AC line BMW 540i 2001 E39 Workshop Manual

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Sunroof
Sunroof with glass roof panel, adjusting - -
< Slide sunroof liner back into roof cavity until approx. 70 mm
(2.75 in) is exposed.
Raise glass sunroof panel to vent position to expose rubber
gaiter (arrow).
- Working from center section of gaiter (arrow), carefully pull
gaiter off slotted mounting on sunroof glass panel.
CA UTIOW-
The gaiters tear easik
* Do not attempt to remove gaiters from lower edge of
sliding mechanism.
- With gaiters removed, three adjusting screws are visible at
front and rear of panel.
4 Sunroof panel is retained by three Torx screws (arrows) on
each side. To adjust sunroof height:
Loosen Torx screws until sunroof can just be moved.
- Push sunroof panel forward.
Push sunroof panel up or down until correct height is
achieved.
Reinstall sunroof gaiter.
Sunroof height adjustment specifications
Rear
Flush1 1 rnrn (0.04 in) higher than roof top
Front Flush
11 rnrn (0.04 in) lower than roof top
Tightening torque Sunroof panel to roof (Torx)
6 Nrn (4.4 in-lb)

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1 Sunroof
Sunroof assembly removal and installation involves headliner
removal, and is not covered in this manual. After sunroof re-
pairs, be sure to follow initialization and adjustment proce-
dures given earlier.
I Sunroof comDonents
1. Left rubber boot suppori
2. Left upper control rail
3. Left side water channel repair ltit
4. Left lower control rail
5. Left cover
6. Left side slider
7. Cross member
8. Sunroof frame
9. Trim panel
10. Gasket
11. Glass roof cover
m5sm.7 - -.
Sunroof panel, removing and installing
(steel or glass)
4 To remove sunroof panel, open sunroof and remove wind
blocker
by removing Tom screw (arrow) on each side.

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721-12
Airbag System (SRS)
Head protection airbag (HPS)
4 Replacement of a head protection airbag (HPS) is an exten-
sive operation, including removal of the following:
Complete dashboard
Complete headliner
Windshield pillar (A-pillar) trim
Door pillar (B-pillar) trim
- Before starting work on the HPS airbag, disconnect negative
(-) cable from battery and cover negative terminal with insu-
lating material.
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in001 General Warnings and Cau-
tions.
Tightening torque HPS
airbag to body 11 Nm (8 ft-lb)
HPS airbag mounting bracket
to A or B-pillar
HPS gas generator to
dashboard reinforcement
(M6
self-tapping screw) 2.5
Nm (22 in-lb)
4 Nm (35 in-lb)

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OBD On-Board Diagnostics
I I
General ........................... OBD-1 Diaqnostic Trouble Codes (DTCs) . . OBD-9
On-Board Diagnostics (OBD I!) ..... OBD-I
Malfunction Indicator Light (MIL)
........ OBD-2
Scan tools and scan tool display.
........ OBD-3
Diagnostic monitors
.................. OED-4
Drive cycle
......................... OED-6
Readiness codes
.................... OBD-6
Diagnostic trouble codes
(DTCs) ........ OBD-7
-
Automatic transmission diagnostic
trouble codes
....................... OBD-9
Engine diagnostic trouble
codes: M52 engine.
................. OED-13
Engine diagnostic trouble
codes: M54 engine.
................. OBD-17
Engine diagnostic trouble
codes: M62 engine.
................. OBD-24
This chapter outlines the fundamentals and equipment
requirements of On-Board Diagnostics
I1 (OBD 11) standards
as they apply to BMW vehicles. Also covered here is a listing
of BMW and OBD
I1 diagnostic trouble codes (DTCs).
ON-BOARD DIAGNOSTICS (QBD !I)
OBD II standards were developed by the SAE (Society of
Automotive Engineers) and CARB (California Air Resources
Board).
OED I1 is the second generation of on-board self-
diagnostic equipment requirements. These standards were
originally mandated for California vehicles. Since
1996 they
have been applied
toall passengervehicles sold in the United
States.
On-board diagnostic capabilities are incorporated into the
hardware and soflwareof the enginecontrol module
(ECM) to
monitor virtually every component that can affect vehicle
emissions. The
OED I1 system works to ensure that
emissions remain as clean as possible over the life of the
vehicle.
Each emission-influencing component is checked by a
diagnostic routine (called a monitor) to verify that it is
functioning properly.
If a problem or malfunction is detected,
the
diagnostic executive built into the OBD I1 system
illuminates a malfunction indicator light (MIL) on the
instrument panel.
The OBD
I1 system also stores diagnostic trouble codes
(DTCs) about the detected malfunction in the ECM so that a
repair technician can accurately find and fix the problem.

