AC line BMW 540i 2001 E39 Workshop Manual

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1 Brakes
- Remove precharge pump mounting bracket fasteners and re-
move pump.
- Installation is reverse of removal, noting the following:
Be sure to replace rubber pump mounts if damaged
01
worn.
Bleed brakes as described earlier.
Tightening torque Brake line
to precharge pump 18 Nrn (13 ft-lb)
DSC pressure sensor (1 999 - 2002 models)
On 1999 and later DSC systems, the DSC pressure sensor is
screwed into the DSC hydraulic unit (right rear of engine com-
partment).
WARNING-
* €39 cars require special BMW service equipment to prop-
erly bleed the brakes. Removal of the
DSCpressure sensor
is not recommended unless this equipment is available. For
safety reasons, the brake system on cars with ABS must be
bled using the procedures described in this repair group.
Switch off ignition and remove
key to male sure brake
system cannot be activated.
- Disconnect electrical harness connector at switch.
- Use BMW special tool 34 5 160 to remove and install sensor.
Inspect threads and sealing surfaces for damage.
* Work quicltly to avoid excessive brake fluid leakage.
Tightening torque
Pressure sensor
to hydraulic 19 Nrn (14ft-lb)
unit
- Reconnect harness connector
- Bleed front brakes as described earlier.
- Press on brakes and check for leaks at sensor.
- Turn on ignition and firmly depress brake pedal. Check that
DSC warning light does not come on.

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340-32
Brakes
The procedure for removing the ABS I ASC or ABS I DSC hy-
draulic unit is similar for all models. The unit is located at the
right rear of the engine compartment.
- Using a clean syringe, empty brake fluid reservoir.
CAUTION-
Brake fluid is highly corrosive and dangerous to the environ-
ment. Dispose of it
properiw
4 Disconnect electrical harness connector (A) at hydraulic unit
(1998 DSC hydraulic unit in V-8 model shown).
Where applicable, detach electrical harness connector to
DSC pressure sensor.
Mark brake lines
(arrows) in relation to their placement on
hydraulic unit. Detach lines from unit using appropriate
sized flare wrench.
Seal open brake fluid lines and bores with suitable plugs to
prevent contamination.
- Carefully push aside brake lines from retainerslgrommets
that may be in the way of hydraulic unit removal. Use care not
to
kink brake lines.
- Remove hydraulic unit mounting screws. Remove hydraulic unit.
- If necessary, separate hydraulic unit from control module.
- Installation is reverse of removal, noting the following:
Check rubber mount for hydraulic unit/control module. Re-
place if damaged.
Make sure all nuts, fluid couplings, thread bores and mat-
ing surfaces are clean.
Avoid bending pins on control module harness connector
when reattaching.
Make sure brake lines are securely seated in grommets
before installing brake lines in hydraulic unit bores.
Bleed brakes using
BMW Service Testeras described earlier.
Tightening torques Brake lines to hydraulic unit
18 Nm (13 ft-lb)
DSC electronic control unit to hydraulic unit 2.9 Nrn (26 in-lb)
(use new screws)
Hydraulic unit to body
8 Nm (6 ft-ib)
Mounting bracket to hydraulic unit 8 Nrn (6 ft-lb)

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[Fenders, Engine Hood
This repair group covers replacement of the front fenders and
removal and installation of the engine hood.
NOJE-
The body is painted at the factory affer assembly Realign-
ment of body panels may expose unpainted metal. Paint all
exposed metal once the work is complete.
Special tools
Most body repairs can be performed using regular automotive
service tools. Some BMW special tools are required to set
body pieces into the
service positions.
Front fender, removing and installing
- Raise front of vehicle and remove wheel
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose.
Placejaclr stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
- Raise hood to service position. See Hood, raising to ser-
vice position.
4 Working beneath vehicle, remove fasteners (arrows) from
left side floor panel and remove panel.
- Remove inner plastic liner from wheel housing.

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41 2-2
Trunk Lid, Tailgate
This repair group covers trunk lid and tailgate removal and in-
stallation. Also included here are replacement proceduresfor
the gas-charged support struts that hold the trunk lid or tail-
gate in the open position.
NO JE -
The body is painted at the factory after assembly. Realign-
ment of body panels may expose unpainted metal. Paint all
exposed metal once the
work is complete.
Trunk lid, removing and installing
4 Raise trunlc lid.
Open tool ltit cover and remove screws attaching tool kit to
trunlc lid (black arrows).
Disconnect tool ltit cover retaining strap from
trunk lid and
remove tool kit.
Remove insulating liner expansion rivets (white arrows).
4 Pry out moulded trim cover (arrow).

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Trunk Lid, Tailgate
4 Pry out trunk light and disconnect electrical harness plug
connector.
- Gently pry trunk liner away from lid and remove.
4 Disconnect Wiring connectors A, B and C. Remove wiring
harness by pulling through opening in lid frame
D.
While supporting trunk lid, loosen left and right top hinge fas-
teners (arrow
A) and remove lower fasteners (arrow B).
NOTE-
Before loosening hinge bolts, mark hinge and hinge bolt lo-
cations for
reins~alla~on
Lift trunk lid straight up to remove.
Installation is reverse of removal. If necessary, align trunk lid
to body as described in
Trunk lid, adjusting.

