1998 BMW 540i Temperature

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Radiator and Coolina ~vsteml
- Disconnect thermostat and cooling system temperature sen-
sor plug connectors.
4 Remove thermostat housing fasteners and remove housing.
- Remove coolant pump pulley bolts and remove pulley from
pump.
Remove fasteners A and B (arrows).
NOTE-
* The coolant pump is retained to the block using different
length bolts.
0 Bolts A: M6 X 105 mm
0 Bolts 8: M6 X 35 mm
Slide coolant pump away from coolant pipes (arrows) while
being careful not to dislodge pipes from fittings at rear of en-
gine.
- Installation is reverse of removal, noting the following:
Replace all sealing O-rings and washers.
Coat O-rings with water-based lubricant during installation.
Fill system with coolant. See Coolant, draining and fill-
ing (6-cylinder models) or Coolant, draining and filling
(V-8 models).

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--
Radiator and Cooling System 1
4 Lift fan and shroud together out of engine compartment.
- Detach upper and lower radiator hoses.
NOTE -
Later models use retaining clips to fasten coolant hoses to
expansion tank and radiator.
- Disconnect temperature sensor harness connector.
4 Remove radiator support bolts and supports (arrows). 6-cyl-
inder shown.
- Slide right side of radiator back toward engine and pull radi-
ator up to remove.
- Installation is reverse of removal, noting the following:
Fill radiator and cooling system. See Coolant, draining
and filling (6-cylinder models) or Coolant, draining
and filling (V-8 models).
Tightening torques
Engine block drain
plug to block 25 Nm (18 it-lb)
Radiator drain plug
to radiator 2 - 3 Nm (18 - 27 in-ib)
Expansion tank, removing and installing
- Raise front of car and support safely.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive
/iff orjacltstands designed for
the purpose. A
floorjacl~ is not adequate support.
- Remove splash shield from under engine.
- Drain radiator as described earlier. See Coolant, draining
and filling (6-cylinder models) or Coolant, draining and
filling
(V-8 models).
I WARNING-
Allow cooling system to cool before opening or draining sys-
I tem.

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180-2
Exhaust System
The exhaust system is designed to be maintenance free, al-
though regular inspection is warranted due to the harsh oper-
ating conditions. Under normal conditions, the catalytic
converter does not require replacement unless it is damaged.
New fasteners, clamps, rubber mounts and gaskets should
be used when replacing exhaust components.
A liberal appli-
cation of penetrating oil to the exhaust system nuts and bolts
in advance may make removal easier.
WARNING -
The exhaust system and catalytic converter operate at
very high temperatures. Allow components to cool before
servicing. Wear protective clothing to prevent burns.
Do not use flammable chemicals near a hot
cataiyiic
converter.
Corroded exhaust system components crumble easily
and often have exposed sharp edges. To avoid injury,
wear eye protection and heavy gloves when working
Exhaust system, removing and installing
The removal and installation procedures given here are gen-
eral procedures for all models. The removal of the exhaust
system as a complete unit is recommended. Once the com-
plete system is removed from the car, individual pipes and
mufflers can be more easily replaced.
WARNING-
Exhaust gases are colorless, odorless, and very toxic. Run
the engine only in a well-ventilated area. Immediately repair
any
leaks in the exhaust system or structural damage to the
car body that
might allow exhaust gases to enter the passen-
ger compartment.
CAUTION-
Use care not to drag or bang oxygen sensors. Oxygen sen-
sors can be easily ruined.

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- .- -
Automatic Transmission
Electronics are used to control the operation of these auto-
matic transmissions. Steptronic transmission functions are
also programmed into the transmission control module
(TCM). The TCM monitors transmission operation for faults
and alerts the driver by illuminating the transmission fault indi-
cator on the instrument panel. Diagnostic trouble codes
(DTCs) stored in the TCM may be downloaded and interpret-
ed by trained technicians using special BMW diagnostic
equipment.
Some minor automatic transmission problems can be cor-
rected by changing the automatic transmission fluid (ATF)
and filter. Begin by checking ATF level and condition.
Checlc
to see if the fluid is dirty or has a burned odor indicating over-
heated fluid. The burned odor may be the results of burned
discs in theclutch paclts. The friction material from the burned
disc can clog valve body passages.
NOTE-
The E39 automatic transmission is not equipped with a dip-
stick.
Checking the ATF level must be done while monitoring
the ATF temperature with the engine idling. The
BMW dealer
is equipped with the special equipment to make this check.

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240-6
I Automatic Transmission Automatic transmission fluid (ATF)
The E39 automatic transmission is filled with either Dexron Ill
ATF or Texaco 80728, a life time oil.
CA UTIOI\C
Use only the transmission fluid that is approved for use by
BMW All other fluids will cause non warrantable transmis-
I sion damage.
Mixing different types of transmission fluids will lead to
transmission failure.
NOTE-
The type of transmission lubricant used can be found on a
stickeron the transmission pan. Dexron
111ATF (blacksticker)
reads "ATF-Oil': Special life time oil (green sticker) reads
'Life-Time Oil': If in doubt, consult an authorized
BMW dealer
for alternate fluid use and current information regarding
transmission operating fluids.
ATF level, checking
Check ATF level if there is evidence of a leak, a complaint re-
lated to fluid level or afler transmission repairs.
The automatic transmission is not equipped with a dipstick.
Checking the ATF level requires that the transmission be at
operating temperature during the checking procedure.
NOTE-
Vehicle must be level throughout tests
- Drive vehicle to warm up ATF to operating temperature.
- Connect BMW diagnostic scan tool DiSplus, MoDiC, GTI or
equivalent to determine transmission oil temperature.
ATF level checking
Fluid temperature
30' - 50°C (85' - 120" F)
- With engine running, switch on air conditioning to increase
engine idle speed.
- Apply parking brake.
- While applying foot brake firmly move gear shift selector
lever through
all gear positions, pausing in each gear briefly.

