fuel filter location BMW 540i 2000 E39 Workshop Manual

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.-. -
Maintenance
Drive axle joint
(CV joint) boots, inspecting
CVjoint protective boots must be closely inspected forcracks
and any other damage that will allow contaminants to get into
the joint.
If the rubber boots fail, the water and dirt that enter
the joint will quickly damage it.
NOTE-
Replacement of the CVjoint boots and inspection of the
joints are described
in 331 Final Drive.
Exhaust system, inspecting
Exhaust system life varies widely according to driving habits
and environmental conditions. If short-distance driving pre-
dominates, the moisture and condensation in the system will
not fully dry out. This will lead to early corrosion damage and
more frequent replacement.
Scheduled maintenance of the exhaust system is limited to
inspection:
* Check to see that all the hangers (arrow) are in place and
properly supporting the system and that the system does
not strike the body.
Check for restrictions due to dents or
kinlts,
Check for weakness or perforation due to rust.
NOTE-
Alignment of the system and the location of the hangers are
described in
180 Exhaust System.
Fuel filter, replacing
The fuel filter is located beneath the center of the car, approx-
imately under the driver's seat.
A protective cover must be
removed to access the filter.
4 Fuel filter for M62 engine (arrow)
- Disconnect battery negative (-) cable
CAUTIOI\C
Disconnecting the battery cables may erase fault codes
stored
in engine control module memory.
WARNING -
Fuel will be expelled forcibly when the filter is removed. Do
notsmoke or work near heaters orother fire hazards. Keep a
fire extinguisher handy

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020-28
1 Maintenance
- When replacing fuel filter:
Use appropriate hose clamping device to clamp off filter
inlet and outlet hoses to lessen fuel spillage.
Loosen center clamping bracket and hose clamps on
either end of filter.
Note arrow or markings indicating direction of flow on
new filter.
Install new filter using new hose clamps
- Drain fuel filter from inlet side into a container and inspect
drained fuel.
Checlc for rust, moisture and contamination.
I - I < If fuel filter is equipped with fuel pressure regulator:
I 2 / Remove vacuum hose (1)
Pull out locking clip (2).
- Remove fuel pressure regulator (3).
Install pressure regulator in new filter.
Clean thoroughly around the filler connections before
removing them.
After assembly, check filter connections carefully for
I
I lealcs before installing cover.
NOTE- ~-
Additional informarion about the fuel filler assembly is in 160
Fuel Tank and Fuel Pump.
Fuel tank and fuel lines, inspecting
lnspectthe fuel tank, fuel lines, and fuel system fordamage or
lealts. Checlc for fuel lealts in the engine compartment or fuel
odors in the passenger compartment. Check for any evapora-
tive emissions hoses that may have become disconnected,
checking carefully at charcoal canister and evaporative emis-
sions purge system. See
130 Fuel Injection and 160 Fuel
Tankand Fuel Pump for component locations and additional
information.
WARNING-
When checlcing for fuel leal(s, the engine must be cold. A hot
exhaust manifold or exhaust system could cause the fuel to
ignite or explode causing serious personal injury Ventilate
the work area and clean up spilled fuel immediately.

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Camshaft Timing chain1
- Disconnect negative cable (-) from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Cautions and
Warnings.
4 Removing top and side engine covers:
Press down on locking pins (arrows) to release locks. Lifl
intake manifold cover straight up to remove.
Pry out caps from side covers.
Remove fasteners
and covers.
NOTE-
Some early models use
pry out trim caps and fasteners to
hold the top cover in place.
Disconnect electrical harness connectors at ignition coils
(A).
Remove left and right side ignition coil mounting fasteners
and coils.
NOTE-
Make note of location of ground strap (arrow).
Remove spark plugs.
- Remove posltlve (+) terminal cable from left cylrnder head
cover.
- Unbolt left and right side cable ducts from fuel rail
Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor and intake air tempera-
ture sensor electrical harnesses
(A and B).
Remove air filter housing mounting fastener (arrow)
Loosen intake hose clamp
(C).
Remove air filter housing with mass air sensor and intake
duct from throttle body assembly.