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51 5-25
Central Lockina and ~nti-~heftl
1
Tilt sensor operation:
1. DWA armed, vehicle level. Tilt sensor sends HlGH sig-
nal to General Module (GM).
2. DWA armed, vehicle tilted. The fluid moves in sensor,
changing resistance value.
HlGH signal changes to
LOW signal. GM activates alarm.
If the vehicle is jacked up or lifted in any way, the angle of the
liquid changes, producing a change in the resistance value.
The sensor signals the GM to activate the DWA alarm. The
sensor resets at the new angle.
This allows the DWA system
to remain armed and to reactivate the alarm if tlie vehicle is
moved again
Locking the vehicle twice within a few seconds will deactivate
the tilt alarm sensor while arming tlie remainder of the sys-
tem. This allows the vehicle to be transported in an armed
state without activating tlie alarm.
Interior protection
The interior motion sensor is mounted in the center of the
headliner panel. Due to the design of the vehicle interior, the
sensor must be installed in the correct direction to ensure
proper operation of the system.
lnterior sensor FIS (1997 - 1999 models)
4 When the alarm system is armed, the FIS sensor emits elec-
tromagnetic waves at
a frequency of 2.45 GHz. As long as
nothing is moving in the vehicle, the waves are reflected
baclc
to the sensor at the same frequency. If a foreign object enters
the vehicle, the frequency of the reflected signal changes.
The sensor detects the changed frequency and triggers the
alarm.
Every time the DWA system is armed, the sensor adapts to
whatever objects might be stationary in the interior. This al-
lows pacltages or objects to be left inside tlie car without ef-
fecting the operation of the system. The sensitivity of the
sensor is set so that the moving object must be at least as
large as a bumble bee. This prevents a false alarm from oc-
curring if a small insect is caught in the vehicle.
FIS is switched off when the vehicle is locked two times within
ten seconds. The DWA LED will flash one time for confirma-
tion. This allows the sensor to be switched off to avoid false
alarms when the windows are left open for venting.

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540-2
Sunroof
This repair group covers the slide-tilt sunroof assembly.
There are two types of sunroof panels available: steel
01
glass. Service procedures are different for each type.
Component locations, initialization, sunroof panel replace-
ment, and sunroof height adjustment are covered. Replace-
ment of the cable assembly or frame require that the
headliner be removed. Removal and repair of the sunroof as-
sembly and othercomponents inside the roof cavity is beyond
the scope of this manual.
When the sunroof is set to the vent position (rear of panel up),
the inside headliner moves rearward approximately
120 mm
(4.7 in) This provides cabin ventilation with less wind noise. A
water channel is incorporated into the sunroof assembly. It
automatically rises when the sunroof panel is in the vent posi-
tion and prevents water from entering the interior during brak-
ing.
Sunroof electronic controls, initializing
- Initialize the sunroof in the following situations:
Malfunctions
such as lack of one-touch function, lack of
comfort openinglclosing or lack of safety (anti-trapping)
features.
If sunroof motor has been removed and reinstalled.
If power supply to the sunroof has been interrupted.
If repairs have been performed on the slideltilt mechanism.
NOTE -
The initialization sequence is dependent on the software ver-
sion of
tlie sunroof module (in the sunroof drive unit).
I WARNING -
I There is no anti-trapping protection during initialization. I

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-.
Sunroof
Sunroof panel, emergency closing
4 Using a plastic tool carefully pry interior light out of headliner.
4 Remove access panel from below sunroof motor by inserting
fingers through light opening and pressing down.
4 Disconnect electrical connections (arrow) and lay switch
panel aside.
4 Insert hex ltey into drive in sunroof motor (arrow), and turn
hex ltey to manually close sunroof.
NOTE-
The hex ley for manually (emergency) closing the sunroof
can be found in the tool
Itit located in the trunk lid (sedan
models) or under the cargo area floor panel (Sport Wagon).

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Sunroof, adjusting
The sunroof is controlled by a set of cables that move the sun-
roof panel along guide rails when the motor is operated. The
sunroof can be adjusted without removing it from the car.
NOTE-
Be sure to check drains in front corners of sunroof carrier if
water is entering car through headliner.
- The sunroof panel should be adjusted under the following cir-
cumstances:
Sunroof misaligned with roof.
Sunroof does not close squarely.
* Wind noise at high speeds (sunroof closed).
Sunroof has been removed.
For correct sunroof alignment:
Sunroof must be fully closed.
Gap must be even all around edge of sunroof.
Front of sunroof must be flush to
1 mm (0.04 in.) below sur-
face of roof.
. Rear of sunroof must be flush to 1 mm (0.04) above sur-
face of roof.
NOTE-
Use a credit card to measure the gap. The card sllould insert
through the gap with equal resistance all around the perimeter.
Sunroof with steel roof panel, adjusting
- The headliner panel must be disengaged from the drive as-
sembly and moved rearward in order to access the roof panel
attaching screws.
CAUTIOI\C
Sunroof panel must never be moved to open position when . .
I the headliner is disenaaaed. 1
- Start with a fully closed roof panel.
- Remove drive motor access cover. See Sunroof motor, re-
placing.
Using hex key from tool kit, turn motor drive 90" counter-
clockwise.
Rear of sunroof panel will drop
2 to 3 mm (0.08 to 0.12 in).
This disengages headliner from sunroof panel.
- Push headliner panel rearward, exposing roof panel attach-
ing screws.

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l Sunroof
4 Adjusting rear roof height:
Remove fasteners
(A) and (6)
Slide in left and right side adjusting wedges (C) until ideal
setting is reached.
Press sunroof panel forward and tighten wedge nuts
(6).
* Tighten center nut (A).
4 Adjusting front roof height.
Loosen lefl and right fasteners
(A)
Set front of sunroof to ideal height by moving panel up or
down.
Tighten fasteners
(A).
Insert hex key in drive motor and turn 90" clockwise.
Pull headliner panel forward until it locks in place.
Tightening torque
Wedge locking nuts 1.5 Nm (1 3 in-lb)