1999 BMW 540i Oul

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020-21
Maintenance
Spark plugs, replacing
E39 engines use a coil-over-spark plug configuration, with
one ignition coil above each spark plug. Sparks plugs should
be removed only after the engine has cooled.
Remove engine
cover(s) over ignition coils:
Remove acoustic cover over fuel injectors
I intake
manifold.
6-cylinder engine: Remove oil filler cap.
Remove plastic trim covers (arrows).
Remove cover hold-down bolts. Remove coil
cover(s)
6-cylinder engine: Temporarily reinstall oil filler cap to
keep out contaminants.
Remove ignition coil grounding harnesses (arrows). 6-cylin-
der coils shown,
V-8 engine is similar.
< Remove ignition coils:
Pull up on spring clips to disconnect ignition coil harness
connectors.
Remove coil mounting bolts. Pull coils up and off spark
plugs.
- Remove spark plugs.

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020-22 Maintenance
1
- Installation is reverse of removal, bearing in mind the
following:
Lightly lubricate new
spark plug threads with
copper-based anti-seize compound.
Thread plugs into cylinder head by hand to prevent
cross-threading.
. Be sure to reinstall and tighten coil grounds.
Tightening torque Spark plug
to cylinder head 25 Nm (18 It-lb)
Interior ventilation microfilter, replacing
Two interior ventilation microfilters are used, one on each
side of the engine compartment at the fire wall.
< To replace the microfilter, unclip the wire fastener and
remove the cover.
Lift out the filter, and replace. Left side shown; right is
similar.
Replace cover and clip wire fastener to retain cover.
Battery, checking, cleaning, and replacing
The battery Is located in the right side of the luggage compart-
ment. Simple maintenance of the battery and its terminal
connections will ensure maximum starting periormance,
especially in winter when colder temperatures reduce battery
power.
Battery cables should be tight. The terminals, cable clamps
and battery case should be free of the white deposits that
indicate corrosion and acid salts. Even a thin layer of dust
containing conductive acid salts can cause battery discharge.

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Maintenance
- To remove battery corrosion:
Disconnect battery cables. Disconnect negative (-)cable
first.
* Remove battery from trunk
Clean terminal posts and cable clamps with a wire brush.
Clean main chassis ground terminal next to battery.
Corrosion can be washed away with a
baking soda and
water solution that will neutralize acid.
Reinstall battery and reconnect cable clamps, positive
(+)
cable first.
Lightly coat outside of terminals, hold down screws, and
clamps with petroleum jelly, grease, or a commercial
battery terminal corrosion inhibitor.
WARNING
-
Battery acid is extremely dangerous. Take care to keep it
from contacting eyes, skin, or clothing. Wear eye protection.
Extinguish all
smolihg materials and do not work near any
oaen flames.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
NOTE-
The original equipment battery in E39 models is mainte-
nance free. The original electrolyte will normally last the
entire service life of the battery under moderate climate con-
ditions.
Battery electrolyte should be maintained at the correct level
just above the battery plates and theirseparators. The correct
level is approximately
5 mm ('14 in.) above the top of battery
plates or to the top of the indicator
marks (if applicable). The
battery plates and the indicator marks can be seen once the
fillercaps are removed.
if theelectrolyte level is low, replenish
it by adding distilled water only.
4 The original equipment BMW battery is equipped with a
built-in hydrometer "magic eye"
(arrow). Battery condition is
determined by the color of the eye:
Green: Adequate charge
* Black: Inadequate charge, recharge
Yellow: Defective battery, replace
Batteries are rated by ampere hours (Ah), the number of
hours a specific current drain can be sustained before com-
plete discharge, or by cold cranking amps (CCA), the number
of amps available to crank the engine in cold weather
condi-

