ignition BMW 540i 2000 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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001 General Warnings and Cautions
PLEASE READ THESE WARNINGS AND CAUTIONS
BEFORE PROCEEDING
WITH MAINTENANCE AND REPAIR WORK.
WARNINGS-
See also CAUTIONS
- Some repairs may be beyond your capability. If you lack the skills, - Catch draining fuel, oil, or brake fluid in suitable containers. Do
tools and equipment, or a suitable workplace for any procedure
not use
foodor beverage containers that might mislead someone
described in this manual, we suggest you leave such repairs to
into
drinking from them. Store flammable fluids away from fire
an authorized BMW dealer service department or other qualified
hazards. Wipe up spills at once, but do not store the oily rags,
shop. which can ignite and burn spontaneously.
. Do not reuse any fasteners that are worn or deformed. Many fas- Always observe good worRshop practices. Wear qoqqles when
teners are designed to be used only once and become
unreliable you operate machine tools or work with battery acid:kloves or
and mav fail when used a second time. This includes, but is not other
~rotective clothino should be worn whenever the iob re-
limited io, nuts, bolts, washers, self-locking nuts or bolts, clrclips yires' working with harmful substances.
and cotter pins. Always replace these fasteners with new parts.
Greases, lubricants and other automotive chemicals contain toxic
. Never work under a lifted car unless it is solidly supported on
substances, many of which are absorbed directly through the
stands
desiqned for the purpose. Do not supeort a car on cinder
skin. Read the manufacturer's instructions and warninos careful-
blochs, hollow tiles orotherbrops that may drurnbie undercontin-
uous toad. Never work under a car that is supported solely by a
iack. Never work under the car
while the enqine is runninq. - -
If you aregoing to work underacaron the ground, makesure that
the ground is level. Block the wheels to
keep the car from rolling.
Disconnect the battery negative
(-) terminal to prevent others
from starting the car while you are under it.
- Never run the engine unless the work area is well ventilated. Car-
bon monoxide kills.
Rings, bracelets and other jewelry should be removed so that
they cannot cause electrical shorts, get caught in running ma-
chinery, or be crushed by heavy parts.
- Tie long hair behind your head. Do not wear a necktie, a scarf.
loose clothing, or a necklace when you work near machine tools
or running engines. if your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
DO not attempt to
work on your car if you do not feel well. You in-
crease the
danger of injuryto yourseliand others if you are tired,
uDset or have taken medication or anv other substance that mav
keep you from being fully alert.
Illuminate your work area adequately but safely. Use a portable
iy. Use hand and eye protection. Avoid direct skin conGct.
Disconnect the battery negative (-) terminal whenever you work
on the fuel system
orthe electrical system. Do not smokeorwork
near heaters or other fire hazards. Keep an approved fire extin-
guisher handy.
. Friction materials (such as brake pads or shoes or clutch discs)
contain asbestos fibers or other friction materials. Do not create
dust by grinding, sanding, or by cleaning with compressed air.
Avoid breathing dust. Breathing any
friclion material dust can
lead to serious diseases and may result in death.
Batteries
giveoff explosive hydrogen gas during charging. Keep
sparks, lighted matches and open flame away from the top of the
battery. If hydrogen gas escaping from the cap vents is ignited, it
will ignite gas trapped in the cells and cause the battery to ex-
plode.
Connect and disconnect battery cables, jumper cables or a bat-
tery charger only wilh the ignition switched off. Do not disconnect
the battery while the engine is running.
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.
. . safety lighiforworking lnsideor under the car. Make sure the bulb - Do not allow battery charging vollage to exceed 16.5 volts. If the
is enclosed bv a wire caoe. The hot filament of an accidentallv
batten! beoins ~roducina oas or boilino violentiv, reduce the
broken bulb can ignite spilled
fuel, vapors or oil. , - - - charglng rate. ~oostlng a sutfaled battery at a igh charging rate
can cause an
explosion.
-
Continued on next page

