hazardous. The AIC system should be serviced only by
trained technicians using approved refrigerant recoverylrecycling
equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
. Do not expose any part of the AIC system to high temperatures
such as open flame. Excessive heat will increase system pres-
sure and may cause the system to burst.
Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away
from the tire repair area. Inflate and deflate the
tire at least four
times before breaking the bead from the rim.
Completely remove the tire from the rim before attempting any re-
pair.
Cars covered by this manual are equipped with a supplemental
restraint system (SRS), that automatically deploys
airbags and
pyrotechnic seat belt tensioners
In the event oi a frontal or side
impact. These are explosive devices. Handled improperly or with-
out adequate safeguards, they can be accidently activated and
cause serious injury.
- The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals and use extreme care when
working on a car with the engine running or the ignition switched
on.
. Place jack stands only at locations specified by the manufacturer.
The vehicle
illtino iack su~olied with the vehicle is intended fortire -. , . changes only. A heavy duty floor jack should be used lo lift vehicle
before installing
jacl( stands. See 010 General.
- Battery acid (electrolyte) can cause severe burns. Flush contact
area
with water, seek medical attention.
Aerosol cleaners and solvents may contain hazardous or deadly
vapors and are highly flammable. Use only in a well ventilated ar-
ea. Do not use on hot surfaces (engines, brakes, etc.).
Do not remove
coolant reservoir or radiator cap with the engine
hot. Danger of burns and engine damage.
CAUTIONS-
See also WARNINGS
- if you lack the slqills, tools and equipment, or a suitable worl(shop
for any procedure described in this manual, leave such repairs to
an authorized BMW dealer or other qualified shop.
BMW is constantly improving its cars and sometimes these
changes, both in parts and specifications, are made applicable to
earlier models. Therefore, part numbers listed in this manual are
for reference only. Always check with your authorized BMW deal-
er parts department for the latest information.
Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read ail the instructions thorough-
ly, and do not attempt shortcuts. Use tools appropriate to the
work and use only replacement parts meeting BMW specifica-
tions.
Use pneumatic and electric tools only to loosen threaded parts
and fasteners. Never use these tools to tighten fasteners, espe-
cially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque specification listed.
Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the
oil. Do not
pour
oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of waste in accordance with Federal, State and
Local laws.
The control module for the anti-lock brake system
(ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp
in excess of 203" F (95°C) and should not be subjected to tem-
peratures in excess of 185°F
(8S°C) for more than two hours.
- Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative
(-) terminal (ground strap) and
the ABS control module connector.
- Always make sure ignition is off before disconnecting battery.
Label battery cables before disconnecting. On some models, bat-
tery cables are not color coded.
Disconnecting the battery may erase fault code@) stored in control
module memory. Using special BMW diagnoslic equipment, check
lor
iauit codes prior to disconnecting the battery cables. If the mal-
I.mct on ndicator Ignt (MIL) s I. ..minaled. see OBD On-Board
Diaanostics
Tl11s iant is iuenlfted as lne Check Ena~ne oht
(1997-2000 models jor~ervlce Engine Soon light (2061 andlater
models). If any other system iaults have been detected (indicated
by an illuminated warning light), see an authorized BMW dealer.
If a normal
or rapid charger is used to charge battery, the battery
must be disconnected and removed from the vehicle in order to
avoid damaging the vehicle.
- Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the
battery a second time.
* Connect and disconnect a battery charger only with the battery
charger switched off.
- Sealed or "maintenance free" batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the bat-
tery's ampere-hour (Ah)
rating.
. Do not allow battery charging voltage to exceed 16.5 volts. If the
battery begins producing gas or boiling violently, reduce the
charging rate.
Boosting a sulfated battery at a high charging rate
can cause an explosion.

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01 0-2
General
This section is intended to help the do-it-yourselfer get start-
ed. Tips on workshop practices, basic tools, and a quick refer-
ence guide to emergencies can be found here.
WARNING-
Do not use this manual unless you are familiar with basic
automotive repair procedures and safe workshop
practices.
0 This manual illustrates the worl quired for most service work; it is not a substitute for full
and up-to-date information from the vehicle manufac-
turer or for proper training as an automotive technician.
Note that it is not possible to anticipate all of the ways
or conditions under which vehicles may be serviced or
to provide cautions as to all of the possible hazards that
may result.
MOW TO USE THIS MANUAL
WARNING -
Your common sense and goodjudgement are crucial to safe
and successful service
work. Read procedures through be-
fore starting them. Think about whether the condition of your
cac your level of mechanical skill, or pour level of reading
comprehension might result in or contribute in some way to
an occurrence that might cause you injury, damage your car;
or result in an unsafe repair. If you have doubts for these or
other reasons about your ability to perform safe repair work
on your car; have the work done at an authorized
BMW deal-
er or other qualified shop.
The manual is divided into ten sections:
0 GENERAL, MAINTENANCE
0 I ENGINE
2 TRANSMISSION
3 SUSPENSION, STEERING AND BRAKES
4 BODY
5 BODY EQUIPMENT
6 ELECTRICAL SYSTEM
7 EQUIPMENT AND ACCESSORIES
- ELE ELECTRICAL WIRING DIAGRAMS
OBD ON-BOARD DIAGNOSTICS

