1997 BMW 540i 121

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121-23
Battery, Starter, ~lternatorl
Solenoid switch, removing and installing
- Remove starter as described previously.
- Disconnect field winding strap between starter motor and
solenoid switch.
NOTE-
If the field winding strap is damaged or burned, a new or
rebuilt starter motor is needed.
< Remove solenoid switch mounting screws (arrows), and
separate solenoid from starter.
Unhoolc solenoid plunger from lever in starter drive
- Installation is reverse of removal. Lubricate solenoid piston
with light grease.
CAUTION- When installing field winding strap to starter, position
itso that
it does not contact the starter body.
Tightening torque
Field strap to starter
13 Nm (10 ff-lb)

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130-67
Fuel Injection /
ME 7.2 system overview
The Bosch ME 7.2 system is used on 1999 - 2002 540i mod-
els.
1 4 The ME 7.2 enaine control module (ECM). located on the
l and a combined total of 134 pins.
--__-- 1 I. 9 pin connector
12 3 4 5 2 24 pin connector
0lliC;nii, 3. 52 pin connector
4. 40 pin connector
5. 9 pin connector
The ME 7.2 system has the following functions or capabilities:
Electronic throttle control (EDK) integrates idle and cruise
control functions. ECM carries out all throttle and idle con-
trol functions directly via EDK system.
Leak diagnosis pump
(LDP) control and feedback monitor-
ing for evaporative system leak testing.
Batterylalternator charge logic (idle speed varies with bat-
tery state of charge).
CAN-Bus communications with instrument cluster.
EWS
111 (3.3) "rolling code" ISN interface.
Ignition
knock sensors.
DSC (dynamic stability control) torque reduction.
Monitoring and control of VANOS
(camshaft timing) with
active Hail sensor for camshaft position monitoring.
Integrated altitude sensor.
One touch engine start control
Single speed secondary air injection system.
Long life spark plugs.
IHKA auxiliary (electric) cooling fan control.
All emissions-related ME 7.2 electrical components are mon-
itored for faults. if driveability complaints are encountered or
the malfunction indicator
light (MIL) is illuminated, interrogate
fault memory using a compatible scan tool.
4 Use a break-out box for ME 7.2 system testing and diagnosis
at the control module
(break out box set: BMW special tool
90
88 6 121 300).
Electrically heated (characteristic
map) cooling system
DME Harness Connector thermostat.

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/steering and Wheel Alignment
Raise engine approximately 40 mm (1.6 in). See 110 Engine
Removal and installation.
Remove right and left engine mounts and remove mount
brackets from subframe.
Empty power steering fluid reservoir using a clean syringe.
Do not reuse power steering fluid.
Remove right tie rod fastener (arrow) from right steering
Itnuckle. Repeat for left.
4 Press right tie rod out of right steering knucltle using BMW
special tool 31
2 240. Repeat for left.
/ ~ock nut Loclting ring
0012143
4 Malte reference measurement (A) of right tie rod end to tie
rod. Record measurement. Repeat for left.
NOJE-
0 Accurate measurement of tie rod end with reference to tie
rod will help approximate correct wheel alignment during
reassembly.
Note correct placement of inner taper on
locling ring
Remove fluid line
banjo bolts (arrows)
from steering rack.

