2002 BMW 540I Service and Repair Manual

Service Manua 5251, 5281, 530i, 540i Sedan, Sport Wagon 1997,1998,1999,2000,2001,2002

-- Benllcy Publishers, a division ol Robcrt Bcnlley, In=. 1734 M~SB~CIIUP~IIS Avenue Cumbitdge. MA02138 USA Information lhat makes 800-423-4885 / 61 7.547.4170 the diiierence" BentleyPublishe~ Technical contact inlormation I We :.€ c3me ,o.lr leeooaca. Pieasc. ;Jam 1 cllriecl 00s an0 zoo ions lo our BhFLt/ recnns? o rcdss'un lor~m a1 http://~~~.BentleyPublishere.com 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 information: http://unw.BentleyPublishers.com/errata/ 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 proceduresrequked formoslservice work. It is not a subsiituti for full and up-to-dateinformation 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 MERCHANTABILTTYAN0 OF FITNESS FOR A PARTICULAR PURPOSE,EVENIFTHE 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 DAMAGESTHAT RESULT FROM ANY USE OFTHE EXAMPLES,INSTRUCTIONS OR OTHER INFORMATIONINTHISBOOK. INNO 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 o f 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 identificationpurposes only, not for ordering. Always check wilh your authorized BMW dealer to verify part numbers and availability before beginningservice 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 open1on 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 free and meets the requirements of the National Standard for Information Sciences- Permanence of Paper for Printed Library Materials. @ OCopyright 2007 Robert Bentley. Inc. Bentiey Publishers is a trademark of Robert Bentley, Inc. All rights reserved. All information contained in this manual is based on the information available to the publisher at the time of editorial closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or ofhenvise, without the prior written consent of the publisher. This includes text, figures, and tables. All rights reserved under Berne and Pan-American Copyright 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

YOU are now in Volume I I Foreword ................... .. .................................................................................. v Index ........................ .. ................................................................ rear of manual General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder Maintenance OiO 020 Maintenance Engine 100 Engine-General 110 Engine Removal and Installation 113 Cylinder Head Removal and Installation 116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain 119 Lubrication System 200 Transmission-General 2 Transmission 210 clutch 230 ManualTransmission I20 Ignition System 121 Battery, Starter, Alternator 130 Fuel Injection 160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System 180 Exhaust System 240 Automatic Transmission 250 Gearshift Linkage 260 Driveshaft Suspension, 300 Suspension, Steering and 330 Rear Suspension Brakes-General 331 Final Drive Steering and No Front Suspension 340 Brakes 320 Steering and Wheel Alignment 400 Body-General 410 Fenders, Engine Hood 411 Doors 412 Trunk Lid, Tailgate 510 Exterior Trim, Bumpers 512 Door Windows Equipment 513 Interior Trim 7 Equipment and 720 seat Belts Accessories 721 Airbag System (SRS) OBD On-Board Diagnostics . . .. 515 Central Lociting and Anti-Theft 520 Seats 540 Sunroof .................................................................... Foreword .............................. .. v Index ................... .. ................................................................ rear of manual Electrical 6 system 600 Electrical System-General 620 Instruments 610 Electrical Comoonent Locations 630 Liohts 611 wipers and washers 612 Switches eati in^ and Air Conditioning Radio . . . . Electrical Wiring Diagrams

