1997 BMW 540i Ele

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Maintenance
< Remove NC compressor belt:
Loosen tensioner mounting fasteners (arrows)
Swing tensioner down to remove belt.
4 To reinstall compressor belt:
Route belt over pulleys.
* Pretension belt by turning adjuster clockwise (arrow) to
stop.
- Tighten tensioner mounting bolts (A).
Tightening torques
Fan clutch to coolant pump (left- hand thread)
with BMW tool
11 5 040
30 Nm (22 ft-lb)
without BMW tool 11 5 040
40 Nm (29 ft-lb)
Tensioner to engine block
8.8 grade
22 Nm (16 ft-lb)
10.9 grade (Ilquid-cooled alternator) 30 Nm (22 ft-lb)
Idle speed
Engine idle speed can change due to a number of factors, in-
cluding normal wear. The idle speed is electronically adaptive
and not adjustable. See
130 Fuel Injection for more informa-
tion.
Catalytic converter and oxygen sensors
OBD II enhanced emission standards require the engine
control module (ECM) to monitor the oxygen content in the
exhaust with oxygen sensors placed before and after the cat-
alytic converter. This allows for tighter control of tail pipe
emissions and also allows the ECM to diagnose converter
problems. If the ECM detects that catalytic converter or oxy-
gen sensor efficiency has degraded past a certain
prepro-
grammed limit, it will turn on the malfunction indicator light
(MIL), and store a diagnostic trouble code (DTC) in the ECM.
See OBD On-Board Diagnostics for more information on
OBD
ll systems.
Replacement of oxygen sensors at the specified intervals
he engine and emission control system will

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Maintenance
continue to operate as designed. Extending the replacement
interval may void the emission control warranty coverage.
See
180 Exhaust System for information on replacing the
oxygen sensors.
Tightening torque
Oxvoen sensor to exhaust
manifold 50 Nrn (37 ft-lb)
NOTE-
A special soclet for replacing the oxygen sensor is available
from most automotive parts stores. The soclet has
a groove
cut down one side to allow the sensor to be installed without
damaging the wire harness.
Power steering fluid, checking level
The power steering system is permanently filled and does not
have a drain. Routinely adding ATF is not required unless the
system is leaking.
4 To check power steering fluid level in fluid reservoir:
Park car on level ground with engine off.
Level is correct
if it is between MlN and MAX marks on
dipstick.
If level is below
MlN mark, add fluid to reservoir to bring
level up.
* Hand-tighten reservoir cap.
Power steering fluid
Dexron
1iiO ATF or equivalent
Spark plugs
E39 models through model year 1998 were equipped with
spark plugs with two electrodes. These are gapped to
0.7 mm
(0.028 in) by the manufacturer and are not adjustable.
Starting with 1999 models, long life spark plugs with
3 or four
electrodes were used. These can be retroactively fitted to
earlier
models. The recommended spark plug replacement
interval
forthese is 100,000 miles.The electrode gap in these
spark plugs is not adjustable.
Spark plug applications
M52 Bosch FBLDCR
M52 TU, M54 Bosch FGR7DQP or NGK BKRBEQUP
M62 to 7/97 Bosch F7LDCR or NGK BKR6EK
M62 from 7/97 Bosch F9LDCR
M62 TU Bosch FGR7DQP or NGK BKRGEQUP

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Maintenance
- To remove battery corrosion:
Disconnect battery cables. Disconnect negative (-)cable
first.
* Remove battery from trunk
Clean terminal posts and cable clamps with a wire brush.
Clean main chassis ground terminal next to battery.
Corrosion can be washed away with a
baking soda and
water solution that will neutralize acid.
Reinstall battery and reconnect cable clamps, positive
(+)
cable first.
Lightly coat outside of terminals, hold down screws, and
clamps with petroleum jelly, grease, or a commercial
battery terminal corrosion inhibitor.
WARNING
-
Battery acid is extremely dangerous. Take care to keep it
from contacting eyes, skin, or clothing. Wear eye protection.
Extinguish all
smolihg materials and do not work near any
oaen flames.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
NOTE-
The original equipment battery in E39 models is mainte-
nance free. The original electrolyte will normally last the
entire service life of the battery under moderate climate con-
ditions.
Battery electrolyte should be maintained at the correct level
just above the battery plates and theirseparators. The correct
level is approximately
5 mm ('14 in.) above the top of battery
plates or to the top of the indicator
marks (if applicable). The
battery plates and the indicator marks can be seen once the
fillercaps are removed.
if theelectrolyte level is low, replenish
it by adding distilled water only.
4 The original equipment BMW battery is equipped with a
built-in hydrometer "magic eye"
(arrow). Battery condition is
determined by the color of the eye:
Green: Adequate charge
* Black: Inadequate charge, recharge
Yellow: Defective battery, replace
Batteries are rated by ampere hours (Ah), the number of
hours a specific current drain can be sustained before com-
plete discharge, or by cold cranking amps (CCA), the number
of amps available to crank the engine in cold weather
condi-