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On-Board ~iaanosticsl
Engine diagnostic trouble codes: M54 engine
P-code
BMW-FC Explanation
PO01 I / 103 I 'A' Camshaft Position Timing Over-Advanced or System Performance (Banlc 1) I I
PO012 1105 I 'A' Camshaft Position Timing Over-Retarded (Bank 1) I I
PO01 4 1104 I 'B' Camshaft Position Timing Over-Advanced or System Performance (Bank 1)
PO01 5
PO030
PO031
PO032
I 1
PO038 179 / HO2S Heater Control Circuit High (Bank 1 Sensor 2)
I I -.
I I
PO050 1 55 I H02S Heater Control Circuit (Bank 2 Sensor 1)
106
25
25
25
PO036
I I
PO051 1 55 I H02S Heater Control Circuit Low (Bank 2 Sensor 1)
'B' Camshaft Position Timing Over-Retarded (Bank 1)
H02S Heater Control Circuit (Bank 1 Sensor 1)
H02S Heater Control Circuit Low (Bank 1 Sensor 1)
H02S Heater Control Circuit Hiqh (Bank 1 Sensor 1)
PO037 1 79 I HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
79
HOPS Heater
Control Circuit (Banlc 1 Sensor 2)
PO052
PO056
PO057
PO058
I I
PO1 03 / 8 I Mass or Volume Air Flow Circuit High. Input
I I -.
I I
PO1 07 1 197 I Manifold Absolute PressureIBarometric Pressure Circuit Low Input
55
61
61
61
PO101
I I
POI08 1197 / Manifold Absolute PressureIBarometric Pressure Circuit High Input
H02S Heater Control Circuit High (Bank 2 Sensor 1)
H02S Heater Control Circuit (Bank 2 Sensor 2)
HO2S Heater Control Circuit Low (Bank 2 Sensor 2)
HO2S Heater Control Circuit Hiqh (Banlc 2 Sensor 2)
PO102 18 I Mass or Volume Air Flow Circuit Low Input
149
I I -
PO122 112 ThrottleIPedai Position SensorISwitch 'A' Circuit Low
PO123 1112 I ThrottleIPedal Position SensorISwitch 'A' Circuit High
Mass
or Volume Air Flow Circuit
RangeIPerformance
PO112
PO113
PO1 17
PO118
PO121
14
14
10
10
118
PO128
PO1 31
PO132
PO133
PO133
PO1 34 Intake
Air Temperature Sensor 1 Circuit Low
Intake Air Temperature Sensor 1 Circuit High
Engine Coolant Temperature Circuit Low
Engine Coolant Temperature Circuit High
ThrottleIPedal Position SensorISwitch 'A' Circuit RanqeIPerformance
I I
168
150
150
229
231
150
PO135
Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
02 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
02 Sensor Circuit High Voltage (Bank 1 Sensor 1)
02 Sensor Circuit Slow Response (Bank
1 Sensor 1)
02 Sensor Circuit Slow Response
(Banlc 1 Sensor 1)
02 Sensor Circuit No Activitv Detected
(Banlc 1 Sensor 1)
188 02 Sensor Heater Circuit (Bank 1 Sensor 1)

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I On-Board Diagnostics
Engine diagnostic trouble codes: M54 engine (continued)
P-code
BMW-FC Explanation
Catalyst System Efficiency Below Threshold (Bank 2)
PO430
PO443
PO444
PO445
PO455
PO456
PO491
PO492
PO500
PO441 1250 / Evaporative Emission System Incorrect Purge Flow
234
I I
68
68
68 143
143
245
246
214
PO604
PI083
PI084
PI085
PI086
Evaporative Emission System Purge Control Valve Circuit
Evaporative Emission System Purge Control Valve Circuit Open
Evaporative Emission System Purge Control Valve Circuit Shorted
Evaporative Emission System Leak Detected (large leak)
Evaporative Emission System Leak Detected (very
small leak)
Secondary Air injection System Insufficient Flow (Bani( 1)
Secondary Air Injection System insufficient Flow
(Banic 2)
Vehicle Speed Sensor
'A'
Idle Air Control System PO505
.
PI 087
PI 088
PI089
PI090
PO600 / 217 I Serial Communication Link
204
100
202
202
203
203
PI091
PI092
PI093
PI094
Pllll
PI112
PI120
Internal Control Module Random Access Memory (RAM) Error
Fuel Control Limit Mixture Too Lean (Bank 1 Sensor
1)
Fuel Control Limit Mixture Too Rich (Bank 1 Sensor 1)
Fuel Control Limit Mixture Too Lean (Bank 2 Sensor 1)
Fuel Control Limit Mixture Too Rich (Banic 2 Sensor 1) ~ ~
229
229
230 235
PI121
PI122
PI123
02 Sensor Circuit Slow Response in Lean Control Range (Bank 1 Sensor 1)
02 Sensor Circuit Slow Response in Rich Control Range (Bank 1 Sensor
1)
02 Sensor Circuit Slow Response in Lean Control Range (Banlc 1 Sensor 2)
Pre Catalyst Fuel Trim System Too Lean
(Bank 1)
236
235
236
230
11
11
114
PI134
PI135
PI136
PI137
PI138
Pre Catalyst Fuel Trim System Too Lean (Banic 2)
Pre Catalyst Fuel Trim System Too Rich
(Bank 1)
Pre Catalyst Fuel Trim System Too Rich (Bank 2)
02 Sensor Circuit Slow Response in Rich Control Range (Banic 2 Sensor 1)
Engine Coolant Temperature Sensor Radiator Outlet Low Input
Engine Coolant Temperature Sensor Radiator Outlet High Input
Pedal Position Sensor Circuit
117
110
110
25
25
25
79
79 Pedal Position Sensor 1
RangeIPerformance Problem
Pedal Position Sensor 1 Low Input
Pedal Position Sensor 1 High Input
02 Sensor Heater Circuit Signal Intermittent (Bank 1 Sensor 1)
02 Sensor Heater Circuit Low Voltage (Bank 1 Sensor
1)
02 Sensor Heater Circuit High Voltage (Bank 1 Sensor 1)
02 Sensor Heater Circuit Signal Intermittent (Bank 1 Sensor 2)
02 Sensor Heater Circuit Low Voltage
(Banic 1 Sensor 2)
-
-

