IKE BMW 540i 1999 E39 User Guide

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Fuel Injection
Table e. Bosch 5.2.1 ECM pin assignments
Pin
I~iqnal 1 Description 1 Note
I I I
46 llnput ICrankshaft position sensor Icrankshaft positionlrpm sensor
38
39
40
41
42
43
44
45 Ground Input
Output
Output
Output
Output
Ground
47
48
49
50
51
Not used
I Not used
52
Shield, knock sensor
Oil level
- thermal
Injection signal
injection signal
Idle speed control - opening winding
Idle speed control - closing winding
Not used
Ground
Ground
-- Ground Input
Ground
Ground Not used Knock sensor
Oil level sensor
Cylinder
4 fuel injector
valve
Cylinder
1 fuel injector valve
Idle speed control valve
Idle speed control valve
Shield, crankshaft sensor
5
6
7
12 Not used
Ground
Intake air temperature sensor
Connector
X60004
8
9 10
11
14 1 1 Not used I
Shield, knock sensor
Shield, sensor
I
Shield, sensor 3
Shield, itnock sensor
Input
- Knoclc sensor
Knock sensor
Knock sensor
Knock sensor
Instrument cluster
Output
2 llnput l~erminal 30 voltage supply /Megrated instrument cluster control module (IKE)
Alt. charge indicator signal, terminal 61 1
Not used
Start signal terminal
50
Not used
15
16
17
18
Output
Ignition switch
Not used
Not used
Activation of relay for fuel pump
Not used
19
Fuel pump relay
Output Not used
I I I 20 loutput ICARB signal /Data link connector
Not
used
Not used
Engine speed signal output (TD)
Not used
Light module
21
Cruise control module (Tempomat)
22 llnput I Right rear wheel speed signal /ABS/ASC or ABSIDSC control module
Oulput
Washer
fluid level,
brake fluid level

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Fuel Injection I
Connector X60004 (continued)
8 10
11
12
13
14
15
16
9
Output 0
Input
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
39
llnput lsignal l~oolant outlet temperature sensor
Output
Output
Ground
Input
Output
I I - I
40 /output Istart signal Istarter relay
Pedal position sensor (PWG), signal
Output Input
Output
input
Input
Input
Input
Input
Input
input
Input
Output
Input/-output
Input/-output
37
Connector X60003
Pedal position sensor
Fuel pump relay, activation
Oil pressure indicator Pedal position sensor (PWG), ground
Pedal position sensor (PWG), signal
Pedal position sensor (PWG), power supply
Not used
Not used Fuel
pump relay
Instrument cluster
Pedal position sensor
Pedal position sensor
Pedal position sensor
Engine speed signal output (TD)
Not used
Signal
back-up light
DM-TL (diagnostic module,
tank leakage)
Signal oil level sensor
Right rear wheel speed, signal
Clutch pedal position switch, signal
Brake light switch, signal
Not used
Voltage supply, terminal
15
Data link, MFL (multi-function steering wheel)
Brake light test signal
AJC compressor signal
DM-TL (diagnostic module, tank
leakage)
Not used
Diagnosis signal
TxD
Communication link (EWS)
Not used
Not used
CAN-BUS hiqh
38 1 Ground l~round I Coolant outlet temperature sensor
OED II plug
Integrated instrument cluster control module (IKE)
Light module
ABSIDSC control module
Clutch pedal position switch
Brake light switch
Fuse
F14
Airbag contact coil spring
Brake light switch
Heating and
A/C control module
OBD
II plug
Electronic immobilizer (EWS)
CAN-Bus link
CAN-Bus link
Input/-output CAN-Bus low

