1999 BMW 540i battery replacement

Downloaded from www.Manualslib.com manuals search engine
121-16
Battery, Starter, Alternator
- installation is reverse of removal.
Tightening torques Belt tensloner to engine block
M8 (8.8 grade) 22
Nm (16 ft-ib)
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-ib)
Pulley to alternator 70
Nm (44 ft-lb)
Terminal 30
(B+) wire to alternator (M8) 13 Nm (10 ft-ib)
Alternator, removing and installing
(M62 engine, air cooled)
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 battery, read the battery discon-
nection cautions
001 General Warnings and Cautions.
- Remove cooling fan and alternator drive belt. See 020 Main-
tenance.
- Pry out trim caps and remove fasteners from plastic cover on
left head. Lift off cover.
Disconnect positive
(+) lead from jump start post (arrow).
Raise car and support in a safe manner.
WARNING-
Make sure the car is stable and well supported at aN times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floorjack is not adequate support.

Downloaded from www.Manualslib.com manuals search engine
--
Fuel Injection I
The PWG potentiometers provide DC voltage signals as in-
put to the ME 7.2 control module for throttle and idle control
functions. Potentiometer signal
1 is the primary signal, poten-
tiometer 2 is used for a plausibility cross-check.
1. Potentiometer 1 ground
2. Potentiometer
1 power
3. Potentiometer 2 ground
4. Potentiometer 2 power
5. Potentiometer 1 signal to ECM
6. Potentiometer 2 signal to ECM
If errors are detected between potentiometer
1 and 2, the
ECM calculates the engine intake air mass (from
MAFsensor
signal) and only utilizes the potentiometer signal that closely
matches the detected
intake air mass. The ECM control mod-
ule uses the air mass signal for a comparative source to pro-
vide fail-safe operation.
If the ECM cannot calculate a
plausible conclusion from the monitored potentiometerthe
EDK motor is switched off and fuel injection cut-out is activat-
ed (no fail-safe operation possible).
EDK is continuously monitored during all phases of engine
operation. If faults are detected, the EDK motor is switched off
and fuel injection cut off is activated. The engine continues to
run extremely roughly at idle speed.
EDK adaptation
When the EDK throttle assembly is replaced, the adaptation
values of the previous EDK must be cleared from the ME 7.2
ECM using the BMW service testeroran equivalentscan tool.
Once the old adaptation values have been cleared, the new
EDK assembly should be installed and adapted as follows:
0 Switch ignition OFF for 10 seconds.
* Switch ignition ON. Afler approximately 30 seconds, the
EDK is briefly activated indicating that the replacement unit
is now adapted to the ME 7.2 system.
NOTE-
This EDK adaptation procedure is also necessary after re-
placing the
ME 7.2 engine control module. However, the ad-
aptation values do not require clearing since they have not
yet been established.
ECM relay, testing
The engine control module (ECM) relay is energized via the
ECM and supplies battery positive
(B+) power to many of the
engine management components and subsystems. If this re-
lay is faulty, the engine will not start.
NOTE-
The ECM relay is also referred to as the DME main relay

Downloaded from www.Manualslib.com manuals search engine
.- -
Fuel Tank and Fuel purnpl
Fuel pump power consumption, testing
To achieve accurate test results, the battery voltage at the
fuel pump connector should be
12.6 volts. Charge the battery
as necessary.
A higher than normal power consumption may indicate a
worn fuel pump, which may cause intermittent fuel starvation
due to pump overheating and seizure. The only remedy is
pump replacement.
A lower than normal power consumption
may indicate a blockage. Be sure to check that the return line
and the pump pickup are not obstructed before replacing the
pump.
- Expose right side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover insu-
lation.
Peel back insulation at perforations to expose fuel tank ac-
cess cover.
Remove right side cover to expose electrical harness con-
nector.
Disconnect harness connector from tank sending unit by slid-
ing lock back. Lift off connector.
Test fuel pump for current draw by attaching digital ammeter
between pump and harness (terminal
2, whitelblue wire) and
connect a jumper wire between pump and harness (terminal
1, brown wire) as shown.
CAUTION-
Do not allow the test leads to short to ground.
NOTE-
See 600 Electrical Systern-General for information on elec-
trical tests
using a digital multirneter.
Run pump as described in Operating fuel pump for tests.
- Compare ammeter reading with specification listed in ac-
companying table.
Fuel
pump current
Current consumption (average) 9.5 amps