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- -
On-Board Diagnostics
Professional diagnostic scan tools available atthe time of this
printing include the BMW factory tools
(DISplus, GTI,
MoDiC) and a small number of aftermarket BMW-specific
tools. See
020 Maintenance.
In addition to the professional line of scan tools, inexpensive
generic OBD
II scan tool software programs and handheld
units are readily available. Though limited, they are
nonetheless powerful diagnostic tools. These tools read live
data streams and freeze frame data as well as a host of other
valuable diagnostic data.
Diagnostic monitors
Diagnostic monitors run tests and checks on specific
emission control systems, components, and functions.
A complete drive cycle is requiredforthe tests to bevalid. See
Drive cycle in this repair group. The diagnostic monitor
signals the
ECM of the loss or impairment of the signal or
component and determines if a signal or sensor is faulty
based on
3 conditions:
* Signal or component shorted to ground
Signal or component shorted to
B+
Signal or component missing (open circuit)
The OBD
II system monitors all emission control systems that
are installed. Emission control systems vary by vehicle model
and year. For example, a vehicle may not be equipped with
secondary air injection, so no secondary air readiness code
would be present.
OBD
II software monitors the following:
Oxygen sensors
Catalysts
Engine misfire
- Fuel tank evaporative control system
Secondary air injection Fuel system
Oxygen sensor monitoring. When driving conditions allow,
response rate and switching time of each oxygen sensor is
monitored. The oxygen sensor heater function is also
monitored. The OBD
II system differentiates between
precataylst and post-catalyst oxygen sensors and reads each
one individually. In order
forthe oxygen sensor to be
effectively monitored, the system must be in closed loop
operation.

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OBD-6
On-Board Diagnostics
Fuel system monitoring. This monitor looks at the fuel
delivery needed (long
/short term fuel trim) for proper engine
operation based on programmed data. If too much or not
enough fuel is delivered over a predetermined time, a DTC is
set and the MIL illuminates.
Fuel trim refers to adiustments to base fuel schedule.
Lono- ., term fuel trim refers to gradual adjustments to the fuel
calibration adjustment as compared to short term fuel trim.
Long term fuel trim adjustments compensate for gradual
changes that occur over time.
Fuel system monitoring monitors the calculated injection time
(ti) in relation to enginespeed, load and precatalyticconverter
oxygen
sensor(s) signals.
Using this data, the system optimizes fuel delivery for all
engine operating conditions.
Evaporative system monitoring. This monitor checks the
the fuel storage system and related fuel lines for leaks. It can
detect very small leaks anywhere in the system.
A leak detection unit (LDP or DMTL) is used to pressurize the
evaporative control system on a continuous basis (as the
drive cycle allows) and to
check system integrity.
Drive cycle
The OED II drive cycle is an important concept in
understanding OBD
II requirements. The purpose of the drive
cycle is to run ail of the emission-related on-board diagnostics
over a broad range of driving conditions.
A drive cycle is considered complete when all of the
diagnostic monitors have run their tests without interruption.
~ora drive cycle to be initiated, the vehicle must be started
cold and brought up to
1 60°F and at least 40°F above its
original starting temperature.
Readiness codes
Inspection/maintenance (I/M) readiness codes are mandated
as part of OBD
II. The readiness code is stored aftercomplete
diagnostic monitoring of specified components and systems
is carried out. The readiness code function was designed to
prevent manipulating an
I/M emission test procedure by
clearing faults codes or disconnecting the ECM or battery.

