1999 BMW 540i service

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Battery, Starter, Alternator
Water-cooled alternator
The water-cooled alternator, used on 1999 and later M62 TU
engines, is a sealed unit housed inside the engine block wa-
ter jacket. It is cooled via the engine cooling system. It is a
"brushless" sealed unit that cannot be serviced. Maintaining
consistent alternator temperatures increases the life span of
the alternator, and elimination of the alternator cooling fan re-
duces alternator noise
significantly.
The M62 TU water-cooled alternator incorporates load start
reduction. This function is intended to shorten the duration of
engine starting, particularly at low ambienttemperatures. The
current load is limited to
20 amps during starting in order to re-
duce alternator braking torque on the engine. Following the
current limiting phase, full power output is then progressively
reached.
Charging system diagnostics requires special test equip-
ment. If the test equipment is not available, charging system
fault diagnosis can be performed by an authorized
BMW
dealer or other qualified repair shop. See Table a. Battery,
alternator and starter troubleshooting for general electri-
cal component troubleshooting.
Before checking the alternator, make sure the battery is fully
charged and capable of holding a charge. Check that the bat-
tery terminals are clean and tight and the alternator drive belt
is properly tensioned and not severely worn.
NOTE-
Some model require up to 15 second to reacli full alternator
output.
CA UTIOG
If the charge indicator light in the instrument cluster remains
on, the charge warning circuit in the instrument cluster may
be faulty. Check that the ground lead is securely
affached to
the grounding stud on the cylinder head
(A). Replacing the
instrument cluster before repairing the ground lead will both
damage the instrument cluster and cause the failure to
reoccur.

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130-2
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This repair group covers service and repair of the Bosch and
Siemens engine management systems used on
1997
through 2002 E39 models. Additional engine management
service and repair information may also be found in the fol-
lowing repair groups:
0 020 Maintenance
120 Ignition System
160 Fuel Tank and Fuel Pump
610 Electrical Component Locations
OBD On Board Diagnostics
NOTE-
Camshaft position sensor, crankshaft speed sensor and
knoclc sensors are covered in 120 Ignition System.
Table a. Engine management system applications
- - ~ ~
1 ~odellmodel year / Engine IDME system I - I
5281, 1997-1 998 IM52. 2.8 liter ISiemens MS 41 .I I 1
528i. 1999ZO00 1~52 TU, 2.8 liter ]siemens MS 42.0 I I
5251, 2001-2002 1~54, 2.5 liter 1 Siemens MS 43.0 I I
530i, 2001-2002 1~54, 3.0 liter ISiemens MS 43.0
5401 1999-2001 1~62 TU, 4.4 liter l~osch ME 7.2
I
OBI) II software and hardware is incorporated in the engine
management control systems. The
OED II system monitors
components that influence exhaust and evaporative emis-
sions. If a problem is detected, the
OED I1 system stores the
associated fault code and condition.
540i. 1997
4 If vehicle emission levels exceed 1.5 times Federally mandat-
ed criteria, the
OED II system illuminates a malfunction indi-
cator light
(MIL) in the instrument cluster.
For the
E39 cars covered by this manual, three different
MIL symbols were used, depending on year and model.
See illustration.
When faults arise, or if the malfunction indicator lamp (MIL) is
illuminated, begin troubleshooting by connecting BMW ser-
vice tester
DISplus, MoDiC, GTl or equivalent scan tool. The
capabilities of OBD
II software has the potential to save hours
540i. 1998 IM62, 4.4 liter /Bosch M5.2.1
M62, 4.4 liter Bosch M5.2

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Fuel Injection
of diagnostic time and to help avoid incorrect component re-
placement and possible damage to system components.
NOTE-
* Professional diagnostic scan tools available at the time of
this printing include the BMW factory tools and a small
number of aftermarket BMW-specific tools. The
CS2000
from Baum Tools Unlimited, the Retriever from Assenma-
chef Specialty Tools, and the MT2500 from Snap-on are
three examples.
In addition to the BMW-specific professional line of scan
tools, there are inexpensive generic OBD
I1 scan tool soft-
ware programs and
handheld units available. Although
these tools have limited capabilities as compared to the
dedicated tools, they are powerful diagnostic tools.
For the
DIY owner, simple aftermarltet DTC readeris avail-
able through
http://www.pealteresearch.com. This tool is
capable of checlting for
DTCs as well as turning off the il-
luminated
MIL and resetting the service indicator lights.
Tools and test equipment
If the equipment required to do the job is unavailable, it is rec-
ommended that these repairs be left to an authorized
BMW
dealer or other qualified BMW repair facility.
4 Low current test light ("noid")
(Tool No. Baum 11 15a)

