1997 BMW 540i Ele

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020 Maintenance
General ........................... .02 0.2
Special tools ........................ .02 0.2
Service Interval Indicator (Sll) ........... .02 0.3
Service Interval Indicator (Sll), resetting ... .02 0.3
Inspection I, Inspection 11 ............... .02 0.5
Maintenance Tables ................ .02 0.6
Fluid and Lubricant Specifications .. .02 0.9
Fluids and lubricants ................. .02 0.10
Engine Oil Service ................ .02 0.1 I
Engine oil. checking level ............. .02 0.12
Engine oil and filter. changing .......... .02 0-13
Engine Compartment Maintenance . .02 0.14
Accelerator and linkage ............... .02 0.14
Air filter. replacing ................... .02 0.1 4
Cooling system service ............... .02 0.15
Engine drive belt service .............. .02 0.16
Idlespeed .......................... 020-19
Catalytic converter and oxygen sensors .. .02 0.19
Power steering fluid, checking level ..... .02 0.20
Spark plugs ........................ .02 0.20
Spark plugs, replacing ................ .02 0.21
Interior ventilation microfilter, replacing ... .02 0.22
Other Mechanical Maintenance ..... .02 0.22
Battery, checking. cleaning. and replacing .02 0-22
Brake fluid. replacing ................. .02 0-24
Brake pad 1 rotor wear. checking ........ .02 0.24
Brake system, inspecting ............. .02 0.25
Parking brake. checking ............... 020-25
Clutch fluid. checking ................. 020-26
Differential oil level. checking ........... 020-26
Drive axle joint (CV joint) boots. inspecting 020-27
Exhaust system. inspecting ............ 020-27
Fuel filter. replacing .................. 020-27
Fuel tank and fuel lines. inspecting ...... 020-28
Suspension. front. inspecting ........... 020-29
Suspension. rear. inspecting ........... 020-29
Tires. checking inflation pressure ........ 020-29
Tires. rotating ....................... 020-29
Transmission service. automatic ........ 020-29
Transmission service. manual .......... 020-30
Transmission fluid. checking and filling
(manual transmission)
................ 020-30
Wheels. aligning ..................... 020-30
Body and Interior Maintenance ..... 020-31
Body and hinges. lubricating ........... 020-31
Exterior washing ..................... 020-31
Interior care ........................ 020-31
Leather upholstery and trim ............ 020-31
Polishing ........................... 020-32
Seat belts .......................... 020-32
Special cleaning ..................... 020-32
Washing chassis ..................... 020-32
Waxing ............................ 020-32
Windshield wiper blade maintenance ..... 020-33

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Maintenance
Service Interval lndicator (Sll)
The BMW Service Interval lndicator (SII) notifies the driver
when oil change and other service is required. The
Sll dis-
plays the phrase "OIL SERVICE"
or"INSPECTI0N" and 7
light emitting diodes (LEDs) in the Instrumentcluster: 5green,
one yellow and one red.
For the
1997 and later 5 Series, BMW introduced an oil
change interval based on fuel consumption. The advantages
of this system are:
Fuel consumption is an accurate method of determining
engine load and the need for service.
The processing electronics are simple.
Resetting of indicator before the scheduled time will not
affect the time to the next service.
4 The Sll is programmed to measure a set volume of con-
sumed fuel. This volume varies between models, dependent
on vehicle and engine size. The
Sil control unit receives a
signal from the engine control module (ECM) when the vehi-
cle is in use. As
20% of the programmed fuel volume is con-
sumed, one of the green LEDs will go out. Each successive
20% of fuel consumption will cause the next LED to go out
until
100% of the measured volume has been consumed. At
this point the yellow LED will come on, indicating that service
is due. When
108% of the measured volume has been con-
sumed, the red LED will illuminate, indicating that service is
overdue.
Service Interval Indicator (SII), resetting
After the specified maintenance has been carried out, the Sll
memory should be reset.
NOTE-
For reference, the BMW oil service requirements are approx-
imately equivalent to the maintenance tliat other European
manufacturers specify at intervals with a maximum of every
15.000 miles or I2 months.

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020-4
Maintenance
1997 to 2000 models
1997 to 2000 models are equipped with a data link connector
(DLC) plug in the right side engine compartment:
Reset
SII using BMW service and scan tool (DISplus or MoD-
iC, GTI) or a specialty tool from another manufacturer. Plug
tool (arrow) into DLC.
CAUTION-
Follow the manufacturer's directions when resetting the Sll. If
the reset procedures are done
incorrect& the tool or the elec-
tronic Service Interval Indicator
may be damaged.
Aftermarket reset tools that can reset all models with the DLC
can be purchased from one of the following suppliers:
Specialty tool suppliers
Assenmacher Specialty Tools
6440
Odell Place
Boulder, CO 80301
303-530-2424
[email protected] http://www.asttool.com
Baum Tools Unlimited,
Inc.
P.O. Box 5867
Sarasota, FL 34277-5867
800-848-6657
[email protected]
http://www.baumtools.com
Peake Research. Automotive Products Division
P.O. Box 28776
San Jose, CA 95159
408-369-0406
support @peakeresearch.com
http://www.peal~eresearch.com
2001 and later models
On vehicles without the data link connector (DLC) in the en-
gine compartment (2001 and latercars), the reset tool can not
be used. Instead, the
Sll can be reset with the trip odometer
reset button in the instrument cluster.
Make sure ignition key is in OFF position.
* Press and hold trip odometer button in instrument cluster,
and turn ignition key to ACCESSORY position.
Keep
button pressed for approximately 5 seconds until
either of following appear in display: OIL SERVICE or
INSPECTION, with RESET.
Press button again and
hold for approximately 5 seconds
until RESET flashes.

