AC line BMW 540i 2001 E39 Workshop Manual

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160-22
Fuel Tank and Fuel Pump
4 Working underneath car, pinch off supply and return fuel hos-
es (arrows), then disconnect hoses from rigid metal lines.
- Remove right rear wheel and wheel housing splash shield.
4 Worlting at right rear wheel housing, loosen hose clamp
(arrow) and disconnect filler pipe from tank.
- Support tank from below. Remove tank strap mounting bolts.
Lower and remove tank, disconnecting right side vent and
other
hoses/electrical connectors as necessary.
Always use new seals, gaskets, O-rings, and hose clamps.
lnspect hoses and replace any that are chafed,
dr~ed out or
cracked.
lnspect heat shield and replace if corroded.
Inspect rubber buffers and
hers on fuel tank, support
straps and on underside of body. Replace rubber parts that
are hardened or damaged.
- After finishing repairs but before starting engine, fill fuel tank
with at least
5 liters (1.5 gallons) of fuel.
CAUTlOI+
The fuelpump will be damaged if run without fuel.
* If the filler neck has been removed from the body, be
sure to reattach the
neck grounding screw (where ap-
plicable). Check electrical resistance between the
ground tab and wheel
hub. The resistance should be
no
hiaher than 0.6f2
Tightening torques
Fuel tank to body 23 Nm (17 ft-lb)
Hose clamp
8 -13 mm dia. 2 Nm (18 in-lb)
Hose clamp 13
- 16 mm dia. 3 Nm (27 in-lb)
Hose clamp 42
- 48 mm dia. 4 Nm (36 in-lb)

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.- Fuel Tank and Fuel pump( -
Fuel expansion tank, removing
and installing
- Raise rear end of car and support safely.
CA U TIOG
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the
ouroose. A floor iack is not adequate support
- Remove left rear wheel and wheel housing inner shield.
4 Remove plastic nut (A) and disconnect hose (B).
4 Tilt vent tank down and loosen or cut off hose clamps
(arrows). Pull hoses off fittings.
- Release vacuum line loclting clips and remove tank
- Installation is reverse of removal. Use new hose clamps.
Tightening torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp 13 - 16 mm dia. 3 Nm (27 in-lb)
Hose clamp
42 - 48 mm dia. 4 Nm (36 in-lb)

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Fuel Tank and Fuel Pump 1
Activated carbon canister I fuel tank leak
detection unit
(LDP or DMTL), removing . . -
and installing
- Raise rear end of car and support safely.
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.
- Remove left rear wheel and inner fender panel
Remove carbon canisterlfuel tank leak detection unit
(V-8 model shown):
Disconnect electrical harness connector
(A) from fuel tank
leak detection unit.
Pinch and remove quick-disconnect fittings at intake line to
air filter housing
(5) and hose to expansion tank (C).
* Remove mounting clamp and lower canister with fuel tank
leak detection unit.
Installation is reverse of removal.
Tightening
torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp
13 - 16 rnm dia 3 Nm (27 in-lb)
Running losses (312-way) valve,
removing and installing
The running losses (312-way) valve is located under the car
beneath the driver's seat, just ahead of the fuel filter. A protec-
tive covershieldsfuel system components from road hazards
and dirt.
The engine control module
(ECM) controls the operation of
the 312-way valve (pulse-width modulated). On engine start
up, the valve solenoid is energized for 20 seconds in order to
supply full fuel volume to the fuel rail.
After20 seconds, the
solenoid is deactivated and sprung closed (the bypass is
opened). This reduces the amount of fuel circulating through
the fuel rail and diverts the excess to return to the fuel tank
through the fuel pressure regulator.
The fuel injectors are supplied with pressurized fuel, but ex-
cess fuel is diverted to the fuel tank without first passing
through the fuel rail. This prevents the excess fuel from ab-
sorbing heat in the engine compartment, thus lowering the
temperature and amount of vaporization in the fuel tank.