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Fuel Injection I
- As an alternative, harness connector housing can be sepa-
rated so that electrical
checlts can be made from backof con-
nector.
4 If replacing ECM, disconnect control module harness con-
nector (arrow) by releasing fastener and pivoting connector
up and
off ECM.
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
- Remove ECM from retaining brackets and lift off holder.
- Installation is reverse of removal.
- Before attempting to start engine, use BMW service tester
DISplus, MoDiC, GTI or equivalent:
- Code replacement ECM with application information (i.e.
engine code, transmission type, etc.).
Align ECM to EWS (electronic immobilizer).
Siemens MS 41.1 ECM pin assignments
ECM pin assignments are given in Table b. For engine man-
agement system schematics, see ELE Electrical Wiring
Di-
agrams.
CAUTION-
a Always wait at least one minute after turning off the ignition
before removing the connector from the
ECM. If the con-
nector is removed before this time, residual power
in the
system relay may damage the
ECM.
Always connect or disconnect the control module con-
nector and meter probes with the ignition
off
When malting checks at the ECM itself, a breakout box
should be used to allow tests to be made with the connector
attached to the ECM. This also prevents damage to the small
terminals in the connector. As an alternative, the harness
connector housing can be separated so that electrical checlts
can be made from the back of the connector.
Table b. Siemens MS
41.1 ECM pin assignments
Pin
1
2
3
4
Signal
output
output
output
qround Componenfffunction
Ignition coil control, cyl. 2
Ignition coil control, cyl. 4
ignition coil control, cyl. 6
Ground Notes
Primary signal,
ignition
coil 2
Primary signal, ignition coil 4
Primary signal, ignition coil 6
Ground

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Fuel Injection
4 Remove electrical harness connector (arrow) from IAT sen-
sor.
CAUTION-
Be sure the ignition switch is in the off position before repiac-
ins the intake temperature sensor.
- Depress loclting clip on side of temperature sensor and pull
straight out of intake manifold.
- Installation is reverse of removal
- Use a new sealing O-ring at base of sensor and lubricate with
assembly lubricant for
ease of installation
MS 42.0 throttle valve assembly, replacing
< The motor driven throttle valve for the MS 42.0 system is re-
- ferred to as MDK (motor driven throttle valve). The MDK unit
is electronically operated to regulate intake air flow by the
ECM.
The
MS 42.0 system uses a throttle cable from the accelera-
tor pedal to the MDK unit. The throttle cable is connected di-
rectly to the integral pedal position sensor
(PWG) in the MDK
unit. This sensor communicates pedal position to the ECM,
which in turn electronically regulates throttle plate position.
The MDK pulley is linked to the throttle shaft by springs to al-
low ASC intervention to override the driver's pedal position.
NO TE -
The MDIC unit is non-adjustable and must be replaced as
a complete unit if found to be faulty.
if replacing the
MDK unit, the adaptation values stored in
the ECM must be clearedand the new unit initialized using
BMW special service tools.
CAUTION-
If the adaptation process is not completed correct& the en-
gine wiii
not start.
- Disconnect battery negative (-) cable in luggage compart-
ment.
CAUTION-
Prior to disconnecting the battern read the battely discon-
nection cautions in
001 General Warnings and Cautions.