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020-24
Maintenance
tions. In general, replacement batteries should always be
rated equal or higher than the original battery.
The battery is held in place by a single hand screw and plate.
A secure battery hold-down is important in order to prevent
vibrations and road shoclt from damaging the battery.
CAUTION-
Prior to disconnecting the baitem read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
NOTE-
Always disconnect the negative (-) cable first, and connect
it last. While changing the battery, clean away any corro-
sion in or around the battery tray
More battery and charging system information is in 121
Battery, Alternator, Starter.
Brake fluid, replacing
Brake fluid absorbs moisture easily, and moisture in the fluid
affects bralte performance and reliability. This is why
BMW
strictly recommends replacing the bralte fluid every two
years. When replacing or adding bralte fluid, use only new
fluid from previously unopened containers. Do not use brake
fluid that has been bled from the system, even
if it is brand
new. Use only DOT
4 brake fluid.
NOTE-
See 340 Brakes for brake fluid flushing procedures.
Brake pad 1 rotor wear, checking
Disc brakes are fitted at all four wheels. Although the brakes
are equipped with a brake pad warning system, the system
only monitors one wheel per axle. Pad thickness should be
checked whenever wheels are off or brake
worlt is being
done.
4 Disc brake pad wear can be checked through opening in
caliper:
Measure distance
(A) of brake pad "eai' to bralte rotor.
See
340 Brakes. Compare to specification below.

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020-26
Maintenance
NOTE-
The parking brake may lose some of its effectiveness if it is
not used frequently This is due to corrosion build-up on the
parking brake drum. To remove corrosion, apply the parking
brake just until it begins to grip, then pull the lever up one
more stop (click). Drive the car approximately 400 meters
(1,300
ft.) and release the brake. To recheck the adjustment
of the parking brake see
340 Brakes.
Clutch fluid, checking
In cars equipped with manual transmission and clutch, the hy-
draulic clutch and the brake system share the same reservoir
and the same bralte fluid. Clutch fluid level and brake fluid lev-
el are checked at the same time.
NOTE-
* See 340 Brakes for more information.
See
210 Clutch for information on the clutch and the
hydraulic clutch operating system.
Differential oil level, checking
The E39 differential is filled with lifetime oil that ordinarily
does not need to be changed.
BMW recommends using only
a specially formulated synthetic gear oil
(SAF-XO) that is
available through an authorized
BM\N dealer parts depart-
ment. For additional information on this lubricant and any
other lubricants that may be compatible, contact an
authorized
BMW dealer service department.
< Check rear differential oil level at filler plug (arrow).
- Check lubricant level with car on a level surface:
Level is correct when fluid just reaches edge of filler hole.
If necessary, top up fluid.
Replace filler plug sealing ring.
Install and tighten oil filler plug when oil level is correct.
NOTE-
Use either a 14 mm or 17 mm Allen socket to remove the
drain plug.
If the car is raised in the air, it should be level when
checking or filling final drive fluid level.
Tightening torque
Filler plug to final drive housing 70 Nrn (52 it-lb)

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020-28
1 Maintenance
- When replacing fuel filter:
Use appropriate hose clamping device to clamp off filter
inlet and outlet hoses to lessen fuel spillage.
Loosen center clamping bracket and hose clamps on
either end of filter.
Note arrow or markings indicating direction of flow on
new filter.
Install new filter using new hose clamps
- Drain fuel filter from inlet side into a container and inspect
drained fuel.
Checlc for rust, moisture and contamination.
I - I < If fuel filter is equipped with fuel pressure regulator:
I 2 / Remove vacuum hose (1)
Pull out locking clip (2).
- Remove fuel pressure regulator (3).
Install pressure regulator in new filter.
Clean thoroughly around the filler connections before
removing them.
After assembly, check filter connections carefully for
I
I lealcs before installing cover.
NOTE- ~-
Additional informarion about the fuel filler assembly is in 160
Fuel Tank and Fuel Pump.
Fuel tank and fuel lines, inspecting
lnspectthe fuel tank, fuel lines, and fuel system fordamage or
lealts. Checlc for fuel lealts in the engine compartment or fuel
odors in the passenger compartment. Check for any evapora-
tive emissions hoses that may have become disconnected,
checking carefully at charcoal canister and evaporative emis-
sions purge system. See
130 Fuel Injection and 160 Fuel
Tankand Fuel Pump for component locations and additional
information.
WARNING-
When checlcing for fuel leal(s, the engine must be cold. A hot
exhaust manifold or exhaust system could cause the fuel to
ignite or explode causing serious personal injury Ventilate
the work area and clean up spilled fuel immediately.

