1997 BMW 540i Cluster

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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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Fuel Injection I
Engine coolant temperature (ECT) sensor,
testing
The ECT sensor is located on the front of the engine in the
coolant~thermostat flange. The ECT sensor is a dual temper-
ature sensor. One circuit provides coolant temperature infor-
mation to the ECM while the other circuit provides coolant
temperature information to the instrument cluster.
The ECM determines the correct ignition timing and
airlfuel
mixture required for the engine by monitoring an applied volt-
age
(5 vdc) to the sensor. Thevoltage drop across the sensor
varies as the coolant temperature (sensor resistance) chang-
es.
NOTE-
The ECT sensor is an NTC (negative temperature coeffi-
cient) type sensor. In other words, as the temperature rises,
resistance through the sensor decreases.
If the ETC sensor input is faulty or non-plausible, the MIL is il-
luminated when OBD
II fault criteria are exceeded. The ECM
assumes a substitute value
(80" C/ 176°F) to maintain engine
operation. The ignition timing is set to a
conse~ativelsafe ba-
sic setting.
Disconnect harness from
ECTsensor (A) at coolant flange at
front of engine.
- Check ECT sensor resistance using a multimeter at sensor
terminals
3 and 4. Peel back protective boot (B) to ID termi-
nal numbers on connector housing.
I ECT sensor resistance @ 20" C (68°F) I 2.2 - 2.7 lkCi
Engine coolant temperature (ECT) sensor,
replacing
I WARNING-
/ Due to risk ofpersonal injury, be sure the engine is cold be- I
I fore replacin~~~~sensor. -
-
I
- Disconnect ECT sensor harness.
- Unscrew ECT sensor from cylinder head and install new sen-
sor.
Use new copper sealing washers when installing sensor.
Replace any lost coolant.
Tightening torque
ECT sensor to coolant flange 13 Nm (10 it-lb)

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I Fuel Injection
Connector X60003 (continued) Electric throttle actuator
25
- 27 28
29
30
31
32
33
I I I
36 jlnput I Knoclc sensor 2, signal 1 Knock sensor
I I I
Input
26
Output
Output
input
Output
Input
I ' I . I
43 1 ln~ut I Electric throttle actuator, signal (Electric throttle actuator
Ground, electric throttle actuator
1 Not
used
Hot film mass air flow sensor
34
- 37
38
39
40
41
42
injection signal
Injection
signal
VANOS valve, signal
Not used
Thermostat characteristic map, signal
Crankshaft position sensor, signal
Not used
35 l~round I~nock sensor, shield 1 ~nock sensor
Cylinder
8 fuel injection valve
Cylinder
5 fuel injection valve
VANOS valve, cylinders
1-4
Characteristic map
Crankshaft positionlrpm sensor
input
input
Ground
Input
Output
Output
Innut
Hot film mass air flow sensor, signal
I
44
45 46
47
48
49
50
51
52
Connector )(GO004
Knock sensor 4, signal
Knock sensor, shield
Oil
level (thermal)
Injection, signal
Injection, signal
Electric throttle actuator, signal
Not used
Ground
Crankshaft position sensor, signal
Not used
Knoclc sensor, shield
Knock sensor
1, signal
Knock sensor
3, signal
Knock sensor, shield
Secondary air injection pump valve, signal
'
Ground
Input
Ground
input Input
Ground
Input
I' I ... I . ~
Knock sensor
Knocic sensor
Oil level sensor
Cylinder
4 fuel injection valve
Cylinder
1 fuel injection valve
Electric throttle actuator
Crankshaft sensor shield
Crankshaft
positionlrprn sensor
Knock sensor
Knock sensor
Knock sensor
Knock sensor
Secondary air injection pump valve
Notes
Instrument cluster
Integrated instrument cluster control
Secondary air injection pump
relay
Pin
1
2
3
Electric (auxiliary) cooling fan 4
Type
Output
Output
Outout
Descriptionlsignal type
Charge indicator signal (terminal
61)
Voltage signal, terminal 30h
Secondam air pump relay, activation
Input
5
Signal, electric (auxiliary) cooling fan, signal
I~ot used