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.-
ignition System
Disabling ignition system
The ignition system operates in a lethal voltage range and
should be disabled any time engine service or repair work is
being done that requires the ignition to be switched on.
The engine management system can be disabled by remov-
ing the DME main relay. The relay is located in the electronics
box (E-box) in the left rear of the engine
compartment, be.
neath the interior microfilter housing.
CAUTION- Relay locations may
vary. Use care when identifying relays.
See
610 Electrical Component Locations.
Checking for spark
CAUTION-
If
a spark test is done incorrecth damage to the Engine Con-
trol Module
(ECM) or the ignition coils may result.
NOTE-
Spark plug replacement is covered in 020 Maintenance.
Check~ng for spark is d~fflcult on englnes wlth d~str~butorless
ignition systems.
Try removing the spark plugs and inspecting for differences between them.
A poor-firing plug may be wet with fuel and/or ~. - ~
black and sooty, but not always. If a coil is not operating, the
engine management system will electrically disable the fuel
injector to that cylinder. The key is to look for differences be-
tween cylinders.
Ignition coil assembly, testing and
replacing
C4 UTION-
Use a digital multimeter for the following tests. I
- Remove plastic engine cover from top of valve cover by pry-
ing off bolt covers and removing cover mounting bolts.
- Raise car slowly while constantly checking position of jack
and car.
- Disconnect harness connector from coil. Connect multimeter
between terminal 15
(+) in connector and ground.
4 Terminal identification are typically molded into connector. In
photo, terminals are from left to right: 1,
4a, 15.

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-
Fuel Injection
ECM relay, testing
The engine control module (ECM) relay is energized via the
ECM and supplies battery positive
(Bc) power to many of the
engine management components and subsystems. If this re-
lay is faulty, the engine will not start.
NOTE-
The ECM relay is also referred to as the DME main relay
ECM relay powers:
ECM
Ignition coils
* Fuel injection
Evaporative leak detection pump
Idle air actuator
- Camshaft sensors Evaporative emissions valve
Hot film mass air flow sensor
Fuel pump relay
Oxygen sensor heaters
4 Working in right rear of engine compartment:
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate duct inward (arrow) to unlock from bulk head and
remove duct.
Release spring lock
(C) to remove lower filter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
With ignition off, remove ECM relay (arrow) in electronics
box (E-box) at rear of engine compartment, right side.
NOTE-
Relay locations can vary Confirm relay identification by
matching wiring colors and terminal numbers.

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130-70
Fuel Injection
ECM relay
--
CAUTION-
Relay positions can vary Be sure to confirm relay position by
identifying the wiring in the
socl(et using the wiring diagrams
in ELE Electrical Wiring Diagrams.
Working in right rear of engine compartment:
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate duct inward (arrow) to unlock from bulk head and
remove duct.
Release spring
loclt (C) to remove lower filter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
4 With ignition off, remove main relay (arrow) in electronics
box (E-box) at right rear of engine compartment.
NOTE-
Relay locations can vary Confirm relay identification by
matching wiring colors and terminal numbers.
4 Check for voltage at terminal 6 of main relay socket (30-red
wire).
If battery voltage is present, continue testing.
If battery voltage is not present, check large red wire in re-
lay socltet. See ELE Electrical Wiring Diagrams.
- Reinstall relay and turn ignition on. Gain access to underside
of relay socket and check for ground at terminal
4 (85-brown
wire).
If ground is present, continue testing.
If ground is not present, switched ground signal from ECM
is missing. Check wire between ECM and relay.
- With ignition on and relay installed, check for battery voltage
at terminal
2 (87-redlwhite wire).
If battery voltage is present, relay has energized and is
functioning correctly.
If battery voltage is not present and all earlier tests are OK.
relay is faulty and should be replaced.

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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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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan