1999 BMW 540i sport

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Errata information
We will evaluate submissions and post appropriate editorial
changes online as text errata or tech discussion. Appropriate
errata will be incorporated with the
boolc text in future printings.
Read errata information for this book before beginning work on
your vehicle. See the following web address tor additional
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WARNING-important safety notice
Do not use this manual unless vou are familiar with basic automotive reoair orocedures and safe
workshoo oracfices. This manual illustrates
the workshop procedures requked formoslservice work. It is not a subsiituti for full and up-to-date information from thevehiclemanufaciurer
or for proper training as an automotive technician. Note that it is not possible for us to anticipate all of the ways or conditions under which
vehicles may be serviced or to provide cautions as to all of the possible hazards that may result.
The vehicle manufacturer will continue to issue service information updates and parls retrofits
after the editorial closing of this manual. Some
of lhese updates and retrofits will apply lo procedures and specifications in this manual. We regret that we cannot supply updates to
purchasers of this manual.
We have endeavored to ensure the accuracy
of the information in this manual. Please note, however, that considering the vast quantity and
the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information contained in this
manual.
FOR
THESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAICES ANY WARRANTIES, EXPRESS OR IMPLIED, THATTHE INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS. AND WE EXPRESSLY DISCLAIM THE IMPLIED WARRANTIES OF MERCHANTABILTTY AN0 OF FITNESS FOR A PARTICULAR PURPOSE, EVEN IFTHE PUBLISHER OR AUTHOR HAVE BEEN ADVISED OFA PARTICULAR PURPOSE, AND EVEN IF A PARTICULAR
1 PURPOSE IS INDICATED IN THE MANUAL. THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LlABlLrrY FOR DIRECT. INDIRECT. INCIDENTAL OR 1 I CONSEQUENTIAL DAMAGES THAT RESULT FROM ANY USE OFTHE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION INTHIS BOOK. IN NO EVENT 1
I Your common sense and oood iudoment are crucial to safe and successful service work. Read orocedures throuoh before startino them. I . -- - -~ ~ ---~. - ~ ~~ Think about whether the condition of your car, &r level of mechanical skill, or your level of reading compreh&sion might resill in or
contribute in some way to an occurrence which might cause you injuly, damage your car, or result in an unsafe repair. If you have doubts
for these or other reasons about your ability to pelform safe repair work on your car, have the work done at an authorized BMW dealer or
other qualified shop.
Part numbers listed in this manual are for identification purposes only, not for ordering. Always check wilh your authorized BMW dealer to
verify part numbers and availability before beginning service work lhat may require new
park.
Before anempting any work on your BMW, read the 001 General Warnings and Cautions, and any WARNING or CAUTION that
accompanies a procedure in the service manual. Review the WARNINGS and CAUTIONS each time you prepare to work on your BMW.
I Spec a too s req.1 red to perlorm cena n service operations arc oenl fed n the manLa an0 arc recomrnenoeo lor JSC Jse ol loo s olner than those recommended In lh s serv ce manual may be oelnmcnlal lo lrlc car's sale open1 on as rvec as lne salely 01 lne person servcng I the car. I
Copies of this manual may be purchased from most automotive accessories and parts dealers specializing in BMW automobiles, from
selected booksellers, or directly from the publisher.
This manual was published by Robert Bentley,
Inc., Publishers. BMW has not reviewed and does not vouch for the accuracy of the
technical specifications and procedures described in this manuai.
Libratv of Conaress Cataloaino-in-Publication Data " " -
BMW 5 Series (E39) : service manual : 523. 528i, 530i. 540i, sedan, sport wagon, 1997,
1998, 1999,2000,2001,2002
~Acludes index.
ISBN 0-8376-0317-X (obi<) ,, , 1. BMW 5 series automobiles--Maintenance and repair--Handbooks manuals, etc. 1.
Robert Bentley, Inc.
TL215.8258623 2003 629.28'722--dc23 2003052231
Bentley Stock No. 8502
Editorial closing 08/03
090807 10987654
The paper used in this publication is acid
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OCopyright 2007 Robert Bentley. Inc. Bentiey Publishers is a trademark of Robert Bentley, Inc.
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conventions.
Cover photos of car exteriors by Jonathan Richard for
Bentley Publishers @ Robert Bentley, Inc. Cover design and use of blue band on
spine and back cover are trademarks
of Bentley Publishers. All rights reserved.
Manufactured in the United States of America

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Selected Boolcs and Repair Information from Bentley Publishers
MINI Cooper
MINI Cooper Service Manual: 2002-2004 Bc,illc!! Pirl~lisl!~~ ISBN 0-8376-1068-0 AlexZanardi - My Swectest Victory rllex Zmmrdi itjill! Ginrz11,cn Gns~x~ri,,i ISBN (1-8376-1249-7
BMW 3 Series IE36) Scrvire Manual: 1992-1998,318ilisliC. 323is/iC, 3?5i/is/iC, 328ilisliC, M3 Be~iili.!~ Pirl?lisliers ISBN 0-8376-0326-9
BMW
5 Series Scrvicc Manual: 1997-2002 525i, 528i. 530i. 540i, Sedan, Sport Wagon Bcrrlluy P~rlilishens ISBN 0-8376-0317-X
Porsclze Tl~c Unfair Advantage hlirrk Do,~ult,re ISBN 0-8376-0073-Iilrcj; Porsche: Excellcncc Was Expected I Going Faster! Mastering the Art of Race Porsche 911 Carrcm Service Manual: 198G1989 B~.~iile!/ Pllblislters ISBN 0-8376-0291-2
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A French I Making of LC M,!r~s hliclael i(ei/scr ISBN 0-8376-0234-3 Porschc911 SC Coupc,Targo,and Cabriolet Scrvict. Manual: 1978-1983 Br>illu!y Ptibiishers ISBN 0-8376-0290-4 Bosclz Soorts Car and Comoctition Drivins P;url ~ri'rp ~vilh forc&rd I)!/ Phil Hill " ISBN 0-8376-0202-5 Boscl~ Aulomativc Handbook 6th Edition Robul.1 Boscli, CIII~H ISBN 0-8376-1243-8
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'7
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New Bcctle 1998-2005, New Beetle Convcrtible2003-2005 Official Factory
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Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Break in the SAC gradually, with light to medium loads, to en-
sure correct operation and long life. Fast sports driving ma-
neuvers may destroy a new
clutch.The following break-in
procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level
grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500
- 4000
rpm.
On medium grades (approx. 12% and up), start
off at ap-
prox. 2500 rpm for the first 5 or so times.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade)
M8 (10.9 grade) 24
Nm
(18 ft-lb)
34 Nm (25 ft-lb)

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230-5
Manual Transmission
Manual transmission applications
Manual transmissions used are based on engine application.
See Table a. Manual transmission applications. For gear
ratio specifications,
seeTable b. Manual transmission gear
ratios.
Table a. Manual transmission applications
Model Year Engine Transmission
5251
Sedan 2001 -2002 M54 Getrag S5D 250G
Sport Wagon 2001-2002
M54 ZF S5D 3202
5281 all 1997-2000 M52, M52 TU ZF S5D 3202
530i Sedan 2001
-2002 M54 ZF
S5D 3202
540i Sedan
1997-2002 M62, M62 TU ZF S6S 420G
NOTE-
Do not rely on casting numbers for transmission code
identification.
Table b. Manual transmission gear ratios
-
Getrag Gear Getrag S5D 250G ZF S5D 3202 S6S 420G 5-speed 5-speed 6-speed
6 th 0.83
Reverse 4.04 3.89 3.75
Final drive 3.15
523: 3.23 2.81
5281 530i: 2.93

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300 Suspension. Steering and Brakes .
Genera8
General ........................... .30 0.2
Aluminum suspension components
...... .30 0.2
Front Suspension ................. .30 0.2
Front suspension 6-cylinder models
(525i.5281. 530i) ..................... .30 0.3
Front suspension V-8 models (540i) ...... .30 0.4
Rear Suspension .................. .30 0.5
Sedan models
....................... .30 0.5
Rear suspension sedan models ........ .30 0.6
Sport Wagon models ................. .30 0.6
Rear suspension Sport Wagon
(with coil springs)
.................... .30 0.7
Rear suspension Sport Wagon
(EHC with air springs)
................. .30 0.8
EHC operational diagram .............. .30 0.9
Steering ......................... .30 0.10
Rack-and-pinion steering ............. .30 0.10
Recirculating ball and nut steering ...... .30 0.10
..................... Brake System 300-10
Wheels and Tires ................. 300-1 1
............... Rim and tire sizes table 300-1 1
Electronic Brake and Stability
.................. Control Systems 300-1 1
E39 electronic brake and stability
........ control systems application table 300-12
........................ ABS system 300-1 2
Automatic Stability Control (ASC)
....... 300-12
ABSIASC traction control system ....... 300-13
Dynamic Stability Control (DSC)
........ 300-14
Ride Height ....................... 300-14
......... Front ride height specifications 300-1 5
......... Rear ride height specifications 300-16

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300-6
/Suspension, Steering and Brakes - General
Rear suspension sedan models
Coil spring
Strut
-
'01 arm
Sport Wagon models
In order to provide a wide, ilat iloor in the cargo compartment,
the rear suspension on the Sport Wagon is unique to itself.
The shoclcabsorber is attached diagonally between the lower
swing arm and a mounting bracket on the subframe. The
spring on each side is mounted between a perch at the top
oi
the wheel bearing carrier and the bottom of the cargo com-
partment floor.
Starting with
1999 Sporl Wagon models, a self-leveling air
suspension system with electronic height control (EHC) was introduced. The system is standard on
V-8 models and op-
tional on 6-cylinder models.
On models fitted with electronic height control (EHC) rear
suspension, the standard coil springs are replaced by air
springs. Air pressure in the air springs is automatically con-
trolled by the
EHC system to compensate for ride height and
load variations.

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--- .
Suspension, Steering and Brakes - General
Rear suspension Sport Wagon
(with coil springs)
Shock absorber 1

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300-8
Suspension, Steering and Brakes - General
Rear suspension Sport Wagon
(EHC with air springs)
Air sprIn9 Shock absorber I
(tiaction strut) arA
(lower control arm) Integral arm 502330210
EHC initiates a control sequence as necessary. The system
offers the following features:
Control system independent from vehicle engine (no en-
gine driven hydraulic pump system)
Individual control of rear wheels
Uneven load identified and compensated for
Uneven road surfaces identified and not compensated for
Automatic control interrupted when cornering
System diagnosable using the
BMW Service Tester (DIS-
plus, GTI, or MoDiC)