2000 BMW 540i coolant reservoir

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I General Warnings and Cautions
WARNINGS (continued)
. The air conditioning system is filled with chemical refrigerant,
which is hazardous. The AIC system should be serviced only by
trained technicians using approved refrigerant recoverylrecycling
equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
. Do not expose any part of the AIC system to high temperatures
such as open flame. Excessive heat will increase system pres-
sure and may cause the system to burst.
Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away
from the tire repair area. Inflate and deflate the
tire at least four
times before breaking the bead from the rim.
Completely remove the tire from the rim before attempting any re-
pair.
Cars covered by this manual are equipped with a supplemental
restraint system (SRS), that automatically deploys
airbags and
pyrotechnic seat belt tensioners
In the event oi a frontal or side
impact. These are explosive devices. Handled improperly or with-
out adequate safeguards, they can be accidently activated and
cause serious injury.
- The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals and use extreme care when
working on a car with the engine running or the ignition switched
on.
. Place jack stands only at locations specified by the manufacturer.
The vehicle
illtino iack su~olied with the vehicle is intended fortire -. , . changes only. A heavy duty floor jack should be used lo lift vehicle
before installing
jacl( stands. See 010 General.
- Battery acid (electrolyte) can cause severe burns. Flush contact
area
with water, seek medical attention.
Aerosol cleaners and solvents may contain hazardous or deadly
vapors and are highly flammable. Use only in a well ventilated ar-
ea. Do not use on hot surfaces (engines, brakes, etc.).
Do not remove
coolant reservoir or radiator cap with the engine
hot. Danger of burns and engine damage.
CAUTIONS-
See also WARNINGS
- if you lack the slqills, tools and equipment, or a suitable worl(shop
for any procedure described in this manual, leave such repairs to
an authorized BMW dealer or other qualified shop.
BMW is constantly improving its cars and sometimes these
changes, both in parts and specifications, are made applicable to
earlier models. Therefore, part numbers listed in this manual are
for reference only. Always check with your authorized BMW deal-
er parts department for the latest information.
Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read ail the instructions thorough-
ly, and do not attempt shortcuts. Use tools appropriate to the
work and use only replacement parts meeting BMW specifica-
tions.
Use pneumatic and electric tools only to loosen threaded parts
and fasteners. Never use these tools to tighten fasteners, espe-
cially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque specification listed.
Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the
oil. Do not
pour
oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of waste in accordance with Federal, State and
Local laws.
The control module for the anti-lock brake system
(ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp
in excess of 203" F (95°C) and should not be subjected to tem-
peratures in excess of 185°F
(8S°C) for more than two hours.
- Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative
(-) terminal (ground strap) and
the ABS control module connector.
- Always make sure ignition is off before disconnecting battery.
Label battery cables before disconnecting. On some models, bat-
tery cables are not color coded.
Disconnecting the battery may erase fault code@) stored in control
module memory. Using special BMW diagnoslic equipment, check
lor
iauit codes prior to disconnecting the battery cables. If the mal-
I.mct on ndicator Ignt (MIL) s I. ..minaled. see OBD On-Board
Diaanostics
Tl11s iant is iuenlfted as lne Check Ena~ne oht
(1997-2000 models jor~ervlce Engine Soon light (2061 andlater
models). If any other system iaults have been detected (indicated
by an illuminated warning light), see an authorized BMW dealer.
If a normal
or rapid charger is used to charge battery, the battery
must be disconnected and removed from the vehicle in order to
avoid damaging the vehicle.
- Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the
battery a second time.
* Connect and disconnect a battery charger only with the battery
charger switched off.
- Sealed or "maintenance free" batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the bat-
tery's ampere-hour (Ah)
rating.
. Do not allow battery charging voltage to exceed 16.5 volts. If the
battery begins producing gas or boiling violently, reduce the
charging rate.
Boosting a sulfated battery at a high charging rate
can cause an explosion.

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Engine Removal and installatid
4 Remove cylinder head top cover:
Remove plastic trim caps
(arrows).
Remove cover retaining fasteners and lifl off cover.
- Remove alternator cooling tube.
4 Drain engine coolant and remove coolant hoses:
* Remove expansion tank cap on coolant reservoir.
Place a
3 gallon pail beneath engine to capture coolant,
* Remove coolant drain plug located on exhaust side of
cylinder
2 of engine block (arrow).
NOTE-
Drain plug for M52 TU and M54 engine shown. Plug for M52
located between cylinders 4 and 5.
Drain radiator by removing plastic drain plug (arrow) from
bottom of radiator.
WARNING-
Use extreme caution when draining and disposing of engine
coolant Coolant is poisonous andlethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingest-
ed.
NOTE-
Catch and dispose of drained coolant according to local,
state, and federal laws.

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110-12
Engine Removal and Installation
4 Remove hoses from thermostat housing by releasing locks
(arrows). If applicable, detach electrical harness connector
for thermostat housing.
NOTE-
Two different types of hose fasteners are used on the E39
car; lock clamp type as shown above or standard band
clamps.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator as described in
170 Ra-
diator and Cooling
System.
CAUTION-
32 mm radiator fan mounting nut has left hand threads.
4 Disconnect coolant hose (arrow) at rear left side of engine
above starter.
4 Disconnect coolant hose (arrow) at front left side of engine
mount.
- Unbolt power steering fluid reservoir and pull aside without
detaching hoses. Secure to fender with cord or stiff wire.

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I Cylinder Head Removal and Installation
4 Drain engine coolant and remove coolant hoses:
Remove expansion tank cap on radiator.
Place a
3 gallon pail beneath engine to capture coolant
Remove coolant drain plug (arrow) located on exhaust
side of cylinder
2 of engine block.
4 Drain radiator into a 3 gallon pail by removing plastic drain
plug (arrow) completely.
Use caution when draining and disposing of engine coolant.
Coolant is poisonous andlethal to humans andpets. Pets are
attracted to coolant because of its sweet smell and taste.
Seek medical
attention immediately if coolant is ingested.
NOTE-
Catch and dispose of drained coolant according to local,
state, and federal laws.
4 Remove thermostat housing:
. Disconnect electrical harness connector at thermostat
housing.
. Remove hoses from thermostat hous~ng by releasing loclts
(arrows).
Unbolt
(4 bolts) and remove thermostat hous~ng.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator shroud as described in
170 Radiator and Cooling System.
CAUTIOI\C
32 mm radiator fan mounting nut has left hand threads. r
4 Remove fasteners (arrows) from heater bypass tube. Pull
tube out of cylinder head and set to side, leaving heater hose
connected.
- Unbolt power steering fluid reservoir and pull aside without
disconnecting hoses. Secure to fender with cord or stiff wire.

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170-1 0
I Radiator and Cooling System
Combustion chamber leak test
- If you suspect that combustion chamber pressure is leaking
into the cooling system past the cylinder head gasket, use an
exhaust gas analyzer to test the vapors rising from the cool-
ant at the expansion tank.
CAUTIO&
Use an extension tube above the reservoir neclc to main-
tain distance between the top of the coolant and the gas
analyzer
nozzle. The gas analyzer is easily damaged if it is
allowed to inhale liquid coolant.
* While running engine to checlc for causes of overheat-
ing, observe coolant temperature carefully in order to
avoid engine damage.
Thermostat
If the engine overheats or runs too cool and no other cooling
system tests indicate trouble, the thermostat may be faulty.
In
V-8 models and 6-cvlinder models nroduced afler 911 998
(M52TU or M54 eng'ne), rheelecrricaily heated rhermostal IS
mon tored by [he OBD II diagnostlc software The fault may ic
in the DME software or hardware, or it may lie in the wiring to
the thermostat. See
OED On-Board Diagnostics.
Coolant, draining and filling
(6-cylinder models)
WARNING -
Allow the cooling system to cool before opening or draining
the cooling system.
- Raise front of car and support safely.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A floor jack is not adequate support.
- Remove splash shield from under engine.
4 Loosen radiator bleed screw at top radiator fitting (arrow).
- Remove cap from radiator expansion tank. Set temperature
controls to
full warm.
gallon pail underneath radiator.