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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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- On installation, drive new center bearing firmly to stop.
Reassemble driveshaft using matchmarks made prior to
disassembly.
- Clean threads and install bolt securing driveshaft halves.
Use thread locking compound
LoctiteO or equivalent.
Tightening torque Driveshaft front half to rear half
(use thread locking compound) 97
Nm (72 fl-lb)
- Install driveshaft as described earlier.
Front centering guide, replacing
The front centering guide centers the driveshafl in relation to
the transmission. The guide is press-fit into a cavity in the
front of the driveshafl and slides onto the transmission output
shaft.
No specifications are given
forwear of the guide, but general-
ly the guide should fit snugly on the transmission output shafl.
NOTE-
Some driveshafts have a dust cap installed on the end of the
driveshaft, over the centering guide. The dust cap may be-
come bent or distorted when the driveshaft is removed or
in-
stalled. Damage to the dust cap should not affect the
centering guide and should not be mistaken for guide wear.
- Remove driveshafl as described earlier
- Pack cavity behind centering guide with heavy grease until
grease is flush with bottom edge of guide.
- Insert 14 mm (approximately 9/16 in.) diameter mandrel or
metal rod into guide. Strike guide with hammer to force cen-
tering guide out.
NOTE-
Tlie mandrel should fit snugly in the centering guide so that
the grease cannot escape around the sides of the mandrel.
- Remove old grease from driveshaft, lubricate new centering
guide with molybdenum disulfide grease
(MolykoteO, Long-
term8 2 or equivalent) and drive it into driveshaft.
4 When installing new driveshafl centering guide, be sure seal-
ing lip of guide faces outward. Drive guide into driveshaft to
a protrusion depth of
4 - 6mm (0.16 - 0.24 in.).
- Install driveshaft as described earlier.

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300-1 4
I Susoension. Steerina and Brakes - General
DSC system I
Dynamic Stability Control (DSC)
Dynamic Stability Control (DSC) utilizes many principles and
components of the ASC traction control system. DSC is ac-
tive throughoutthe driving range, unlike ASC which is only ac-
tive during acceleration and braking. DSC helps stabilize the
vehicle in cornering and avoidance maneuvers by adjusting
engine controls such as throttle, ignition, fuel injection and the
application of
brake pressure individually to the wheels.
Inputs
fi- 0
2 4-* .. o
[11-' IJ
411m4
3?-
G
4 The DSC control module uses various inputs to determine
vehicle instability during braking, cornering, or reduced trac-
tion situations. Based upon these inputs the ABSIDSC con-
trol module sends outputs to the engine control module and
the ABSIDSC hydraulic unit to activate torque reduction pro-
tocols and braking intervention.
-
ABSIDSC control module
OUI~YIS
4
The DSC system can be toggled on and off by a switch
mounted on the center console. Turning off the DSC system
does not disable ABS or ASC functions.
+
Measure ride height (A) from center of fender arch to bottom
of wheel rim.
Car in normal loaded position on the ground. See Normal
loaded position.
Engine
control
module
Specified tires and wheels, correct tire pressure, even tire
wear
-'* 9-
.%A
Correct wheel bearing play
T'== ..t, 9 B
-.m
Model with air suspension (EHC): Disconnect electrical har-
ness connector to air supply pump to prevent automatic
height regulation.
When finished, reset ride height using BMW diagnostic
scan tools DIS or
MoDiC.
NOTE-
Airsupply pump is located beneath a cover under the spare
tire in the floor of the cargo compartment.
- If ride height is outside specification listed, install new
springs. Suspension spring removal and installation is cov-
ered in
310 Front Suspension and 330 Rear Suspension.
Normal loaded position
Each front seat 68 kg (150 Ib)
Center of rear seat 68 kg (150 lb)
Trunk 21 kg (46 lb)
Fuel tank full