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160-25
Fuel Tank and Fuel pump1
The 312-way valve is also activated briefly if an engine misfire
is detected. This provides full fuel flow through the fuel rail to
determine if the misfire was caused by a lean fuel condition.
The valve is monitored by the ECM forfaults.
- Using BMW or compatible scan tool, read out fault memory.
See
OBD On-Board Diagnostics.
- Turn off ignition.
- Raise car and support safely.
CA UTIOW
Male sure the car is stable and well suppodedat all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floor jack is not adequate support.
- Worlting under car beneath driver's seat, remove protective
panel from fuel filter and 312-way valve.
- Clamp off fuel lines at 312-way valve.
4 To remove 312-way valve (V-8 model shown):
Disconnect electrical harness connector
(A) from valve.
Remove vacuum hose
(B) from fuel pressure regulator.
* Remove hose clamps (arrows) and disconnect fuel lines.
Remove
M6 mounting nuts and lower 312-way valve.
WARNING-
Fuel will be spilled. Use shop rags to capture fuelas fuellines
are disconnected. Do not
smoke or work near heaters or oth-
er fire hazards.
- Installation is reverse of removal. Use new hose clamps
NOTE-
Install protective cover and seals correctly to keep moisture
and road dirt out of underbody fuel system components.
Tightening torques Hose clamps
8 - 13 mm dia.
2 Nm (18 in-lb)
Hose clamps
10 - 16 mm dia.
2 Nm (18 in-lb)
Hose clamps
18 mm dia. 3 Nm (27 in-lb)
Hose clamps 42
- 48 mm dia. 4 Nm 136 in-ib)

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170-5
Radiator and Cooling System
Fan switch calibration (M52, M62 engine)
coniprairoi OUt rlgnal
Auto. ciimilte ~ontioi inpuls via CAN bus
Electric fan activation:
Low speed
91°C (196°F)
High speed 104' C (21 9' F)
< In models manufactured after 911998 (M52 TU engine, M54
engine.
M62 TU engine), the electric cooling fan is controlled
by the engine control module (ECM) via the output final
stage.
The output final stage is mounted on the fan housing, next to
the fan motor. The fan is operated using a pulse width modu-
lated signal. Fan circuit wiring is protected by a 50-amp fuse.
Electric fan activation is based on the following inputs to the
ECM:
Radiator outlet temperature
Calculated catalytic converter temperature
Vehicle speed
* Battery voltage
Calculated
A/C pressure
When the vehicle is first started, the ECM activates the elec-
tric fan briefly at 20% of its maximum speed, then switches
off. This is for diagnostic monitoring. The voltage generated
by the fan when it slows down (acting as a generator) must
match the stored rpm values in the fan output stage toconfirm
that the fan is operating correctly.
NOTE-
If the ECM fault memory indicates a cooling fan fault, check
that the fan is not seized and that it spins freely.
When
A/C is switched ON, the electric fan is not immedi-
ately turned on.
After the engine is switched
OFF the fan may continue to
run at varying speeds for up to 10 minutes, based on cal-
culated catalyst temperature.
Transmission fluid heat exchanger
Automatic transmission fluid lines circulate transmission fluid
(ATF) to and from a heat exchanger at the radiator.
All 6-cylinder
models andV-8 models produced to 911998 are
equipped with a transmission cooler located in a cooling cas-
sette in front of the radiator.

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. --
Radiator and Cooling system/
4 Pry out expansion rivets (A) on left and right side of fan
shroud. Loosen hose clamp
(6) and remove hose from ex-
pansion tank.
Remove expansion tank: Remove expansion tanlc cap, vent plug
(A) and tank retain-
ing clips (arrows).
Lift expansion
tanlc upward and off lower retaining lugs.
Push shroud back to expose expansion tank vent line. Re-
move line.
Using 32 mm wrench
(BMW special tool 11 5 040) on fan
clutch nut (arrow), turn wrench in a clockwise direction
(working from front of car) while counterholding pulley with
BMW special tool 11 5 030. Spin fan off coolant pump.
NOTE-
The radiator cooling fan nut (32 mrn wrench) has left-hand
threads.
Disconnect electrical harnesses from
AUC (air quality) sen-
sor and coolant level sensor.

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Exhaust system1
Exhaust manifold removal procedures are organized accord-
ing to engine code. If necessary, see
100 Engine-General
for engine code and application information.
Exhaust manifolds, removing and installing
(M52 engine)
4 Exhaust manifolds for the M52 engine.
Always use new retaining nuts and gaskets when removing
and installing the exhaust manifolds.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work under a lined car unless it is solidly supported on
jack stands designed for that purpose. Never work under a
car that is supported solely by a jack.
- Disconnect secondary air check valve and pipe from exhaust
manifold.
- Unbolt front exhaust pipe@) from exhaust rnanifold(s)
- Remove exhaust support bracket from transmission.
- Loosen and remove nuts from exhaust manifolds and remove
manifolds. Discard nuts and gaskets.
NOTE-
On cars with oxygen sensors mounted in the exhaust mani-
folds, use care when removing manifolds.
To be safe, remove
the sensors from the manifolds before removing manifolds.
- Installation is reverse of removal
Coat exhaust manifold mounting studs with copper paste
before installing new nuts.
Install manifold gaskets with arched side facing manifolds.
Tightening torque
Exhaust manifolds
to cylinder head 20 Nm (15 ft-lb)