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On-Board ~ia~nosticsl
Engine diagnostic trouble codes: M62 engine (continued)
P-code
I I -
I I - -.
PI445 1186 / Diagnostic Module Tank Leakage (DM-TL) Pump Control Circuit Signal Low
PI357
PI382
PI386
PI413
PI414
PI441
PI442
PI443
PI444
P1356 1 53 I Misfire during Start Cylinder 8
BMW-FC
I P1523
I
I - -
1165 I 'A' Camshaft Position Actuator Signal Low (Banlc 1)
Explanation
P1381 1215 I Control Module Self-Test, Knock Control Onset (Bank 1)
53
21 6
21 4
84
84
1
1
1
186
PI 446
PI 447
PI 448
PI449
PI 450
PI451
PI452
PI476
Misfire Cylinder 8 with Fuel Cut-Off
Control Module Self-Test, Knock Control Test Pulse (Bank 1)
Control Module Self-Test, Knock Control Circuit Baseline Test (Bank 1)
Secondary Air Injection Pump Relay Control Circuit Signal Low
Secondary Air Injection Pump
Relay Control Circuit Signal High
Leakage Diagnostic Pump Control Open Circuit
Leakage Diagnostic Pump Control Circuit Signal Low
Leakage Diagnostic Pump Control Circuit Signal High
Diagnostic Module Tank Leakage (DM-TL) Pump Control Open Circuit
186
189
189
189
2
2
2
184
P1524
P1525
P1526
PI527
PI528
PI633
PI 634
PI 635
I I
PI 638 / 131 I Throttle Valve Position Control Throttle Stuck Temporarily
. -
Diagnostic Module Tank Leakage (DM-TL) Pump Control Circuit Signal High
Diagnostic Module
Tank Leakage (DM-TL) Pump Current Too High during Switching Solenoid Test
Diagnostic Module Tank Leakage (DM-TL) Pump Current Too Low
Diagnostic Module
Tank Leakage (DM-TL) Pump Current Too High
Diagnostic Module Tank Leakage (DM-TL) Switching Solenoid Control Open Circuit
Diagnostic Module
Tank Leakage (DM-TL) Switching Solenoid Control Circuit Signal Low
Diagnostic Module
Tank Leakage (DM-TL) Switching Solenoid Control Circuit Signal High
Leakaqe Diaqnostic Pump Clamped Tube
I I
165
165
166
166
166
136
133
134
'A' Camshaft Position Actuator Control Circuit Signal High (Banlc 1)
'A' Camshaft Position Actuator Control Open Circuit (Bank 1)
'A' Camshaft Position Actuator Control Open Circuit (Bank 2)
'A' Camshaft Position Actuator Control Circuit Signal Low (Bank 2)
'A' Camshaft Position Actuator Control Circuit Signal High (Bank 2)
Throttle Valve Adaptation Limp-Home Position Unknown
Throttle Valve Adaptation Spring Test Failed
Throttle Valve Adaptation Lower Mechanical Stop not Adapted
Throttle Valve Control Circuit
PI 636
PI639
P1643
P2088
P2089
PI 637 / 130 I Throttle Valve Position Control, Control Deviation
132
131
135
165
165 Throttle
Valve Position Control Thronle Stuck Permanently
Throttle Valve Actuator Start Test Amplifier Balancing Plausibility
'A' Camshaft Position Actuator Control Circuit Low (Banlc 1)
'A' Camshaft Position Actuator Control Circuit High (Bank 1)

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INDEX 7
WARNING
Your common sense, good
judgement, and general alertness are
crucial to safe and successful service
work. Before
attempting any work on
your BMW, be sure to read 001
General Warnings and Cautions
and the copyright page at the front of
the manual. Review these warnings
and cautions each time you prepare
to
work on your BMW. Please also
read any warnings and
caulions that
accompany
/he procedures in the
manual.
Jack stands
010-16
Jump starting 010-19
Keys
515-1 1
Knock sensor
see Ignition system
Leak detection,
fuel tanlr
see Fuel tank, leak detection unit
Leather upholstery
see Maintenance, leather
upholstery and trim
LDP
(leak detection pump)
see Fuel
tanir, leal( detection unit
Level sender
see Fuel tank
see also Fuel pump
License
plate iight
630-1 1
Lifters see Cylinder head and vaivetrain
Lifting the car
010-5 Lights
bulb applications
630-2
control module (LCM) 630-3
foglights 630-8 headiighls 630-4
automatic headlight adjustment
(LWR)
630-7
vertical aim system 630-8 interior lights 630-12
bulb applications 630-13
side turn signal 630-9
taillight 630.10 trunk light bulb 630-14
turn signals, taillights 630-12
LOClCS see Central loci(ing
see also Door loclrs
Lubrication system
oil
level warning switch, replacing
119-20
oil pan, removinglinstalling
6-cylinder 119-10
V-E lower 119-13 V-8 upper 119-15
oil pressure
checiring 11
9-4
warning system, testing 119-5 warning switch, replacing 119-20
oil pressure
reliel valve
6-cylinder 119-26
V-8 11 9-27
oil pump, removinglinstalling
6-cylinder
119-22
V-8 1 19-4
troubieshooting 119-3
Luggage compartment
seeTrunk
MAF (mass air flow) sensor
see 130 under appropriate fuel
injection system Maintenance
accelerator linkage
020-14 air filter 020-14
automatic transmission 020-29
battery 020-22
body lubrication 020-31 body and interior 020-31
braire fluid 020-24
brake padlrotor wear 020-24
brake system 020-25 clutch fluid 020-26
cooling system 020-15
CV ioint boots 020-27
differential oil level 020-26
drive bells 020-16 engine comparlmenl 020-14
engine cooling system 020-16
engine oil 020-1 1 exhaust system 020-27
exterior washing 020-31
fluid and lubricant specifications 020-9
fuel lilter 020-27 fuel lanir and fuel lines 20-28
idle speed 020-19
inspection 020-5
interior care 020-31
lealher upholslery and trim 020-31
maintenance tables 020-6
manual transmission oil 020-30
microiilter 020-22 oxygen sensors 130-72, 180-8
parlcing brake 020-25
power steering fluid level 020-20
seat belts
020-32 service indicator 020-3
spark plugs 020-20
special cleaning 020-32 suspension, front 020-29
suspension, rear 020-29
tires 020-29
washing
020-32
waxing 020-32 windshield wiper blade 020-33
wheels, aligning 020-30
Malfunction indicator iight (MIL)
OED-2
Manifold, exhaust
see Exhaust system
Manifold,
intake
see Intake maniiold