1997 BMW 540i Tire

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340-8
1 Brakes
Brake bleeding is usually done for one of two reasons: either
to replace old brake fluid as part of routine maintenance or to
expel trapped air in the system that resulted
from opening the
brake hydraulic system during repairs.
Read the
Warnings listed below before beginning the bleed-
ing procedure an on any
E39 car. If air enters the ACS or DSC
hydraulic unit, the factory BMW Service Tester MUST be
used in conjunction with a bralte pressure bleeder before the
vehicle is driven.
The BMW
ServiceTester (DISpluslGT1iMoDiC) must be
used to bleed the braltes if:
Any hydraulic brake system components are replaced, in-
cluding bralte lines.
Air has enter the
ABSIASC or ABSlDSC hydraulic unit.
WARNING -
* The ASC and DSC systems use electronic controls and a
sophisticated hydraulic unit Once air enters the hydraulic
unit, it is very difficult to remove using traditional methods.
For this reason, pressure
brake bleeding should be done
in conjunction with the BMW
Sewice Tester (DIS-
plus/GTl/MoDiC). The tester electrically cycles the hy-
draulic unit solenoids in the hydraulic unit while
pressurized brake fluid is forced through the system.
When flushing the brake fluid from the system, use ex-
treme care to not let the
brale fluid reservoir run dry If
air enters the hydraulic unit, the BMW Service Tester
MUST be used to bleed the brale system before the
vehicle is driven.
Always use new brake fluid from an unopened container. It is
important to bleed the entire system when any part of the hy-
draulic system has been opened. Be sure to have the special
equipment needed before beginning the job.
When bleeding the
braltes, start atthe wheel farthest from the
master cylinder and progress in the following order:
right rear brake
left rear brake
* right front brake
left front brake

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.- -
Brakes
Disconnect master cylinder brake lines (A)
Plug open brake lines to prevent contamination.
Remove master cylinder mounting nuts
(6) and remove
cylinder.
NOTE-
It may be necessary to remove the brake booster with master
cylinder attached due to limited access.
Bralce master cylin-
dercan then be removed from booster. See Brake booster,
removing and installing later
in this repair group.
- During reinstallation, make sure all nuts, fluid couplings,
thread bores, and mating surfaces are clean.
- Mount master cylinder to bralte booster using new sealing O-
ring and new self-locking nuts.
CAUTIOI\C
* Be sure to align master cylinderpushrod and booster
pushrod.
* Do not over-torque master cylinder mounting nuts. This
could damage the brake booster and prevent proper
vacuum build-up.
Tightening torque Brake master cylinder to brake booster
26 Nm (19 ft-lb)
- Connect bralte fluid lines to master cylinder.
Tightening torque Brake fluid line to master cylinder
18 Nm (13 ft-lb)
- Carefully reinstall fluid reservoir using new sealing grommets.
- Reconnect precharge pump fluid supply hose, if applicable. -
- Reconnect hydraulic clutch fluid supply hose, if applicable.
- Remainder of installation is reverse of removal.
Top up with fresh brake fluid.
Bleed entire brake system as described earlier

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1 Brakes
ABS COMPONENT REPLACEMENT
CA UTIOW-
If the tires on the car are of different makes, the ABS/trac-
tion controlsystem may overreact. Only fit tires of the same
make and treadpattern.
In adverse conditions, such as trying to rock the car out
of deep snow or other soft surface, or when snow
chains are fitted, it is advisable to switch off traction
control and allow
tlie car driveline to operate conven-
tionally.
All E39 vehicles are equipped with
Antilock Braking System
(ABS). Early production models featured ABS with Automatic
Stability Control (ABS
I ASC). Later models came equipped
with ABS and Dynamic Stability Control (ABS
/ DSC). This
manual will refer to these systems as ABS. ASC or DSC will
be specified when necessary.
For ABS system and component descriptions, see
300 Sus-
pension, Steering and Brakes-General.
Wheel speed sensor, replacing
- Raise applicable end of car.
Make sure that the car is firmly supported on
jack stands de-
signed for the purpose. Place
jack stands beneath structural
chassis points. Do not place jack stands under suspension
< Front sensor: Unscrew mounting bolts (arrows) at steering
knuckle.
4 Rear sensor: Unscrew mounting bolt (arrows) in rear wheel
bearing carrier.
NOTE-
ABS wheelspeed sensor application may vary depending on
traction control system installed.

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51 0-1 0
Exterior Trim, Bumpers Rear bumper, removing
and installing
Remove expansion rivets from rear inner fender well panels
(arrows).
Working in luggage compartment:
Raise spare tire cover.
- Remove trim panel covering luggage compartment latch.
Open battery cover trim panel on right side and luggage
compartment.
Open left side trim panel.
4 Remove expansion rivets (arrows) from rear panel.
Remove left and
remove panel. right
side panel mounting
nuts (arrow) and

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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

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Steering description 300-10
liuid see Maintenance
gearbox
320-25
idler arm 320-30
lock 320-12
pitman arm 320-28 power steering pump 320-17
rack & pinion 320-19
steering column 320-10 motors 320-16
removinglinstalling 320-14
trim 320-10
steerino wheei 320-7 tie rods-
6-cvlinder, reelacinq 320-22
V- center tie' rod, replacing 320-32
variations 310-5
Steering box
see Steering, gearbox
Steering column switches
see Switches
Steering column
see Steering
Steering lock
see Steering
Steering
wheei switches
see Switches
Stepper motor
see
AIC
Steptronic transmission
see Gearshift
Strut see Front suspension
see also Rear suspension
Subframe see Rear suspension
Sunroof initializing
540-2
adiustinq 540-5 . . cornponents, removingiinstailing
540-9
emergency closing 540-4
Suspension, front
see Front suspension
see also
Aluminum suspension
cornponents
Suspension, rear
see Rear suspension
see also Aluminum suspension
cornponents
Swing arm
see Rear suspension, suspension
arms
Switches
ASCIDSC 612-12 back-ue
manual transmission 230-8
automatic transmission, see
Automatic transmission, range
switch
center console switches
612-11
central ioci(ing 612-1 1
hazard 612-1 I headlight 612-9
ignition cylinder 320-1 1. 612-6
outside mirror 612-11
pedal cluster switches 612-8 seat heater 612.12
steering column positioning 612-7
steering column switches 612-6 steering wheel switches 612-2
turn signaliheadlight dimmer 612-6
window 612-1 1
wipers 612-6
Tailgate
412-6 emergency release 400-4,412-6,
515-21
taiigatelrear window
loclring 515-14 see also Trunldtaiioate ioclr - see also Central ioclcing
Taillights
see Lights
Tape player
650-3
TCM (transmission control module)
see Automatic transmission
Tension strut
see Front suspension
Thermostat see Cooling system
see also Electrically heated
thermostat
Throttie body
see 130 under appropriate
fuel injection system
Throttie
cable
130-38
Throttie position sensor
see 130 under appropriate luel
injection system
Throw-out bearing
see Clutch, mechanical
Thrust arm
see Front suspension
Tie rod
see Steering
Tightening fasteners
010-8
Tilt sensor 515-24
Timing chain
see
Camshaft timing chain
Tire, changing
010-18
Tires
300-1 1
see also Maintenance
Toe
320-34
Tools
010-13