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MS 43.0 throttle valve assembly, replacing
The electronic throttle valve assembly forthe MS43.0 system
is referred to as
EDK (electronic throttle valve). There is no
mechanical (cable) link between the accelerator pedal and
the throttle plate.
< The accelerator pedal module (PWG) at the pedal assembly
communicates the pedal position directly to the ECM. The
module provides two variable voltage signals (via two Hail
sensors) to the ECM for pedal position and rate of movement.
NOTE-
The EDK unit is non-adjustable and must be replaced as a
complete unit if found to be faulty
If replacing the
EDK unit, the adaptation values stored in
the
ECM must be cleared and the new unit initialized using
BMW special service tools.
CAUTIOIG
If the adaptation process is not completed correctk the en-
qine will not start
- Disconnect battery negative (-) cable in luggage compart-
ment.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Warnings and Cau-
tions.
< Remove complete air filter housing:
- Disconnect electrical harness connector on mass air flow
sensor
(A).
Disconnect vacuum line at intake boot (6).
Loosen intaite air duct clamp (C).
Remove filter housing mounting screws.
Disconnect air duct and lift complete air filter housing and
MAF sensor out of engine compartment, pulling it forward
away from throttle housing.

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130-38
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Throttle cable, adjusting
(MS 42.0)
The throttle assembly on MS 42.0 cars uses a throttle cable.
The cable should be adjusted any time it is disconnected or
replaced. This procedure requires the factory scan tool or an
equivalent to read and adjust throttle angle. It is recommend-
ed the procedure be done by an authorized
BMW dealer ser-
vice department
Basic adjustment:
Ensure that at idle (accelerator pedal in rest position) throt-
tle cable has detectable play at throttle lever attaching
point. Play must not exceed maximum allowable.
Adjust by turning knurled adjuster
(arrow) on end of throt-
tle cable sheath at throttle housing.
NOTE-
Faulty throttle adjustment values must be reset using the
BMW service tester
DISplus, MoDiC, GTI or equivalent.
Max.
play at throttle plate lever
ldle speed control valve,
checking and replacing
3 mm (0.125 in)
The Idle speed control valve regulates Idle speed by red~rect-
ing air around the throttle valve. The ldle speed control valve
is mounted
d~rectly above the throttle housing. Accessing the
valve is best accomplished by
flrst removing the air fllter
housing and associated ducting.
Thevalve is supplied with batteryvoltage from the ECM relay.
The idle speed control valve incorporates a two-coil rotary ac-
tuator. The ground sides of each coil are pulsed simulta-
neously by the ECM. The duty cycle of each circuit is varied to
achieve the required idle speed.
A faulty idle speed control valve sets a fault code and the MIL
is illuminated when
OED II fault criteria are exceeded.
Before checking the idle speed control valve, confirm that the
throttle position sensor is working correctly.
- With engine running, check that idle speed control valve is
buzzing.
- Turn on AIC system or shift transmission into drive. ldle
should remain steady or increase slightly.
- If idle speed valve is not buzzing, or if idle decreases when
AIC is turned on, stop engine and disconnect harness con-
nector from idle speed valve.

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Working inside E-box, disconnect ECM harness connector
(arrow) by releasing fastener and pivoting connector up and
off ECM.
CA UTIOW
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
Remove ECM from retaining brackets and lift off holder.
Installation is reverse of removal
Before attempting to start engine, use
BMW service tester
DISplus, MoDiC, GTl or equivalent:
* Code replacement ECM with application information (i.e
engine code, transmission type, etc.).
Align ECM to EWS (electronic immobilizer).
Siemens MS 42.0 and MS 43.0
ECM pin assignments
ECM pin assignments are given in Table c. For engine man-
agement system schematics, see
ELE Electrical Wiring Di-
agrams.
/ CAUTIOW I
Al~ays wait at least one mfnule after turning off the ignition
before
remov;ng [he connecror irom rhe ECM. If the con-
nector is removed before this time, residual power
in the
system relay may damage the
ECM.
Always connect or disconnect the control module con-
nector and meter probes with the ignition off.
When making checks at the ECM itself, a
breakout box
should be used to allow tests to be made with the connector
attached to the ECM. This also prevents damage to the small
terminals in the connector. As an alternative, the harness
connector housing can be separated so that electrical checks
can be made from the back of the connector.
Table
c. Siemens MS 42.0 and MS 43.0 ECM pin assignments
Pin
lslgnal l~om~onentlfunction 1 Notes
Connector
X60001 9-pin black
1 loutput I~erminai 15 I Unloeder relay terminal 15
2 I 1 Not used I
3 Not used
4 Ground
Ground Ground
point