1999 BMW 540i service

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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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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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020-30
Maintenance
fluid use and the most-up-to-date information regarding
transmission operating fluids.
The automatic transmission is not equipped with a dipstick.
Therefore, checking the ATF level is an involved procedure
which includes measuring and maintaining a specified ATF
temperature during the checking procedure.
For more complete
ATF service information, including
checking
ATF level and ATF filter replacement procedures,
see
240 Automatic Transmission.
Transmission service, manual
Manual transmission service consists of inspecting for leaks
and checking the fluid. Evidence of transmission leaks is
like-
ly to be seen around the driveshaft mounting flange and at the
bottom of the bellhousing.
NOTE-
For more information on identifying oil
leaks and their
causes, see 230 Manual Transmission and210 Clutch.
Transmission fluid, checking and filling
(manual transmission)
Tne manual transmss'on inslalleo 'n rne E39 models s f;lled
with a special liierime iluid (ivlTF-LT-I). oi. ordinarily
does
not need to be changed.
< Check manual transmission oil level at transmission filler plug
(A). Make sure car is on level surface.
NOTE- Transmission fluid level
checking and replacement
procedures are covered in 230 Manual Transmission.
Wheels, aligning
BMW recommends checking the front and rear alignment
once a year and whenever new tires are installed.
NOTE-
See 320 Steering and Wheel Alignment for a more detailed
discussion of alignment requirements and specifications.

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020-32
Maintenance
using a soft cloth. Regular use of a good quality leather condi-
tioner will reduce drying and cracking of the leather.
Polishing
Use paint polish only if the finish assumes a dull loolc afler
long service. Polish can be used to remove tar spots and tar-
nish, but
afleiwards a coat of waxshould be applied to protect
the clean finish. Do not use abrasive polish or cleaners on
aluminum trim or accessories.
Seat belts
Dirt and other abrasive particles will damage seat belt web-
bing. If it is necessary to clean seat belts, use a mild soap so-
lution. Bleach and other strong cleaning agents may weaken
the belt webbing and should be avoided.
WARNING-
Do not clean the seat belt webbing using dry cleaning or oth-
er chemicals. Allow wet belts to
dry before allowing them to
retract.
-
The condition of the belt webbing and the function of the re-
tractor mechanisms should be inspected. See
720 Seat Belts
for seat belt inspection information.
Speciai cieaning
Tarspots can be removed with a bug and tar remover. Never
use gasoline,
lterosene, nail polish remover, or other unsuit-
able solvents. Insect spots also respond to tar remover.
A bit
of baking soda dissolved in the wash water will facilitate their
removal. This method can also be used to remove tree sap
spots.
Washing chassis
Periodic washing of the underside of the car, especially in
winter, will help prevent accumulation of road salt and rust.
The best time to wash the underside is just afler the car has
been driven in wet conditions. Spray the chassis with a pow-
erful jet of water. Commercial or self-service carwashes may
not be bestforthis, as they may recycle the salt-contaminated
water.
Waxing
For a long-lasting, protective, and glossy finish, apply a hard
wax after the car has been washed and dried. Use carnauba
or synthetic based products. Waxing is not needed after
every washing. You can tell when waxing is required by
look-

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110-3
Engine Removal and lnstallationl
Q Fuel line plugs
(Tool No.
BMW 13 5 281 / 13 5 282)
4 Fuel line removal tool
(Tool No.
BMW 16 1 050)
CAUTION-
Disconnecting the battery may erase fault code@) storedin
memoiy Check for fault codes prior to disconnecting the
battery cables.
If the MIL (Malfunction Indicator Light, also may be
called "Check Engine" or "Service Engine Soon" light)
is illuminated, see
OBD On-Board Diagnostics for
DME fault code information.
It orhersysrem faults have been detected, as indicated I
by an ~llum~nated ABS, SRS orASC/DSC ~arning light,
see the appropriate repair group in this manual or an
authorized BMW dealer for more information on fault
codes.
NOTE- Engine removal procedures are similar for all 6-cylinder
models. When differences
exist, they are noted at the be-
ginning of each step. Engine are referred to by engine
code. See
100 Engine-General for engine code and appli-
cation information.
@ Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse
gaskets, O-rings or seals during reassembly.
The
intake manifold must be removed on &cylinder mod-
els before the engine can be removed.
WARNING-
Due to risk of personal injury, be sure the engine is cold be-
fore beginning the removal procedure.

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11 0-4
/Engine Removal and Installation
- Disconnect negative (-) cable from battery.
CAUTION- Prior to disconnecting the
batteg read the battery discon-
nection cautions
in 001 General Cautions and Warnings.
- Remove engine hood, or place in service position. See 410
Fenders, Engine Hood.
4 Remove left and right interior ventilation ducts (lefl side
shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic loclting tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclocltwise to
unloclt from bulkhead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring
loclt (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel:
Remove rubber sealing gasket (arrow).
- Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift off panel.
Remove complete air filter housing:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intalte duct
(6) and (where applicable) disconnect idle speed control
valve electrical harness connector.
Disconnect harness connector (C) from mass air flow sen-
sor.
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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110-16
Engine Removal and Installation
ENGINE, REMOVAL AND
INSTALLATION (V-8 MODELS)
NOTE-
Engine removal procedures are similar for all V-8 models.
When differences exist, they are noted at the beginning of
each step. Engine are referred to by engine code. If neces-
sary, See
100 Engine-General for engine code andappli-
cation information.
Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse gaskets, O-rings or seals during reassembly
WARNING
-
Due to risk ofpersonal injury, be sure the engine is cold be-
fore beginning the
removal procedure.
- Disconnect negative (-) cable from battery.
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove engine hood or place hood in service position. See
410 Fenders, Engine Hood.
Remove
intake manifold cover, version 1:
Remove plastic trim caps (arrows).
Remove cover mounting fasteners and
lift off cover.
Remove intake manifold cover, version
2:
Press down on locking pins (arrows) to release locks
Lifl cover straight
up to remove.

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11 3-2
Cylinder Head Removal and Installation
This group covers cylinder head removal and installation as
well as cylinder
headlvalve diagnostic procedures.
In the procedures in this repair group, engines are referred to
by engine code. If necessary, see
100 Engine-General for
engine code and application information.
The information given in this repair group assumes that the
engine is installed in the engine bay. On the
6-cylinder en-
gines, the VANOS control unit must be removed in orderto re-
move the cylinder head from the engine block. On
M52TU
and M54 engines, camshafts must be removed from the cylin-
der head before the head is removed.
The cylinder head removal and installation procedures for the
M62 V-8 are also included, butthe proceduresforthe M62TU
V-8 with VANOS are not provided.
For cylinder head and valvetrain reconditioning information,
see
116 Cylinder Head and Valvetrain.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
If a head gasket problem is suspected, a compression test or
leak-down test will usually detect the fault See Diagnostic
Testing later
in this group.
Special tools
Special BMW service tools are required to properly remove
and install the cylinder head on engines covered by this man-
ual. The special tools are used to time the valvetrain to the
crankshaft, and to remove the VANOS control unit, the cam-
shafts and the
Tom (El2) head bolts. Read the entire proce-
dure through before beginning the job.