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OBD-23
On-Board ~iagnostics]
I I
PI625 / 147 I Pedal Position Sensor Potentiometer Supply Channel 2 Electrical 1
Engine diagnostic trouble codes: M54 engine (continued)
P-code
BMW-FC Explanation
PI 604
PI604
PI619
PI620
PI624
PI632
PI633
PI634
P1 634
PI 634
PI 635
PI 636 50
51 123
123
146 i I
I
I Barometric Pressure Circuit Low
Control
Module Self-Test,
Speed Monitoring
Control Module Self-Test, Speed Monitoring
Map Cooling Thermostat Control Circuit Signal Low
Map Cooling Thermostat Control Circuit Signal High Pedal Position Sensor Potentiometer Supply Channel
1 Electrical (M52: Coolant Thermostat (Coolant
Temperature Below Thermostat Regulating Temperature))
115
115
115
135
136
115
109
PI639
PI675
PI694
P2088
P2089
P2090
P2091
I I
P2229 1197 I Barometric Pressure Circuit High
Throttle
Valve Adaptation Conditions Not Met
Throttle
Valve Adaptation Limp-Home Position Unknown
Throttle Valve Adaptation Spring Test Failed
Throttle
Valve Adaptation Spring Test Failed
Throttle
Valve Adaptation Spring Test Failed
Throttle Valve Adaptation Lower Mechanical Stop not Adapted
Throttle Valve Control Circuit
Throttle Valve Position Control, Control Deviation
PI 637
I I
P2270 1215 1 02 Sensor Signal Stuck Lean (Banic 1 Sensor 2)
PI 638 1160 I Throttle Valve Position Control Throttle Stucic Temporarily
162
161
135
136
21
21 19
19 Throttle
Valve Position Control Throttle
Stucic Permanently
Throttle Valve Actuator Start Test Re-Adaptation Required
Throttle Valve Actuator Start Test Spring Test and Limp-Home Position Failed
'A' Camshaft Position Actuator Control Circuit Low (Banlc 1)
'A' Camshaft Position Actuator Control Circuit High (Banlc 1)
'B' Camshaft Position Actuator Control Circuit Low (Bank 1)
'B' Camshaft Position Actuator Control Circuit High (Bank 1)
P2271
P2272
P2273
P3041
P3198 I I -
215
216
21 6
10481
10205 02
Sensor Signal Stucic Lean (Bank 1 Sensor 2)
02 Sensor Signal
Stuclc Lean (Bank 2 Sensor 2)
02 Sensor Signal Stuclc Lean (Bank 2 Sensor 2)
02 Sensor Lean and Rich Voltage Thresholds not Reached (Bank 2 Sensor 2)
Engine Coolant Temperature Gradient Too High
Engine Coolant Temperature Signal Stuck
P3199
P3238 1 10289 I Control Module Monitoring TPU Chip Defective
10207