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--- -
Maintenance
Table b. Inspection I Service (continued)
I I I I
Warm engine Dealer service
required recommended
Check windshield
washer fluid level and
antifreeze protection.
Add washer fluid as necessary.
Replace ventilation
microfilter. (Note:
reduce replacement intervals in dusty
operation conditions)
Reset Service interval Indicator
(Sil).
Additional
repair
information
Tools Required
*
eck aim of washer jets and adjust if
necessary.
covers, obvious damage or attachment o
s or accessories.
Road test
Check braking performance, steering,
heating and air conditioner operation.
Check manual transmission and clutch
operation or automatic transmission
operation. New
parts
required
*
Bodylelectrical
121
630
630
Checic battery state of charge
Check operation of:
headlights,
parking iights, back-up lights.
license plate lights, interior lights,
glove box
illumination, engine compartment light,
trunk light, turn signals, emergency
flashers, stop iights.
Check operation of horn and headlight
dimmer switch
:i:

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--- -
Maintenance
Table c. Inspection II Service
Additional
New parts Warm engine Dealer service repair
Tools required required required recommended information
Engine compartment maintenance
Replace air filter element. (Note: reduce
replacement intervals in dusty operating
conditions).
Replace brake
fluid every 2 years (time
interval begins from vehicle production
date).
Cooling system service
Spark plug service
Brake
system maintenance
:j:
*
Replace coolant every 3 years (time
interval begins from vehicle production
date).
Replace oxygen sensor every 160,000
itm
(1 00,000 miles).
020
FLUID AND LUBRICANT
SPECIFICATIONS
:I:
Oxygen sensor service
*
x:
Spark plugs:
M52
1 M62 engine:
Replace every 60,000 itm (48.000 miles).
M52
TU I M54 1 M62 TU engine:
Replace every 160,000
ltm (100.000
miles).
< Engine oil viscosity (SAE grade) vs. operating temperature
range for the BMW engines covered in this manual.
Fluid and lubricant capacities and specifications are listed be-
low. See
Fluids and lubricants.
:I:
*
*
*
WARNING -
The use of fluids that do not meet BMW" specifications may
impair performance and
reliabilitl: and may void warranty
coverage.
340
170
180
* 020

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020-1 4
Maintenance
- When oil flow has diminished to an occasional drip, reinstall
drain plug with a new metal sealing washer and torque plug.
Tightening torque Engine oil drain plug to oil pan
25 Nrn (1.8 ft-lb)
6-cylinder oil filter assembly
r------ 1
< Working at oil filter housing (1):
Lubricate and install new oil filter O-rings (3, 4).
Install a new filter cartridge (5).
lnstall and tighten housing cover (2).
6-cylinder oil filter assembly shown, V-8 is similar.
Tightening torque Cover to oil filter housing
25 Nm (1.8 it-lb)
- Refill crankcase with oil. Approximate oil capacity is listed in
Tabled. Engine oil with filter change. Use dipstick to
check correct oil level.
- Start engine and check that oil pressure warning light
immediately goes out.
- Allow engine to run fora few minutes to circulate new oil, then
check for leaks at drain plug and oil filter. Stop engine and re-
check oil level
The section describes other routine maintenance done in the
engine compartment. Information on engine oil service is
giv-
enkar~ier inthis group.
For these procedures, it is not necessary for the car to be
raised and supported off the ground.
Accelerator and linkage
The accelerator and linkage at the throttle housing should be
lubricated periodically. Use ageneral purposeoil on the joints
and bearings of the linkage. Use a multipurpose grease on
the bearing points of the throttle plate.
Air filter, replacing
The specified replacement intervals forthe air filter are based
on normal use. If the car is operated primarily in dusty
conditions, the air filter should be serviced more frequently.

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Maintenance
< Release mass air flow sensor clips (A).
Release upper air filter housing clips (B).
4 Lift air filter upper housing, and remove filter element.
NOTE-
V-8 engine air filter assembly shown in illustration. 6-cylinder
air filter assembly is similar but located at the left front of the
engine compartment.
- On installation, install O-ring for mass air flow sensor into
retaining clips in air filter upper housing.
- Replace air filter and upper air filter housing, and attach
upper air filter housing clips.
Cooling system, checking
Antifreeze raises the boiling point and lowers the freezing
~oint of the coolant. BMW recommends enaine coolantthat is
a 50 150 mixture of distilled water and ethGene glycol-based
antifreeze.
Routine cooling system maintenance consists of maintaining
the coolant level and inspecting hoses. Because the coolant's
anticorrosion and antifreeze additives gradually lose their ef-
fectiveness, replacement of the coolant every three years is
recommended.
CAUJION-
Use only BMWapprovedphosphate-free antifreeze when
filing the cooling system. Use of antifreeze containing
phosphates is harmful to the cooling system.
4 Float in radiator tank indicates coolant level. Inspect while
coolant is cold.
When upper mark on float is level with top of filler neck,
coolant is at minimum allowable level.
When lower mark on float is level with top of filler neck,
coolant is at maximum level.
Hose connections should be tight and dry. Coolant seepage
nnection indicates either that hose clamp is

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< 6-cylinder engine with hydraulic belt tensioners.
Use long-handled wrench to turn
A/C belt tensioner (A)
clockwise. Remove AfC belt.
* Similarly, turn main engine drive belt tensioner (B)
clockwise and remove belt.
< Some models have a dust cover over belt tensioner release
lug, which must be pried off prior to removing belt.
4 6-cylinder engine with spring-loaded belt tensioners.
Use long-handled wrench to turn
AfC belt tensioner
release lug
(A) clocltwise (against spring tension).
Remove
AfC belt.
Similarly, turn main engine drive belt tensioner lug
(B)
clocltwise and remove belt.