1998 BMW 540i Radiator and Cooling System

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Camshaft Timing chain1
4 Remove oil lines from camshaft supports (arrows).
- 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.
- Remove engine drive belts alternator and AlC compressor.
See
020 Maintenance.
4 Remove vibration damper bolts (arrows) and remove
damper.
4 Mount BMW special tool 11 2 450 to crankshaft hub while
aligning damper locator pin with hole (arrow) in special tool.
CAUTION-
Crankshaft center bolt is torqued to 410 Nm (300 ft-lb) use
BMWspecial tool I I 2 450 to secure crankshaft when remov-
ing center bolt.
- Loosen and remove cranltshaff center bolt.

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Camshaft Timing chain1
< Remove Automatic Stability Control (ASC) throttle body:
Disconnect electrical harness from throttle position sensor.
Disconnect ASC actuator cable (arrow).
Remove
3 mounting fasteners and remove throttle body.
4 Disconnect fuel tank vent valve line and cap off line (arrow).
- Drain engine coolant and remove hoses from thermostat
housing. See
170 Radiator and Cooling System.
- Remove water pump and thermostat housing. See 170 Ra-
diator and Cooling System.
- Remove left side upper timing chain cover retaining bolts and
remove cover.
4 Counter hold right intake camshaft
CAUTION-
Counter hold camshaft with a 27mm open-end wrench while
loosening sprocket bolts. Grind wrench if necessary to pre-
vent damage to head.

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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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121-18
I Battery, Starter, Alternator
Alternator, removing and installing
(M62 TU engine, water cooled)
V-8 models produced after 9/98 are equipped with a water
cooled alternator.
CAUTION-
Allow engine to cool before removing alternator as coolant
will
escape from the alternator water jacket.
- Disconnect negative (-) battery cable
CAUTION- Prior to disconnecting the
battew read the battery discon-
nection cautions given in
001 General Warnings and Cau-
tions.
- Remove radiator cooling fan and fan shroud. See 170 Radi-
ator and Cooling System.
- Drain engine cooling system. See 170 Radiator and Cool-
ing System.
- Remove alternator drive belt. See 020 Maintenance.
- Disconnect battery lead (terminal 30 or B+) and two-pin har-
ness connector from front of alternator.
I < Remove bolts securing alternator to water jacket and remove
aling ring
alternator.
NOTE- If necessary, raise car and remove engine compartment
splash shield to access lower alternator mounting bolts.
The upper coolant hose can also
be removed to assist al-
ternator removal.

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Battery, Starter, Alternator
- Installation is reverse of removal, noting the following:
Replace alternator rubber sealing O-ring.
* Fill and bleed cooling system as described in 170 Radiator
and Cooling System.
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)
Terminal 30 (Bc) wire to alternator (ME) 13 Nm (10 ft-lb)
STARTER
Starter troubleshooting
Typical starter wiring terminal identification is shown. Large
wire at terminal
30 (not shown in photo) is direct battery volt-
age. Smaller wire at terminal
50 operates starter solenoid via
ignition switch.
If starter turns engine slowly when ignition is in start position:
Check battery state of charge.
Inspect starter wires, terminals, and ground
connectlons
for good contact. In particular, make sure ground connec-
tions between battery, body and
englne are completely
clean and tight.
If no faults are found, starter may be faulty and should be
replaced.
- If starter fails to operate, check EWS (drive-away protection
system). Try another ignition key.
If no faults can be found,
have the EWS system checked using
BMW scan tool equip-
ment.
Checkclutch pedal operated
starter lock-out switch or gear
position switch (automatic).
NOTE-
* A factory-installed drive-away protection system, also re-
ferred to as
EWS, is used on E39 cars. This system pre-
vents operation of the starter if a specially coded ignition
key is not used.
On cars with automatic transmission, the transmission
gear position switch signals
EWS to prevent the engine
from starting in gear positions other than PARK or NEU-
TRAL.
On cars with manual transmissions, a starter immobiliza-
tion switch
at the clutch pedal is used to prevent the starter
from operating unless the clutch pedal is pushed fully to
the floor.

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Fuel Injection
- Ignition:
Direct ignition
Knock control
4 Primary1 secondary ignition monitoring
- Emissions:
OBD II compliance
Secondary air injection
Pre- and post-catalyst oxygen sensors
0 Electrically heated DME-mapped thermostat
Misfire detection
Evaporative emission control and
leak detection
Malfunction indicator light (MIL)
Performance controls:
Dual VANOS control
Output of injection signal (TI) for fuel economy gauge
Output of engine rpm (TD) for tachometer
AIC compressor control
0 Electric radiator cooling fan
CAN-Bus communication
Stability and traction system
(ABSIASCIDSC) interlace
Electronic immobilizer (EWS)
Cruise control
ECM programming

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176 Radiator and Cooling System
General ........................... .I7 0.2
Special tools
........................ .I7 0.2
Cooling system overview
(M52 TU shown. others similar) ......... .I7 0.3
Coolant pump
....................... .I7 0.3
Thermostat
......................... .I7 0.3
Mechanical thermostat (M52 engine)
..... .I7 0.4
Electrically heated thermostat
.......... .I7 0.4
Radiator and expansion tank
........... .I7 0.4
Mechanical cooling fan with viscous clutch
.I7 0.4
Electric (auxiliary) cooling fan ........... .I7 0.4
Transmission fluid heat exchanger
....... .I7 0.5
Warnings and cautions
................ .I7 0.7
Troubleshooting ................... .I7 0.7
Cooling system inspection
............. .I7 0.8
Cooling system pressure test
........... .I7 0.9
Combustion chamber leak test
......... .I7 0.10
Thermostat
........................ .I7 0.1 0
Cooling System Service ........... 170-10
Coolant. draining and filling
(6-cylinder models)
.................. 170-1 0
Coolant. draining and filling (V-8 models)
. 170-12
Cooling system. bleeding
............. 170-14
Mechanical (viscous clutch) cooling fan.
removing and installing
............... 170-14
Electric cooling fan.
removing and installing
............... 170-15
Thermostat. removing and installing
(M52engine) ....................... 170-16
Thermostat. removing and installing
(M52 TU or M54 engine) .............. 170-17
Thermostat. removing and installing (V-8 models)
....................... 170-1 8
Coolant pump. replacing (6-cylinder models)
.................. 170-1 9
Coolant pump. replacing (V-8 models) ... 170-20
Radiator. removing and installing
....... 170-22
Expansion tank. removing and
installing . . 170-24

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I Radiator and Cooling System
This section covers component repair information for the en-
gine cooling system.
Heater core replacement is covered in
640 Heating and Air
Conditioning.
Special tools
Special tools are necessaryfor belt-driven fan clutch removal
and also for pressure testing the cooling system.
4 Cooling fan counterhold wrench
(Tool No. BMW
11 5 030)
4 Cooling fan wrench
(Tool No. BMW
11 5 040)
< Expansion tank cap test adaptor
(Tool No.
BMW 17 0 007)
17 0 002 4 Cooling system pressure tester set
1 17 o 005 (Tool No. BMW 17 0 OOZi17 0 005)