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/ On-Board Diaanostics I
Engine diagnostic trouble codes: M62 engine
P-code
PO01 1
PO012
PO020
PO021
PO022
PO030
PO031
PO032
I I
PO038 / 14 I H02S Heater Control Circuit High (Bank 1 Sensor 2)
PO010 / 33 / 'A' Camshaft Position Actuator Circuit (Bank 1)
BMW-FC
I I -.
Explanation
33
33
34
34
34 13
13
13
PO36
'A' Camshaft Position Timing Over-Advanced or System Performance (Bank 1)
'A' Camshaft Position Timing Over-Retarded (Bank 1)
'A' Camshaft Position Actuator Circuit (Bank 2)
'A' Camshaft Position Timing Over-Advanced or System Performance (Banlc 2)
'A' Camshaft Position Timing Over-Retarded (Banlc 2)
H02S Heater Control Circuit (Bank 1 Sensor 1)
H02S Heater Control Circuit Low (Bank 1 Sensor 1)
HOPS Heater Control Circuit Hiqh (Banlc 1 Sensor 1)
PO050
PO051
PO052
PO056
PO057
PO058
PO037 / 14 / H02S Heater Control Circuit Low (Bank 1 Sensor 2)
14
I I -.
Ir-1 ThrottleIPedal Position SensorISwitch 'A' Circuit
Low-
HO2S Heater Control Circuit (Bank 1 Sensor 2)
5
5
5
4
4
4
PO102
PO1 13
PO116
PO117
PO118
PO119
PO120
PO121
H02S Heater Control Circuit (Banlc 2 Sensor 1)
H02S Heater Control Circuit Low (Bank 2 Sensor 1)
H02S Heater Control Circuit High (Bank 2 Sensor 1)
H02S Heater Control Circuit (Bank 2 Sensor 2)
HO2S Heater Control Circuit Low (Bank 2 Sensor 2)
HO2S Heater Control Circuit Hiqh (Bank 2 Sensor 2)
PO103 1115 I Mass or Volume Air Flow Circuit High Input
115
124
123
123
123
123
117
118
PO1 23
PO125
PO128
PO1 30
PO131
POI 32
PO133
Mass or Volume Air Flow Circuit Low Input
lntalte Air Temperature Sensor 1 Circuit High
Engine Coolant Temperature Circuit
RangeIPerlormance
Engine Coolant Temperature Circuit Low
Engine Coolant Temperature Circuit High
Engine Coolant Temperature Circuit Intermittent
ThrottleIPedal Position SensorISwitch 'A' Circuit
ThrottieIPedal Position SensorISwitch 'A' Circuit RanqeIPerformance
118
123 139
10
10
10
15
ThrottleIPedai Position SensorlSwitch 'A' Circuit High
insufficient Coolant Temperature for Closed Loop Fuel Control
Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
02 Sensor Circuit (Bank
1 Sensor 1)
02 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
02 Sensor Circuit High Voltage (Bank
1 Sensor 1)
02 Sensor Circuit Slow Response (Bank 1 Sensor
1)

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OBD-28
1 On-Board Diagnostics
Engine diagnostic trouble codes: M62 engine (continued)
P-code
PI134
PI135
PI136
PI137
PI138 I I . .
PI139
~ PI152
PI153
PI155
PI156
PI157
PI158
PI159
I I
PI 327 1211 / Knoclc Sensor 2 Circuit Low Input (Banlc 1)
BMW-FC
13
13
13
14
14
I I -.
Explanation
02 Sensor Heater Circuit Signal Intermittent (Bank 1 Sensor 1)
02 Sensor Heater Circuit Low Voltage (Bank 1 Sensor 1)
02 Sensor Heater Circuit High Voltage (Bank 1 Sensor 1)
02 Sensor Heater Circuit Signal Intermittent (Bank 1 Sensor 2)
02 Sensor Heater Circuit Low Voltaqe (Bank 1 Sensor 2)
PI151 15 1 02 Sensor Heater Circuit Signal intermittent (Bank 2 Sensor 1)
14
~ 5
5
4
4
4
28
28
PI160
02 Sensor Heater Circuit High Voltage (Bank 1 Sensor 2)
02 Sensor Heater Circuit Low Voltage (Banic 2 Sensor 1)
02 Sensor Heater Circuit High Voltage (Bank 2 Sensor 1)
02 Sensor Heater Circuit Signal Intermittent (Banlc 2 Sensor 2)
02 Sensor Heater Circuit Low Voltage (Bank 2 Sensor 2)
02 Sensor Heater Circuit High Voltage (Bank 2 Sensor 2)
Fuel Trim Adaptation Additive Low (Bank 1)
Fuel Trim Ada~tation Additive Hish (Banlc 1)
PI 328
PI 332
PI 333
PI 340
PI341
PI342
PI343
I
I Misfire During Start Cylinder 3 1
PI161 129 / Fuel Trim Adaptation Additive High (Bank 2)
29
I I
Fuel Trim
Adaptation Additive Low (Banlc 2)
21 I
21 3
213 62
62
50
50
PI344
Knock Sensor 2 Circuit High input (Bank 1)
Knoclc Sensor 4 Circuit Low Input
Knock Sensor
4 Circuit High Input
Multiple Cylinder Misfire During Start
Multiple Cylinder Misfire with Fuel Cut-Off
Misfire During Start Cylinder
1
Misfire Cvlinder 1 with Fuel Cut-Off
PI 347
PI348
PI349
PI 350
PI351
PI352
PI353
PI345 1 57 I Misfire Cylinder 2 with Fuel Cut-Off
57
I I
Misfire During Start Cylinder 2
55
52
52
51
51
54
54
Misfire Cylinder 3 with Fuel Cut-Off
Misfire During Start Cylinder
4
Misfire Cylinder 4 with Fuel Cut-Off
Misfire during Start Cylinder
5
Misfire Cylinder 5 with Fuel Cut-Off
Misfire during Start Cylinder
6
Misfire Cvlinder 6 with Fuel Cut-OW
Misfire during Start Cylinder
7 PI354
PI355 1 56 I Misfire Cylinder7 with Fuel Cut-Off
56