1997 BMW 540i Harness

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120-15
Ignition system1
Exhaust camshaft position sensor, replacing
(M52 TU and M54 engines)
- Make sure ignition has been turned off.
4 Working at front of engine on exhaust (right) side, detach ex-
haust camshaft position sensor electrical harness connector
(arrow) and remove sensor.
- Installation is reverse of removal, noting the following:
Use a new O-ring when installing sensor.
- Use scan tool to read out and clear ECM fault memory.
Tightening torque
Exhaust camshaft sensor
to cylinder head 10 Nm (7 ft-lb)
Intake camshaft position sensor, replacing
(M62 and M62 TU engines)
- Make sure ignition has been turned off
4 Remove top engine cover by releasing quick release fasten-
ers (arrows) by pressing down.
4 Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor and
intalte air tempera-
ture sensor electrical harnesses
(A and B).
Remove air filter housing mounting fastener (arrow).
Loosen hose clamps
(C and D).
Remove hose at idle air stabilizer.
Remove air filter housing with mass air flow sensor.
- Remove intalte hose from throttle body.

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120-1 6
Ignition System
Remove camshaft sensor (arrow) from front of right cylinder
head.
Disconnect camshaft sensor harness from cable duct above
right cylinder head.
Installation is reverse of removal, noting the following:
Use new O-ring when installing sensor.
Be sure wiring is rerouted in same orientation.
Use scan tool to read out and clear ECM fault memory.
Tightening torque Intake camshaft sensor to timing chain 5 Nm
(3.5 ft-lb)
cover
Knock sensors
Knock sensors, replacing (M52, M52 TU and M54
engines)
The knock sensors are bolted to the left side of the cylinder
block under the intake manifold.
- Remove intalte manifold as described in 113 Cylinder Head
Removal and Installation.
D~sconnect knock sensor electrical harness connector (A) on
left side of engine cylinder block.
Remove knock sensor
mount~ng bolts (arrows) on side of
cyllnder block. Remove sensors.
Note the installed angle of the
lnocl~ sensor on the bloc/( be-
fore removing it. Reinstall the sensor
in the same position. Be
sure to use a torque wrench when tightening the sensor
mounting bolt.
< Clean lknock sensor contact surface on engine bloclc and
sensor (arrows) before installing
ltnock sensor.
Tightening torque
Knock sensor to head 20 Nm (15 ft-lb)
- Use scan tool to read out and clear ECM fault memory.
Knock sensors, replacing
(M62 and M62 TU engines)
The
knock sensors are bolted to the side of the cylinder block
under the
intake manifold.

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121-10
I Battery, Starter, Alternator
- Strip approximately 15 rnm (0.6 in) of insulation from cable
end.
terminal harness
Shrink insulation
Terminal connector
4 Push terminal connector of new cable over stripped end of
old cable. Tighten clamp.
- Slip shrink-fit insulation over positive cable. Attach new safe-
ty harness to end of positive cable. Shrink insulation with hot
air blower.
- Reinstall cable in cable bracket and attach to battery.
- Reattach negative battery cable. Reinstall luggage cornpart-
rnent trim pieces.
- Use BMW scan tool DlSplus or equivalent to read out airbag
control module fault memory. Correct faults, then clear mem-
ory.
1 1 4 Various versions of alternators have been used in E39
vehicles. See Table e.
Table e. Alternator application chart
Model Alternator type
Air cooled, 90 amp or 120 amp
Air cooled, with multi-function control
(MFR), 120 amp or 140 amp
Air cooled with multi-function control
(MFR), 120 amp or 140 amp
540i 1997 Air
cooled. 120
amp or 140amp sazrz~orsl 1998 ~~~ ~ .~ . ...~ ~ ~-~~~~ Air cooled; with integrated mu~ii-
function control (MFR). 120 amp 140
amp 1999-2002 Water
cooled, with integrated multi-
function control (MFR), 90-150 amp
(variable output)

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Battery, Starter, ~lternatorl
Charging system quick-check
Use a digital multimeter to measure voltage across the bat-
tery terminals with key off and then again with engine running.
Battery voltage should be about 12.6 volts with key off and be-
tween 13.5 and 14.5 volts with engine running.
NOTE-
The regulated voltage (engine running) should be between
13.2 and 14.5, depending on temperature andoperating con-
ditions.
If the voltage is higher than 14.8, the voltage regula-
tor or
mulitfunction controller is most likely faulty
Check for clean and tight battery cables. Check ground cable
running from negative
(-) battery terminal to chassis and
ground cable running from engine to chassis. Check alterna-
tor drive belt condition and tension.
Charging system, checking
CAUTIOI\C
* Do not disconnect the battery while the engine is running.
Damage to the alternator and/or engine electronic systems
may result.
Only use a digital multimeter when testing charging
system components.
--7
4 Turn ignition key on. Check that battery warning light comes
on.
NOTE-
If the warning light does not come on, repair bulb or wiring
faults before continuing to checlc the charging system.
/ Charge indicator
502820805
4 6-cylinder engines only, remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