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Fuel Injection I
Connector X60004 (continued)
8 10
11
12
13
14
15
16
9
Output 0
Input
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
39
llnput lsignal l~oolant outlet temperature sensor
Output
Output
Ground
Input
Output
I I - I
40 /output Istart signal Istarter relay
Pedal position sensor (PWG), signal
Output Input
Output
input
Input
Input
Input
Input
Input
input
Input
Output
Input/-output
Input/-output
37
Connector X60003
Pedal position sensor
Fuel pump relay, activation
Oil pressure indicator Pedal position sensor (PWG), ground
Pedal position sensor (PWG), signal
Pedal position sensor (PWG), power supply
Not used
Not used Fuel
pump relay
Instrument cluster
Pedal position sensor
Pedal position sensor
Pedal position sensor
Engine speed signal output (TD)
Not used
Signal
back-up light
DM-TL (diagnostic module,
tank leakage)
Signal oil level sensor
Right rear wheel speed, signal
Clutch pedal position switch, signal
Brake light switch, signal
Not used
Voltage supply, terminal
15
Data link, MFL (multi-function steering wheel)
Brake light test signal
AJC compressor signal
DM-TL (diagnostic module, tank
leakage)
Not used
Diagnosis signal
TxD
Communication link (EWS)
Not used
Not used
CAN-BUS hiqh
38 1 Ground l~round I Coolant outlet temperature sensor
OED II plug
Integrated instrument cluster control module (IKE)
Light module
ABSIDSC control module
Clutch pedal position switch
Brake light switch
Fuse
F14
Airbag contact coil spring
Brake light switch
Heating and
A/C control module
OBD
II plug
Electronic immobilizer (EWS)
CAN-Bus link
CAN-Bus link
Input/-output CAN-Bus low

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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.

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Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Break in the SAC gradually, with light to medium loads, to en-
sure correct operation and long life. Fast sports driving ma-
neuvers may destroy a new
clutch.The following break-in
procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level
grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500
- 4000
rpm.
On medium grades (approx. 12% and up), start
off at ap-
prox. 2500 rpm for the first 5 or so times.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade)
M8 (10.9 grade) 24
Nm
(18 ft-lb)
34 Nm (25 ft-lb)

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400-1 0
Body-General
Seats
4 Anatomically correct seats are constructed from polyure-
10 way seat adjustment thane foam
containing areas or "zones" of different firmness.
They offer good lateral support without constricting the occu-
pant.
The seats have a passive internal ventilation system: Cylin-
drical cavities within the cushions and backrests generate a
pumping effect as the ride motions cause occupant motion.
This
helps remove moisture and feeds fresh air into the seats.
Other features of the seating system:
The seat bases have steel springs for added support and
strength.
The seat control switches are along the outside edge of
the
seat.
Heated seats are an option in all models
In cars equipped with seat position memory, three different
seat confiaurations can be memorized by the seat control
module(s): Seat memory coordinates with outside mirror
memory. These functions are controlled by the seat mem-
ory
module(s).
* For security reasons, the release lever to fold the rear seat
backrest forward is installed in the trunk.
Sport Wagon models: Rear seat
baclts are split 60140, with
the center armrest on the left seat back.
The center armrest incorporates a non adjustable head-
rest. When folded down, the armrest opens out with
cup-
holders and a storage compartment. See 520 Seats for
more details.
instruments and controls
Everything in the interior passengercompartment essential to
the driver is logically grouped and easy to reach. All instru-
ments and controls have been arranged ergonomically and
are fully integrated into the overall design of the vehicle.
Tilt-telescopic steering wheel has
30 mm (1.2 in) of vertical
and longitudinal adjustment.
Multifunction steering wheel contains two
ltey pads con-
taining controls for the sound system, telephone and
cruise control.
Padded dashboard houses the instrument cluster and the
ventilation and heating system.

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Instrument cluster
Instrument cluster uses large easy-to-read analog instru-
ments and is removable as a unit without removing the dash-
board. On-board computer and Check Control functions are
integrated into the instrument cluster displays.
Service Interval Display
Service Interval Display calculates vehicle service needs
based on current driving patterns, and indicates to the driver
when the car requires
service
On-board navigation
An integrated on-board navigation system, based on Global
Positioning System (GPS) technology, is optionally available
on
E39 cars. When installed, a multifunction monitor is includ-
ed in the center of the dash above the radio. in addition to dis-
playing navigation system information, this monitor accesses
On-Board Computerfunctions, audiosystem controls, mobile
phone dialling and memory, and automatic ventilation.
Park Distance Control (PDC)
Park Distance Control (PDC) is an optional system which
uses ultrasonic sensors in the rear bumper trim to warn the
driver of approaching too close to obstacles when parlting.
Central body electronics
E39 vehicles are equipped with an integrated complex of
electronic modules connected mostly via K-Bus. This system,
called central body electronics (ZKE
Ill), is primarily con-
trolled by the general module (GM
Ill). An overview of ZKE Ill
functions is found in 600 Electrical System-General. Details
of ZKE
Ill functioning is in the following repair groups:
- 512 Door Windows
* 515 Central Locking and Aniti-Theft
520 Seats
a 540 Sunroof
611 Wipers and Washers
620 Instruments