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Tool for bleeding clutch hydraulics (Tool No. 21 5 030)
21 5 030 I
The clutch is hydraulically actuated by the master and slave
cylinders. With the self-adjusting clutch
(SAC), clutch disc
wear is automatically taken up through the self-adjusting
pressure plate springs, making pedal feel consistent through-
out the life of the clutch.
A soft or spongy feel to the clutch pedal, long pedal free-play,
or grinding noises
from the gears while shifting can all indi-
cate problems with the clutch hydraulics. In these circum-
stances it is best to
star? with a clutch fluid flush, followed, if
necessary, by replacement of the hydraulic parts.
NOTE-
The clutch hydraulic system shares the fluid reservoir and flu-
id with the brake hydraulic system.
Clutch hydraulic system,
bleeding and flushing
If the clutchlbralte fluid is murky or muddy, or has not been
changed within the last two years, flush the system and
change the fluid. Flushing the old fluid from the clutch lines is
done using a bralte system pressure bleeder.
- Remove brake fluid reservoir cap. Using a clean syringe, re-
move brake fluid from reservoir. Refill reservoir with clean
DOT
4 bralte fluid.
Worlting inside engine compartment, remove left
interiorven-
tilation filter housing:
Release 3 plastic taps
(A) on duct. Earlier models use a
single release latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Remove filter housing cover.
Release spring lock
(B) on interior ventilation housing and
remove housing.

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21 0-6
1 Clutch
Hydraulic system, bleeding
(using
BMW special tool 21 5 030)
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder. Leave fluid line attached.
4 Use BMW special tool 21 5 030 to press slave cylinder push-
rod completely into slave cylinder.
Hold slave cylinder so that bleeder valve is at highest point.
Open bleeder valve and allow brake fluid to expel until
clean fluid comes out, free of air bubbles.
* Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly unscrew and detach special tool 21
5 030 from
slave cylinder.
CAUTION-
Do not remove tool if hydraulic system is pressurized.
- Reinstall slave cylinder.
Tightening torque Slave cylinder to transmission case
22 Nm (1 6 ft-lb)
- Slowly operate clutch pedal about 10 times. Fill reservoir with
clean fluid as necessary.
Clutch master cylinder, replacing
The clutch master cylinder is mounted to the pedal assembly
directly above the clutch pedal.
Working inside engine compartment, remove left interior
ventilation filter housing:
Release 3 plastic taps
(A) on duct. Earlier models use a
single release latch.
Rotate duct inward to remove
Disconnect electrical harness to hood position switch.
Remove filter housing cover.
Release spring
loclc (B) on interior ventilation housing and
remove housing.

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21 0-8
Clutch
4 Remove hydraulic line locking clip (1) and pull line (2) off
master cylinder.
CAUTION-
. To prevent brake fluidspill, wrap clutch master cylinder with
shop rags when removing hydraulic fluid lines from master
cylinder.
* Brake fluid damages paint andstains carpets. Clean off
any brake fluid on or
in the car immediately.
- Remove master cylinder with supply hose
4 Remove switch module from master cylinder.
Press locking button
(A) to release harness connector.
Pull harness connector
(8) off switch module.
Use screwdriver to lever
off switch module (C).
- Installation is reverse of removal.
CA UTlON-
Switch module must snap firmly into place on the master cyl-
inder during installation.
Tightening torques
Clutch master cylinder to pedal cluster
10 Nm (89 in-lb)
Fluid line
to master cylinder or slave cylinder 17 Nm (13 ft-lb)
- Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as
described earlier.
Clutch slave cylinder, replacing
4 Working inside engine compartment, remove left interiorven-
tilation filter housing:
Release
3 plastic taps (A) on duct. Early models: release
latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Release spring lock (B) on interior ventilation housing and
remove housing.
- Pinch off brake fluid supply hose to clutch master cylinder us-
ing BMW special tool
13 3 01 0 or equivalent hose clamping
tool.