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[~us~ension, Steering and Brakes - General
This section of the manual covers front and rear suspension,
braking and steering systems, and contains wheel, tire and
wheel alignment information and specifications. Also covered
here are the integrated braking and suspension systems in-
cluding
antilock braking (ABS), traction control (ASCIDSC),
and electronic height control (EHC).
Vehicle ride height information is at the end of this repair
group. Alignment information is in
320 Steering and Wheel
Alignment.
Aluminum suspension components
In order to reduce vehicle weight, aluminum suspension com-
ponents are used in some models. A test with a magnet will
easily reveal the metal used. If working with aluminum com-
ponents, be sure to read and follow the cautions below.
CAUTION-
* Due to the chemical and corrosion characteristics of alumi-
num, do not bring into contact with battery acid.
Do not use wire brushes with brass or iron bristles.
Only use brushes with stainless steel bristles.
Do not expose to flying sparks from
grinding/cutting op-
erations.
Do not subject to steel welding splashes.
Do not expose to temperatures over
80°C (176"F),
even for short periods. Temperatures in painting facili-
ties are not a problem.
The E39 front suspension subframe is used as a rigid mount-
ing platform for the front suspension arms, stabilizer bar and
steering gear.
The suspension arms, known as the lower control arms and
the tension struts (thrust arms), are connected to the
sub-
frame through rubber bushings. The arms are connected to
the steering
knucltles in a double pivot configuration.
Each front strut assembly includes a tubular strut and a coil
spring. The upper strut mount includes a bearing. The lower
end of each strut housing is fitted to the steering knuckle. The
integral wheel bearing and hub are bolted to the steering
Iknucltle.
6-cylinder and V-8 models use different steering systems and
other front suspension components.

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31 0-2
I Front Suspension
This repair group covers the repair and replacement of com-
ponents that make up the front suspension of E39 cars.
Two different types of steering systems are used in the E39
series. 6-cylinder
(5251,5281 and 530i) models are equipped
with a rack and pinion type steering system mounted to an
aluminum subframe.
V-8 (540i) models use a steering gear-
box type system mounted to a steel subframe.
See
300 Suspension, Steering and Brakes-General for a
description of the front suspension and components, as well
as specifications for setting ride height.
CAUTION-
Some E39 models are equipped with aluminum suspen-
sion components. The foiiowing cautions apply:
Due to the chemical and corrosion characteristics of
aluminum, do not bring into contact with battery acid.
* Do not clean with wire brushes with brass or iron bris-
ties. Only use brushes with stainless steei bristles.
Do not expose to flying sparks from grinding/cutting op-
erations.
* Do not subject to steei welding splashes.
Do not expose to temperatures over 80°C (176°F).
even for short periods. Temperatures in painting faciii-
ties are not a problem.
Special tools
Special service tools are required for most of the work de-
scribed in this repair group. In addition to the tools depicted in
the illustrations, avariety of press tools are necessaryfor con-
trol arm bushing replacement. Read the procedures through
before beginning any job.
31 2 210 I < Strut nut socket
(Tool No. 31 2 210)

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Steering and Wheel Alignment
Steering system warnings and cautions
WARNING -
The BMW airbag system is complex. Special precautions
must be observed when servicing the system. Serious in-
jury may result if system service is attempted by persons
unfamiliar with the BMW
airbag system and its approved
service procedures. BMW specifies that all inspection and
service should be
peiformed by an authorized BMW deal-
e,:
The BMW E39 is equipped with an airbag mounted in
the steering wheel. The
airbag is an explosive device
and should be treated with extreme caution. Always fol-
low the
airbag removal procedure as outlined in 721
Airbag System (SRS).
BMW airbags are equipped with a bacli-up power sup-
ply inside the
airbag control module. A 5 second wait-
ing period should be observed after the battery cable
has been disconnected. This will allow the reserve
power supply to discharge.
Do not reuse self-locking nuts. They are designed to
be used only once and may fail if reused. Always re-
place them with new locliing nuts.
* Do not install bolts and nuts coated with undercoating
wax, as correct tightening torque cannot be assured.
Always clean the threads with solvent before installa-
tion, or install new parts.
Do not attempt to weld or straighten any steering com-
ponents. Always replace damagedparts.
CAUTION--
- Some E39 models are equipped with aluminum suspen.
sion components. The following cautions apply:
Due to the chemical and corrosion characteristics of
aluminum, do not bring into contact with battery acid.
Do not clean with wire brushes with brass or iron bris-
tles. Only use brushes with stainless steel bristles.
Do
not expose to flying sparks from grindinghutting op-
erations.
Do not subject to steel welding splashes.
* Do not expose to temperatures over 80% (176°F).
even for short periods. Temperatures in painting iacili-
ties are not a problem.