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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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.
General
WARNING-
Never run the engine in tile work area unless it is well-ven-
tilated. The exhaust should be vented to the outside. Car-
bon monoxide (CO) in exhaust kills.
Remove all neckties,
scarfs, loose clothing, or jewelry
when working near a running engine or power tools.
Tuck in shirts. Tie long hair and secure it under a cap.
Severe injury can result from these things being
caugiit
in rotating parts.
Remove rings, watches, and bracelets. Aside from the
dangers of moving parts, metallic jewelry conducts
electricity and may cause shorts, sparks, burns, or
damage to the electricalsystem when accidentally con-
tacting the battery or other electrical terminals.
Disconnect the battery negative
(-) cable whenever
working on or near the fuel system or anything that is
electrically powered. Accidental electrical contact may
damage the electrical system or cause a fire.
Fuelis highly flammable. When working around fuel, do
not
smoke or work near heaters or other fire hazards.
Keep an approved fire extinguisher handy.
The fuel system is designed to retain pressure even
when the ignition is off When worlcing with the
fuelsys-
tem, loosen the fuel lines slowly to allow the residual
pressure to dissipate gradually. Take precautions to
avoid spraying fuel.
. Illuminate the worlc area adequately and safely Use a
portable safety light for worlcing inside or under the car.
A fluorescent type
light is best because it gives off less
heat. If using a light with a normal incandescent bulb,
use rough service bulbs to avoid
breakage. The hot fil-
ament of an accidentally broken bulb can ignite spilled
fuel or oil.
Keep sparks, lighted matches, and any open flame
away from the top of the battery. Hydrogen gas
emitted
by the battery is highly flammable. Any nearby source
of ignition may cause the battery to explode.
Never lay
tools or parts in the engine compartment or
on top of the battery. They may
fallinto confinedspaces
and be difficult to retrieve, become caught in belts or
other rotating parts when the engine is started, or
cause electrical shorts and damage to the electrical
system.

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.
General
Torque wrench
A torque wrench is used to precisely tighten threaded fasten-
ers to a predetermined value. Many of the repair procedures
in this manual include BMW-specified torque values
in New-
ton-meters (Nm) and the equivalent values in foot-pounds
(ft-
Ib).
4 Several types of torque wrenches are available. An inexpen-
sive beam-type (top) is adequate but must be read visually. A
ratchet-type (bottom) can be preset to indicate (click) when
the torque value has been reached. They all do the same job,
but offer different convenience features at different prices.
The most convenient ones have a built-in ratchet, and can be
preset to indicate when a specific torque value has been
reached. Follow the wrench manufacturer's directions
for use
to achieve the greatest accuracy.
A torque wrench with a range up to about 150 Nm (1 10 ft-lb) BOIBFNG has adequate capacity for most of the repairs covered in this
manual. For recommended torque values of
10 Nm orbelow,
the English system equivalent is given in inch-pounds (in-lb).
These small values may be most easily reached using a
torque wrench calibrated in inch-pounds. To convert
inch-
pounds to foot-pounds, divide by 12.
Digital multimeter
4 Many of the electrical tests in this manual call for the mea-
surement of resistance (ohms) or voltage values. For safe
and accurate tests of sensitive electronic component and
systems, a multimeter or digital
volt/ohm meter (DVOM) with
high input impedance (at least
10,000Sr) should be used.
Some meters have automotive functions such as dwell and
pulse width that are useful for troubleshooting ignition and
fuel injection problems.
CAUTIOI\C
Vehicle electronic systems may be damaged by the high cur-
rent draw of a test light with a normal incandescent bulb. As
a general rule, use a high impedance digital multimeter or an
LED test light for all electrical testing.

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020-4
Maintenance
1997 to 2000 models
1997 to 2000 models are equipped with a data link connector
(DLC) plug in the right side engine compartment:
Reset
SII using BMW service and scan tool (DISplus or MoD-
iC, GTI) or a specialty tool from another manufacturer. Plug
tool (arrow) into DLC.
CAUTION-
Follow the manufacturer's directions when resetting the Sll. If
the reset procedures are done
incorrect& the tool or the elec-
tronic Service Interval Indicator
may be damaged.
Aftermarket reset tools that can reset all models with the DLC
can be purchased from one of the following suppliers:
Specialty tool suppliers
Assenmacher Specialty Tools
6440
Odell Place
Boulder, CO 80301
303-530-2424
[email protected] http://www.asttool.com
Baum Tools Unlimited,
Inc.
P.O. Box 5867
Sarasota, FL 34277-5867
800-848-6657
[email protected]
http://www.baumtools.com
Peake Research. Automotive Products Division
P.O. Box 28776
San Jose, CA 95159
408-369-0406
support @peakeresearch.com
http://www.peal~eresearch.com
2001 and later models
On vehicles without the data link connector (DLC) in the en-
gine compartment (2001 and latercars), the reset tool can not
be used. Instead, the
Sll can be reset with the trip odometer
reset button in the instrument cluster.
Make sure ignition key is in OFF position.
* Press and hold trip odometer button in instrument cluster,
and turn ignition key to ACCESSORY position.
Keep
button pressed for approximately 5 seconds until
either of following appear in display: OIL SERVICE or
INSPECTION, with RESET.
Press button again and
hold for approximately 5 seconds
until RESET flashes.