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General
0 GENERAL, MAINTENANCE covers general vehicle infor-
mation
(010 General) as well as the recommended mainte-
nance schedules and service procedures to perform BMW
scheduled maintenance
work (020 Maintenance).
The next seven sections
(1 through 7) are repair based and
organized by three digit repair groups. Most major sections
begin with a GENERAL repair group,
e.g. 100 Engine-Gen-
eral. These "00 (double zero) groups contain descriptive the-
ory of operation and system troubleshooting information. The
remainder of the repair groups within a section contain the
service and repair information. The last two sections contain
detailed electrical wiring schematics and OBD
II scan tool and
diagnostic information.
Warnings, cautions and notes
Throughout this manual are many passages with the head-
ings WARNING, CAUTION, or NOTE. These very important
headings have different meanings.
WARNING-
The text under this heading warns of unsafe practices that
are very
likely to cause injury, either by direct threat to the per-
son(~) performing the work
orby increasedrisl( of accident or
mechanical failure while
drivinq.
CAUTION-
A CAUTION calls attention to importantprecautions to be ob-
senfed during the repair work that will help prevent acciden-
tally damaging the car or its parts.
NOTE-
A NOTE contains helpful information, tips that will help in do-
ing a betterjob and completing it more easily.
Please read every WARNING, CAUTION, AND NOTE in
001
General Warnings and Cautions and as they appear in re-
pair procedures. They are very important. Read them before
you begin any maintenance or repair job.

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General
Cars with discharged or dead batteries can be jump-started
using the good battery from another car. See owner's manual
for proper instruction on jump starting. When jump-starling
the engine, always note the following warnings.
4 Lower car. With all wheels on ground, fully tighten nuts in a
WARNING-
* Battery acid (electrolyte) can cause severe burns, and will
damage the
cal; clothing, and you. If electrolyte is spilled,
wash the surface with large quantities of water.
M itgets into
eyes, flush them with water for several minutes and call a
doctor.
B4
5
43
2 BOOIFNG.
Batteries produce explosive and noxious gasses.
Keeps sparks and flames away. Do not smoke near
batteries.
Do notjump-start the engine
ifyou suspect that the bat-
tery is frozen. Trappedgas may explode. Allow the bat-
tery to thaw first.
Do not quick-charge the battery (for boost starting) for
longer than one minute, and do not exceed
16.5 volts
at the battery with the boosting cables attached. Wait at
least one minute before boosting the battery a second
time.
crisscross pattern.
Torque wheel nuts when installing wheel.
Check inflation pressure of spare tire.
Tightening torque
Wheel to wheel hub 120 Nm (89 ft-ib)
Jump starting
Indicator and warning lights
Many vehicle systems are self-monitored for faults while driv-
ing. Generally,
a red warning lamp that comes on during driv-
ing should be considered serious. If you cannot immediately
determine the seriousness of the warning light, stop the vehi-
cle in a safe place and turn the engine off as soon as possible.
Consult the owner's manual for additional information on the
warning lamp and the recommended action.
If the Malfunction Indicator Lamp (MIL)
(Check Engine or Ser-
vice Engine Soon warning light) comes on orflashes, it indi-
cates that an emissions-related fault has occurred. Faults
such as a bad oxygen sensor or a dead fuel injector can
cause the exhaust or evaporative emissions to exceed a
specified limit. When these limits are exceeded, the MIL will
be turned on. The engine can be safety driven with the light
on, although the emission systems should be
checked as
soon as possible. See OBD On-Board Diagnostics for

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Table b. Inspection I Service (continued)
Checlt transmission and differential for
external lealts.
Check CV joint boots for damage or leaks.
Visually
check fuel tank, fuel lines, and
connections for
leaks.
New parts
Tools Required required
Check condition, position, and mounting
ol
exhaust system. Visually check and adjusl
if necessary.
Check power steering system for lealts.
Check power steering
fluid level and adjust
if necessary.
Check steering racidbox and tie rods for
tightness. Checit condition of front axle
joints, steering
linkage, and steering shaft
joints.
Check overall thickness of front and rear
bralte pads using
BMW special tool. If
replacement is necessary:
Examine brake disc surface.
Clean brake pad contact points in calipers
Grease wheel centering hubs.
Checlt thickness of parking brake linings
only when replacing rear brake shoes.
Checit operation of pariting brake and
adjust as necessary.
Checlt front control arm bushings for
damage or wear.
Check brake system connections and
lines
for leaks, damage, and incorrect
positioning Warm
engine
(~ealer service Irepair , required recommended lnformat~on
Check parking braite actuator. Adjust if
necessary
Check ail tire pressure (including spare)
and correct if necessary.
Checlt condition of tires (outer tread
surface), tread wear pattern: in case of
uneven wear, perform wheel alignment.
inspect entire body according to terms of
rust oerforation limited warrantv. (Must be
*:
4:
2 ~ perfdrmed at least every two years). I
Read out on-board diagnostic (OBD 11) fault
codes.
Checkengine coolant
system1 heater hose
connections for
leaks.
Checit coolant level and antifreeze
protection level. Add coolant as necessary.
* 100113010BD
I
170