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020-26
Maintenance
NOTE-
The parking brake may lose some of its effectiveness if it is
not used frequently This is due to corrosion build-up on the
parking brake drum. To remove corrosion, apply the parking
brake just until it begins to grip, then pull the lever up one
more stop (click). Drive the car approximately 400 meters
(1,300
ft.) and release the brake. To recheck the adjustment
of the parking brake see
340 Brakes.
Clutch fluid, checking
In cars equipped with manual transmission and clutch, the hy-
draulic clutch and the brake system share the same reservoir
and the same bralte fluid. Clutch fluid level and brake fluid lev-
el are checked at the same time.
NOTE-
* See 340 Brakes for more information.
See
210 Clutch for information on the clutch and the
hydraulic clutch operating system.
Differential oil level, checking
The E39 differential is filled with lifetime oil that ordinarily
does not need to be changed.
BMW recommends using only
a specially formulated synthetic gear oil
(SAF-XO) that is
available through an authorized
BM\N dealer parts depart-
ment. For additional information on this lubricant and any
other lubricants that may be compatible, contact an
authorized
BMW dealer service department.
< Check rear differential oil level at filler plug (arrow).
- Check lubricant level with car on a level surface:
Level is correct when fluid just reaches edge of filler hole.
If necessary, top up fluid.
Replace filler plug sealing ring.
Install and tighten oil filler plug when oil level is correct.
NOTE-
Use either a 14 mm or 17 mm Allen socket to remove the
drain plug.
If the car is raised in the air, it should be level when
checking or filling final drive fluid level.
Tightening torque
Filler plug to final drive housing 70 Nrn (52 it-lb)

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Maintenance
BODY AND INTERIOR MAINTENANCE
Body and hinges, lubricating
Door locksand loclccylinderscan be lubricated with an oil that
contains graphite.
Body and doorhinges, hood latch and doorcheclc rods should
be lubricated with
SAE 30 or SAE 40 engine oil. Lubricate
seat runners with multipurposegrease. Do not apply any oil to
rubber parts.
If door weather-strips are sticking, lubricate
them with silicone spray or talcum powder. The hood release
cable should be lubricated as well.
The use of winter
lock deicer sprays should be lkept to an
absolute minimum, as the alcohol in the deicer will wash the
grease out of the lock assemblies and may cause locks to
corrode internally or to become difficult to operate.
Exterior washing
The longer dirt is left on the paint, the greater the risk of dam-
aging theglossy finish,
eitherby scratching or by thechemical
effect dirt particles may have on the painted surface.
Do not wash the car in direct sunlight. If the engine hood is
warm, allow it to cool. Beads of water not only leave spots
when dried rapidly by the sun or heat from theengine, but also
can act as small magnifying glasses and burn spots into the
finish. Wash the car with a mixture of lukewarm water and a
car wash product. Rinse using plenty of clear water. Wipe the
body dry with a sofl cloth towel or chamois to prevent
water-spotting.
Interior care
Dirt spots can usually be removed with lultewarm soapy water
or a dry foam cleaner. Use spot remover for grease and oil
spots. Do not pour the liquid directly on the carpet or fabric,
but dampen a clean cloth and rub carefully, starting at the
edge of the spot and working inward. Do not use gasoline,
naphtha, or other flammable substances.
Leather upholstery and trim
Leather upholstery and trim should be periodically cleaned
using a slightly damp cotton or wool cloth. The idea is to get
rid of the dirt in the creases and pores that can cause brittle-
ness and premature aging. On heavily soiled areas, use a
mild detergent (such as
wooliteQ) or other specially formulat-
ed leather cleaners. Dry the trim and upholstery completely