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Maintenance
Suspension, front, inspecting
Inspection of the front suspension and steering includes a
check of all moving parts
forwear and excessive play. Inspect
ball joint and tie-rod rubber seals and boots for cracks
ortears
that could allow the entry of dirt, water, and other
contaminants. See
310 Front Suspension.
Suspension, rear, inspecting
Differential and rear drive axle service consists of checking
and changing the gear oil, inspecting for leaks, and checking
the drive axle
CV joint boots for damage.
The areas where
lealts are most likely to occurare around the
drive shaft and drive axle mounting flanges. For more infor-
mation on identifying oil leaks and theircauses, see
330 Rear
Suspension and
331 Final Drive.
Tires, checking inflation pressure
Correct tire pressures are important to handling and stability,
fuel economy, and tire wear. Tire pressures change with tem-
perature. Pressures should be
checked oRen during season-
al temperature changes. Correct inflation pressures can be
found on the driver's door pillar and in the owner's manual.
Note that tire pressures should be higher when the car is
more heavily loaded.
WARNING-
Do not inflate any tire to a pressure higher than the tire's max-
imum inflation pressure listedon the sidewall. Use care when
adding air to warm tires. Warm tire pressures can increase as
much as
4 psi (0.3 bar) over their coldpressures.
Tires, rotating
BMW does not recommend tire rotation. Due to the car's sus-
pension design, the front tires begin to wear first at the outer
shoulder and the reartires begin to wearfirst at the middle of
the tread or inner shoulder. Rotating the tires may adversely
affect road handling and tire grip.
Transmission service, automatic
The automatic transmissions installed in E39 models are
filled with special automatic transmission fluid. The transmis-
sion lubricant type can be found on the "type-plate" on the
side of the transmission. The recommended lubricants are
listed earlier in this repair group. See Fluids and lubricants.
If in doubt, consult an authorized BMW dealer for alternate

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Maintenance
BODY AND INTERIOR MAINTENANCE
Body and hinges, lubricating
Door locksand loclccylinderscan be lubricated with an oil that
contains graphite.
Body and doorhinges, hood latch and doorcheclc rods should
be lubricated with
SAE 30 or SAE 40 engine oil. Lubricate
seat runners with multipurposegrease. Do not apply any oil to
rubber parts.
If door weather-strips are sticking, lubricate
them with silicone spray or talcum powder. The hood release
cable should be lubricated as well.
The use of winter
lock deicer sprays should be lkept to an
absolute minimum, as the alcohol in the deicer will wash the
grease out of the lock assemblies and may cause locks to
corrode internally or to become difficult to operate.
Exterior washing
The longer dirt is left on the paint, the greater the risk of dam-
aging theglossy finish,
eitherby scratching or by thechemical
effect dirt particles may have on the painted surface.
Do not wash the car in direct sunlight. If the engine hood is
warm, allow it to cool. Beads of water not only leave spots
when dried rapidly by the sun or heat from theengine, but also
can act as small magnifying glasses and burn spots into the
finish. Wash the car with a mixture of lukewarm water and a
car wash product. Rinse using plenty of clear water. Wipe the
body dry with a sofl cloth towel or chamois to prevent
water-spotting.
Interior care
Dirt spots can usually be removed with lultewarm soapy water
or a dry foam cleaner. Use spot remover for grease and oil
spots. Do not pour the liquid directly on the carpet or fabric,
but dampen a clean cloth and rub carefully, starting at the
edge of the spot and working inward. Do not use gasoline,
naphtha, or other flammable substances.
Leather upholstery and trim
Leather upholstery and trim should be periodically cleaned
using a slightly damp cotton or wool cloth. The idea is to get
rid of the dirt in the creases and pores that can cause brittle-
ness and premature aging. On heavily soiled areas, use a
mild detergent (such as
wooliteQ) or other specially formulat-
ed leather cleaners. Dry the trim and upholstery completely