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Maintenance
0 Service due is shown with RESET if the measured con-
sumption limit has been reached and resetting is possible.
If RESET is not shown, the minimum limit has not been
reached and resetting is not possible.
While display is flashing, press button briefly to reset
Sll.
After display has shown new interval, the following will
appear in display for approximately
2 seconds: END SIA.
NOTE-
The system can only be reset again after the vehicle has
been driven approximately 50 to
75 miles (consumes at
least2.5gallons of fuel). If the display shows RESETwhen
resetting, the minimum driving distance has been fulfilled
and the system can be reset again.
0 It is possible to interrupt and end the reset procedure by
changing the position of the ignition
ley.
lnspection I, lnspection II
The Service Interval Indicator (SII) signals the need for main-
tenance and inspection. There are two sets
of inspection re-
quirements, alternating throughout a car's maintenance
history. If the last inspection interval was lnspection I, the next
inspection interval (following an oil service) will be lnspection
11, the next after that will be lnspection I, and so on.
lnspection
I tasks are listed in Table b. lnspection I Service.
lnspection
II includes most of the tasks from lnspection I with
additional lnspection
II tasks. A complete listing of lnspection
II tasks is in Table c. lnspection I1 Service.
NOTE-
For reference, the BMW lnspection I and lnspection I1 re-
quirements are approximately equivalent to the maintenance
requirements that other European manufacturers specify.
ln-
spection I is normally due at intervals with a maximum of
30,000 miles or
24 months. lnspection I1 is normally due at
intervals with a maximum of 60,000 miles or
48 months.

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020-21
Maintenance
Spark plugs, replacing
E39 engines use a coil-over-spark plug configuration, with
one ignition coil above each spark plug. Sparks plugs should
be removed only after the engine has cooled.
Remove engine
cover(s) over ignition coils:
Remove acoustic cover over fuel injectors
I intake
manifold.
6-cylinder engine: Remove oil filler cap.
Remove plastic trim covers (arrows).
Remove cover hold-down bolts. Remove coil
cover(s)
6-cylinder engine: Temporarily reinstall oil filler cap to
keep out contaminants.
Remove ignition coil grounding harnesses (arrows). 6-cylin-
der coils shown,
V-8 engine is similar.
< Remove ignition coils:
Pull up on spring clips to disconnect ignition coil harness
connectors.
Remove coil mounting bolts. Pull coils up and off spark
plugs.
- Remove spark plugs.

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Engine-General
This section covers system descriptions and general informa-
tion on engines and engine management systems. Also cov-
ered is basic engine troubleshooting.
For specific repair procedures, refer to the appropriate repair
group:
110 Engine Removal and Installation
0 113 Cylinder Head Removal and Installation
116 Cylinder Head and Valvetrain
0 117 Camshaft Timing Chain
119 Lubrication System
120 Ignition System
130 Fuel Injection
0 170 Radiator and Cooling System
E39 models are fitted with a variant of either an inline 6-cylin-
der or a
V-8 engine. See Table a.
Table a. Engine specifications

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Two common causes of driveability problems are incorrect
system voltage and bad grounds.
System voltage
Digital motor electronics (DME) requires that the system (bat-
tery) voltage be maintained within a narrow range of DC volt-
age.
DC voltage levels beyond or below the operating range,
or any
AIC voltage in the electrical system can cause havoc.
When troubleshooting an illuminated MIL, make sure the bat-
tery is fully charged and capable of delivering all its power to
the electrical system. An undercharged battery can amplify
AIC alternator output ripple.
To
make a quick check of the battery charge, measure the
voltage across the battery terminals with all cables attached
and the ignition off.
Afully charged battery will measure 12.6
volts or slightly more, compared to 12.1 5 volts for a battery
with a 25% charge.
The DME system operates at low voltage and current levels,
making it sensitive to small increases in resistance. The elec-
trical system is routinely subjected to corrosion, vibration and
wear, so faults or corrosion in the wiring harness and connec-
tors are not uncommon. Check the battery terminals
forcorro-
sion or loose cable connections. See 121 Battery, Starter,
Alternator for additional information.
If a battery cable connection has no
v~sible faults but is still
suspect, measure the voltage drop across the connection. A
large drop indicates excessive resistance, meaning that the
connection is corroded, dirty, or damaged. Clean or repairthe
connection and retest.
NOTE-
For instructions on conducting a voltage drop test and other
general electrical troubleshooting information, see
600 Elec-
trical System-General.
Visually inspect all wiring, connectors, switches and fuses in
the system. Loose or damaged connectors can cause inter-
mittent problems, especially the small terminals in the ECM
connectors. Disconnect the wiring harness connectors to
check for corrosion, and use electrical cleaning spray to re-
move contaminants.
Main grounds
Good grounds are critical to proper DME operation. If a
ground connection has no visible faults but is still suspect.
measure the voltage drop across the connection. A large volt-
age drop means high resistance. Clean or repair the connec-
tion and retest.
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