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Engine identifying features
4 The M52 engine (MY97-98 528i) used a single on-off vari-
able intake valve timing system (called VANOS). The cylinder
block is cast iron and the cylinder head is aluminum. The en-
gine management system is Siemens MS 41
.I and features
NGK-type (0-5 volt) oxygen sensors.
NOTE-
VANOS is an acronym based on the German words Variable
Nocltenwellen Steuerung (variable camshaft timing).
4 The M52 TU engine (MY99-00 5281) and the M54 engines
(MY01-02 525il530i) are fitted with double VANOS. The en-
gine
blocits are constructed of aluminum alloy with cast iron
cylinder sleeves.
4 The double VANOS (variable camshaft control) system incor-
porates true variable control of both the
intake and exhaust
camshafts, as compared to the single VANOS system on the
M52 engine
(onloff control of the intaite camshaft only).
The M54 engines use a fully electronic throttle control (drive
by wire). There is no accelerator cable connecting the throttle
pedal to the throttle housing in these cars.

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100-4
I Engine-General
The M62 90" V8 engine uses four valves per cylinder, double
overhead camshafts and light alloy cylinder head and cylin-
der
bloclc engine construction.
On 1997 and 1998 540i models, Bosch engine management
systems are utilized. Table a lists engine management sys-
tem applications.
4 For the 1999 model year, the M62 TU VANOS engine was in-
troduced to the 540i models. This engine is primarily a carry-
over from the earlier M62 engine, but contains many unique
identifying components and technology:
Variable camshaft timing (VANOS) for the intake valves.
Bosch ME 7.2 engine management system with electronic
throttle control. There is no accelerator cable connecting
the throttle pedal to the throttle housing in these cars.
Compact water-cooled generator (alternator).
E39 vehicles are equipped with sophisticated self-diagnostic
engine management systems. These systems monitor and
store diagnostic fault information. If the malfunction indicator
lamp (MIL) illuminates, the first diagnostic test should be to
connect a dedicated scan tool for BMW automobiles and in-
terrogate the fault memory.
If the malfunction indicator light (MIL) comes on orflashes, it
indicates that an emissions-related fault has occurred and
that fault information is stored in memory within the ECM.
4 The MIL in E39 cars displays one of these warning graphics
in the instrument cluster.
The diagnostic capabilities of these systems have the poten-
tial to save hours of diagnostic time and prevent incorrect
5 placement. See OBD On-Board Diagnostics.

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Two common causes of driveability problems are incorrect
system voltage and bad grounds.
System voltage
Digital motor electronics (DME) requires that the system (bat-
tery) voltage be maintained within a narrow range of DC volt-
age.
DC voltage levels beyond or below the operating range,
or any
AIC voltage in the electrical system can cause havoc.
When troubleshooting an illuminated MIL, make sure the bat-
tery is fully charged and capable of delivering all its power to
the electrical system. An undercharged battery can amplify
AIC alternator output ripple.
To
make a quick check of the battery charge, measure the
voltage across the battery terminals with all cables attached
and the ignition off.
Afully charged battery will measure 12.6
volts or slightly more, compared to 12.1 5 volts for a battery
with a 25% charge.
The DME system operates at low voltage and current levels,
making it sensitive to small increases in resistance. The elec-
trical system is routinely subjected to corrosion, vibration and
wear, so faults or corrosion in the wiring harness and connec-
tors are not uncommon. Check the battery terminals
forcorro-
sion or loose cable connections. See 121 Battery, Starter,
Alternator for additional information.
If a battery cable connection has no
v~sible faults but is still
suspect, measure the voltage drop across the connection. A
large drop indicates excessive resistance, meaning that the
connection is corroded, dirty, or damaged. Clean or repairthe
connection and retest.
NOTE-
For instructions on conducting a voltage drop test and other
general electrical troubleshooting information, see
600 Elec-
trical System-General.
Visually inspect all wiring, connectors, switches and fuses in
the system. Loose or damaged connectors can cause inter-
mittent problems, especially the small terminals in the ECM
connectors. Disconnect the wiring harness connectors to
check for corrosion, and use electrical cleaning spray to re-
move contaminants.
Main grounds
Good grounds are critical to proper DME operation. If a
ground connection has no visible faults but is still suspect.
measure the voltage drop across the connection. A large volt-
age drop means high resistance. Clean or repair the connec-
tion and retest.
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