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400-9
Body-General
Battery safety terminal
(BST)
4 Starting with 1999 models (9198 production and later), a py-
rotechnic (explosive charge) device automatically discon-
nects the battery positive terminal during impacts. Key
features,
like power windows and door locks, remain opera-
tional.
Security
Electronic immobilization (EWS)
Ignition key transponder signal All
E39 vehicles incorporate an electronic immobilization sys-
tem known as EWS. This svstem uses a wireless comrnuni-
cation link between a transponder chip in the ignition key and
the ring antenna surrounding the ignition switch. The EWS
control module blocks the starting of the vehicle unless the
correct coded ignition key is used.
NOTE-
Electronic immobilization is sometimes referred to as the
driveaway protection system.
Antitheft alarm (DWA)
This is adealer-installed option for which the E39 vehicles are
factory-wired. When armed, the system monitors door
loci(
contacts and trunk and engine hood locks and sounds a siren
if it detects tampering.
E39 interiors have a unique character, with a combination
of
sporty features and innovativedesign. All body versions were
made in a wide choice of interior and exterior colors. New col-
ors with matching leather or leatherette upholstery were intro-
duced for each model year.
Driving
comfort is enhanced by power steering, tilt steering
wheel, height-adjustable front seats, and electrically adjust-
able and heated rear-view mirrors. Inside the car there are
reading lights at four seating positions.

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411-3
Doors
4 Pull up on locking clip and remove connector.
4 With door fully open, unscrew pin bolts (arrow) from top and
bottom hinges.
Disconnect door
check by squeezing mounting pin tabs
(arrow) and driving pin up.
Remove door by lifting up off lower hinge halves.
CAUJION-
Be careful not to damage door or otherpainted body surfac-
es.
Make sure no load is placed on wirinq harness.
Installation is reverse of removal. Keep in mind the following:
Mount and align rear doors first, followed by the front
doors.
Align door so that panel gaps are equal on either side, see
specifications at the end of this procedure. If necessary,
adjust door hinges. See Door hinge adjustment.
* Adjust door striker so that trailing edge of front door is
slightly higher
(I mm 10.04 in.) than leading edge of rear
door. See
515 Central Locking and Anti-Theft.
Repair any paint damage and paint any exposed metal.

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51 5 Central Locking and Anti-Theft
........................... General .51 5.2
Central Locking ................... .51 5.2
General Module
..................... .51 5.2
Central locking inputs and outputs
....... .51 5.3
Doorlocks
........................... 515-5
Trunklock
........................... 515-7
Remote entry (FZV)
.................. .51 5.7
Remote entry (FZV) inputs and outputs ... .51 5.8
Car Memory I Key Memory ............ .51 5.12
Trunk lid soft close (SCA)
............. .51 5.13
SCA subsystem
.................... .51 5.14
........ Tailgate and rear window locks
.51 5.14
Sport Wagon tailgate and rear
window
lock schematic ............... .51 5.15
Door Handles and Locks .......... .51 5.16
Door handle (outer), removing
and installing
....................... .51 5.16
Door latch, removing and installing
..... .51 5.17
Outer door lock cylinder, removing
and installing
....................... .51 5.18
Trunk Lock Assembly ............. 515-1 9
Trunk lock. removing and installing
...... 515-19
Trunk lock striker plate. removing
and installing
....................... 515-20
Tailgate lock. emergency release
....... 515-21
... Electronic Immobilization (EWS) 515-21
EWS variations
..................... 515-22
......... EWS control module. replacing 515-23
Transmitter
1 receiver module .......... 515-23
....................... Ring antenna 515-23
Anti-theft System (DWA) ........... 51 5-24
DWA LED Status
.................... 51 5-24
Tilt sensor
......................... 515-24
Interior protection .................... 51 5-25
Glass breakage sensors
.............. 515-26
Emergency disarming
................ 51 5-26

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515-20
Central Locking and Anti-Theft
4 Disconnect actuator rod (arrow) from trunk loclc assembly.
4 Remove trunk latch fasteners (arrows).
- Remove latch and disconnect wiring harness.
- Installation is reverse of removal.
Trunk lock striker plate, removing and
installing
4 Remove left and right trim panel fasteners (arrow).
- Remove (4) trim panel expansion rivets (A) and remove trim
panel.
1 4 Remove striker plate mounting fasteners (arrows).