Downloaded from www.Manualslib.com manuals search engine
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)

Downloaded from www.Manualslib.com manuals search engine
330-2
I Rear Suspension
This repair group covers removal and replacement of E39
rear suspension components. A general description of sus-
pension systems and ride height specifications can be found
in 300 Suspension, Steering and Brakes - General.
CAUTIOI\C
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
sparl~s from grinding/cutting op-
erations.
* Do not subject to steel welding splashes.
0 Do not expose to temperatures over 80°C (176°F).
even for shortperlods. Temperatures in painting facili-
ties are not a problem.
Special tools
Special service tools are required for some of the work de-
scribed in this repair group. Most of these tools are special-
ized press jigs and pullers that might be replaced by standard
pullers of various sizes.
Read the procedures through before beginning any job.
< Strut upper mounting nut socket
(Tool No. BMW
31 2 21 0)
I Axle shaft removal and installation set
Spring compressor (Tool No. BMW
31 3 340.31 3 350)

Downloaded from www.Manualslib.com manuals search engine
Doors
This repair group covers front and rear door repair informa-
tion. It includes removal and installation of front and rear
doors and trim panels.
For information on
airbag removal and installation, see 721
airbag.
For information on the power door windows and door glass
replacement, see
512 Door Windows.
For information on the power door
loclting system, see 515
Central Locking and Anti-Theft.
WARNING-
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures
relatinq to the airbaq system.
Front or rear door, removing and installing
- Disconnect negative (-) battery cable.
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in
001 General Cautions and warn-
ings.
Remove harness connector mounting bolt (arrow) at door
pillar.

Downloaded from www.Manualslib.com manuals search engine
51 5-12
I Central Locking and Anti-Theft
Key battery
9
4 1997 - 1999 models: Two lithium batteries are used to sup-
ply power to key transmitter. When replacement is neces-
sary, remove cover and two fasteners (arrows) from rear of
key to access batteries
NOTE-
If you replace the batteries within one minute, the FZV ley
will not require a new initialization procedure.
2000 and later models: FZV key battery is recharged by ring
antenna while ltey is in ignition switch. There is no need to re-
place ltey battery.
Car Memory 1 Key Memory
A number of features and functions can be customized to the
driver(s) preference. The identity of the vehicle user is provid-
ed by a
s~gnal from the keyless entry system (FZV).
Car Memory and Key Memory are actually two separate func-
tions, although they are marketed as a combined feature.
Car Memory
Pr'or ro new
veh c,e de very, the BMW scan roo (DISp us,
GTI or MOD C) is ~sed lo cooc ine driver preierences nro ine
appropriate control modules. Thereafter these choices can-
not be changed without
recoding with a BMW scan tool.
The functions that can be set using Car Memory include:
Alarm system (DWA) features such as armingldisarming
with
lkeyless entry (FZV), activation of tilt sensor or interior
sensor
lnterior light activation when central
locking is used
Convenience opening of
windows/sunroof
lnterior and external lighting preferences
Heating
I A/C preferences (IHKA)
Seat and mirror preferences (triggered by Key Memory)
Instrument cluster display units (for example: km vs. miles)

Downloaded from www.Manualslib.com manuals search engine
l Seats
Seat repair and component replacement is possible once the
seat has been removed from the vehicle.
Before servicing front seats read safety regulations on han-
dling
airbag modules and pyrotechnic seatbelt tensioners.
See
720 Seat belts and 721 Airbag system (SRS).
WARNING-
. The front seats are equipped with pyrotechnic seat belt
tensioners. These tensioners are powerful devices and
should be handled with exfreme care. Incorrect handling
can trigger off the tensioner and cause injury.
BMW recommends that all repair or replacement
worlc
on pyrotechnic devices must be carried out by a quali-
fied
BMW technician.
Be sure to disconnect the battery and wait
5 seconds
before attempting to work on pyrotechnic devices.
During body straightening and welding with an electric
arc welder, always disconnect the battery and the con-
nection to the pyrotechnic gas generators.
Seat switch and memory module, removing
and installing
- Remove front seat. See Front seats, removing and install-
ing.
- Carefully pull seat adjusting ltnobs straight out to remove.
Remove screw fastener
(A) and trim clips (B), turn side panel
downward to remove.
Disconnect electrical harness connector
(arrow).