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Maintenance
< Remove NC compressor belt:
Loosen tensioner mounting fasteners (arrows)
Swing tensioner down to remove belt.
4 To reinstall compressor belt:
Route belt over pulleys.
* Pretension belt by turning adjuster clockwise (arrow) to
stop.
- Tighten tensioner mounting bolts (A).
Tightening torques
Fan clutch to coolant pump (left- hand thread)
with BMW tool
11 5 040
30 Nm (22 ft-lb)
without BMW tool 11 5 040
40 Nm (29 ft-lb)
Tensioner to engine block
8.8 grade
22 Nm (16 ft-lb)
10.9 grade (Ilquid-cooled alternator) 30 Nm (22 ft-lb)
Idle speed
Engine idle speed can change due to a number of factors, in-
cluding normal wear. The idle speed is electronically adaptive
and not adjustable. See
130 Fuel Injection for more informa-
tion.
Catalytic converter and oxygen sensors
OBD II enhanced emission standards require the engine
control module (ECM) to monitor the oxygen content in the
exhaust with oxygen sensors placed before and after the cat-
alytic converter. This allows for tighter control of tail pipe
emissions and also allows the ECM to diagnose converter
problems. If the ECM detects that catalytic converter or oxy-
gen sensor efficiency has degraded past a certain
prepro-
grammed limit, it will turn on the malfunction indicator light
(MIL), and store a diagnostic trouble code (DTC) in the ECM.
See OBD On-Board Diagnostics for more information on
OBD
ll systems.
Replacement of oxygen sensors at the specified intervals
he engine and emission control system will

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100-4
I Engine-General
The M62 90" V8 engine uses four valves per cylinder, double
overhead camshafts and light alloy cylinder head and cylin-
der
bloclc engine construction.
On 1997 and 1998 540i models, Bosch engine management
systems are utilized. Table a lists engine management sys-
tem applications.
4 For the 1999 model year, the M62 TU VANOS engine was in-
troduced to the 540i models. This engine is primarily a carry-
over from the earlier M62 engine, but contains many unique
identifying components and technology:
Variable camshaft timing (VANOS) for the intake valves.
Bosch ME 7.2 engine management system with electronic
throttle control. There is no accelerator cable connecting
the throttle pedal to the throttle housing in these cars.
Compact water-cooled generator (alternator).
E39 vehicles are equipped with sophisticated self-diagnostic
engine management systems. These systems monitor and
store diagnostic fault information. If the malfunction indicator
lamp (MIL) illuminates, the first diagnostic test should be to
connect a dedicated scan tool for BMW automobiles and in-
terrogate the fault memory.
If the malfunction indicator light (MIL) comes on orflashes, it
indicates that an emissions-related fault has occurred and
that fault information is stored in memory within the ECM.
4 The MIL in E39 cars displays one of these warning graphics
in the instrument cluster.
The diagnostic capabilities of these systems have the poten-
tial to save hours of diagnostic time and prevent incorrect
5 placement. See OBD On-Board Diagnostics.

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110-3
Engine Removal and lnstallationl
Q Fuel line plugs
(Tool No.
BMW 13 5 281 / 13 5 282)
4 Fuel line removal tool
(Tool No.
BMW 16 1 050)
CAUTION-
Disconnecting the battery may erase fault code@) storedin
memoiy Check for fault codes prior to disconnecting the
battery cables.
If the MIL (Malfunction Indicator Light, also may be
called "Check Engine" or "Service Engine Soon" light)
is illuminated, see
OBD On-Board Diagnostics for
DME fault code information.
It orhersysrem faults have been detected, as indicated I
by an ~llum~nated ABS, SRS orASC/DSC ~arning light,
see the appropriate repair group in this manual or an
authorized BMW dealer for more information on fault
codes.
NOTE- Engine removal procedures are similar for all 6-cylinder
models. When differences
exist, they are noted at the be-
ginning of each step. Engine are referred to by engine
code. See
100 Engine-General for engine code and appli-
cation information.
@ Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse
gaskets, O-rings or seals during reassembly.
The
intake manifold must be removed on &cylinder mod-
els before the engine can be removed.
WARNING-
Due to risk of personal injury, be sure the engine is cold be-
fore beginning the removal procedure.

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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.