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- -
/Battery, Starter, Alternator -- - -. - --I
< Check for battery voltage at alternator terminal 30 (B+) (ar-
row):
Pull back rubber insulating cover at terminal 30 at rear of
alternator.
Connect voltmeter between terminal 30 and ground and
check for battery voltage.
If voltage is not present, check
wiring for faults.
NOTE-
On V-8 engines, access to the rear of the alternator is limited.
Check for battery voltage between the jump start post on the
left cylinder head and ground.
r Disconnect harness connector from alternator. Turn ianition
on and check for battery voltage between terminal
lgand
ground. If voltage is not present, check wiring and fuses for
faults.
Reconnect connector to alternator.
Locate the blue wire coming from terminal
61E of the alter-
nator connector. Carefully connect the positive
(+) test lead
to the wire using a piercing test lead end.
Turn ignition key on and check for voltage. Voltage should be
less than 1.5 VDC and charge indicator lamp should light.
- Making sure all test equipment and tools are clear, start en-
gine. Voltage should increase to
8.0 VDC or higher. The
charge indicator light should go out.
If voltage does not increase and system is not charging,
the fault is in alternator.
- If voltage does not increase, but system is charging, inter- - roaate svstem for faults usina an appropriate BMW scan - .. . tool and'reset fault memory.
- If a load tester is not available, a quick alternator output test
can be done by running engine at about 2000 rpm and turn-
- -
ing on electrical loads (fans, lights, rear window defroster, -
- and wipers). With all accessories on, battery voltage should
be above 12.6
V.

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Battery, Starter, ~lternatorl
Alternator, removing and installing
(6-cylinder engine)
A replacement alternator should have the same rating as the
original. Alternator manufacturer and ampere rating are nor-
mally marked on the alternator housing.
- Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given
in 001 General Warnings and Cau-
I tions.
Remove complete air filter housing:
Loosen intake duct hose clamp
(A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
* Remove air filter housing mounting screw (D),
Disconnect vent tube (E).
Loosen air intake duct clamp (F).
Carefully lifl air filter housing out of engine bay.
Remove alternator drive belt. See belt removal procedures in
020 Maintenance.
- Remove radiator cooling fan and fan shroud. See 170 Radi-
ator and Cooling System.
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
- Unbolt power steering fluid reservoir and bracket. Suspend to
one side without detaching fluid hoses.
- Disconnect alternator air cooling tube.
- Disconnect wiring from rear of alternator.
'4 Remove upper and lower mounting bolts (arrows) and lift
alternator.
If idler pulley for belt interferes, remove pulley cover and
retaining bolt to remove pulley. out

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121-17
Bauery, Starter, Alternator
- Remove engine splash shield from underneath car.
Working underneath car at rear of alternator, loosen alterna-
tor air cooling duct clamp
(arrow) and remove duct.
Remove three alternator mounting fasteners
(arrows)
Pull alternator forward and disconnect wiring from rear of
alternator.
Release clip retaining wiring harness to alternator.
Rotate alternator forward and then up and out of engine com-
partment, using care to not damage radiator.
CAUTIOe
Protect radiator with heavy cardboard or sheet metal.
Installation is reverse of removal,
Tightening
torques
Fan clutch to coolant pump
with BMW special tool
11 5 040 30
Nm (22 ft-lb)
without BMW special tool 11 5 040 40 Nm (29 ft-lb)
Pullev to alternator 70 Nm 144 it-lb) -,
Terminal 30 (Bt) wire to alternator (ME) 13 Nm 110 ft-lb

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I Battery, Starter, Alternator
- Check for battery voltage at terminal 50 of starter motor with
key in start position. If voltage is not present, check wiring be-
tween ignition switch and starter terminal. Check the EWS
system and other inputs that disrupt terminal
56 to the start-
er. See ELE Electrical
Wiring Diagrams. If voltage is
present and no other visible wiring faults can be found, prob-
lem is most likely in starter motor.
Starter, removing and installing
(6-cylinder engine)
The starter is removed from below. Access to starter bolts is
difficult. Be sure to have the proper tools on hand before pro-
ceeding.
NOTE-
Access to the starter wiring is very limited. Forbetteraccess,
it may be necessary to remove the intake manifold.
- Disconnect negative (-) battery cable.
CAUTIOI\C
Prior to disconnecting the battern read the baltery discon-
nection cautions
in OOlGeneral Cautions and Warnings.
Remove complete air filter hous~ng:
Loosen intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw (D)
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.
Disconnect throttle cable.
Raise vehicle and support safely.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive
lift orjack stands designed for
the purpose. A
floorjaclc is not adequate support
- Working underneath car, remove engine splash shield
- Disconnect fuel lines and harness connectors from retaining
brackets, as necessary.