Selected Boolcs and Repair Information from Bentley Publishers MINI Cooper MINI Cooper Service Manual: 2002-2004 Bc,illc!! P i r l ~ l i s l ! ~ ~ 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<iirlLcldui,~sse!t ISBN 0-8371,-0235-1 0-8376-0069-3(~1bJ Going Faster! Mastering the Art of Race Porsche 911 Carrcm Service Manual: 198G1989 B~.~iile!/ Pllblislters ISBN 0-8376-0291-2 Porschc 911 Enthusiast's CompanionT3' Aiirinri Slr~,tzlli~~r ISBN 0-8376-0293-9 BMW 6 Scries Enthusiasl's CompanionTh1 Jc~.li'iil!/ liV0l10li ISBN 0-8376-0193-2 Driving Tlw Skip Bizl.bul- Riicing Sclaiol ISBN 0-8376-0227-0 BMW 7 Series Servicc Manual:1988-1994, 735i,735iL, 74%. 740iL. 750iL Beritlc!/ I'irblislrens ISBN 0-8376-0328-5 A French I<iss With Dcalh: Steve McQuecn and the 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, C I I I ~ H ISBN 0-8376-1243-8 Bosch 1-landbookfor Automotive Elcctrics and Elcchonics Rillrcr I Bwcli, GrjilrH ISBN 0-8376-1050-8 Bosch Handbook for Diesel-Engine Managcmcnt Ril1iei.t Bosdl, ClrrbH ISBN 0-8376-1051-6 Bosch Handbook for Gasolinc-Engine Management Robcrf Bosclr, G~ribH ISBN 0-8376-1052-4 ' 7 Battle for lhe Bcelle I<iir.l Liid~,igsc>t ISBN 0-8376-0071-5 Jells, Golf, GTI Scrvicc Manual: 1999-2005 1.8L lurbo, 1.9LTDI diesel, PD dicscl, 2.0L ga5aline. 2.81 VRG B~.!iIlcy Pt,blislicrs ISBN 0-8376-125-9 New Bcctle ServiceManual:1998-20021.8L turbo, 1.91 TDI diesel, 2.0L gasoline Bailicy P~irirlishers ISBN 0-8376-0376-5 New Bcctle 1998-2005, New Beetle Convcrtible2003-2005 Official Factory Rcpair Manual an CD-ROM I~olkiatgurr ~JAriicricn ISBN 9784-8376-1265-2 Boscll Fuel Injection and Enginc Management Clml-Its 0. Pmbsi, SAE ISBN 0-8376-0300-5 Clzevrolet Corvctlc Illustralcd Encyclopedia Torn Beifurli ISBN 0-8376-0928-3 Racc Car Aerodynamics losupli Kntz ISBN 0-8376-014>8 Road &Track Illustrated Automotive Dictionary Joltri Dilrkl ISBN 0-8376-11143-6 Scientific Design of Exl~aust and Intake Systems I'lrililr H. S,sillr 0-8376-0309-9 Corvette Fuel Injection &Electronic Enginc Managcment 1982-2001: Clmrlcs 0. I1rol,sl, SAE ISBN 0-8376-0861-9 I'acrat Ser\,irc hl.>nu.~l: 1998-2004.1.81. lurbu, 2.RL Vb, .l.IIL \\'8, inrludinl: tv.~gc>n and 4blOTION Giiitlc!/ P~iiblislicrs ISBN 0-8376-0360-2 Zora Arkus-Duntov:Thc Lcgcnd Behind corvt.ttc Je1.q Birl-1011 ISBN 0-8376-0858-9 Ci~evmlcl by the Numbers 1965-1969: The Essential Chcvrolct Paris Refcrcncc illn,i Cnl2i11 ISBN 0-8376-0956-9 Passat. Passat Waron 1998-2005 Official Gnlf, GTI, Jctta 1993-1999, Cabrio 199% 2002 Official Factory Repair Manual on CD-ROM Volhsiraigu>t oJA,rtrricn ISBN 978-0-8376-1263-8 Jetta, Golf, GTI: 1993-1999, Cabtio: 1995- 2002 Scrvicc Manual ll~iillcy I'trblisln.~~~ ISBN 0-8376-0366-8 Alfa Romco All-Alloy Twin Cam Companion 195G1994 1'nl Bncdulr ISBN 0-8376.0275-0 Alfa Romco Owner's Bibl~'~' 1'1~1 Bmrlul! ISBN 0-8376-0707-8 Ford Ford Fuel Injection and Electronic Engine Control: 1988-1993 Clinrlcs 0. Pmirsl, SrlE ISBN 0-8376-03Lll-3 Arldi Audi A4 Repair Manual: 1996-2001.1.8L lurbo, 2.8L. including Avant and quatlro Buirile!/ Ptrhlislters ISBN 0-8376-0371-.I EuroVan Official Factory Rcp.,ir Manual: 1992-1999 I/~llhio~sar, ifAii!wicn ISBN 0-8376-0335-8 Tbc Official Ford Mustang 5.0 Technical Reference & I'crformancc Handbook: 1979-1993 A1 l<inci~u~ihrirri,i ISBN 0-8376-0210-6 Audi A6 Sedan 1998-2004, Avant 1999- 2004, allroad quallro 2001-2005, 5 6 Avant 2002-2004, RS6 2003-2004 Official Factory Rcpair Manual on CD-ROM Ai!dioJ/in,er.ini ISBN 978-0-8376-1257-7 Jccp CJ Rubuildcr's Manual: 1972-1986 MOSI~S Lltii~l ISBN 0-8376-0151-7 Jccp Owner's Biblen', Third Edition Moscs Lzrdel ISBN 0-8376-1117-2 Automotive Reference Bcnlluy Publishers has published iewicc manualsand autornohilcboolissinrc 1950. Plcasc write to us at 1734 Mniincliusctts Ave..Cnmbridge, kIA02138,i~isit ourivcb sitc, ol-c,lll 1-800-12345'15 ini a free copy ofnurcolaiog. BMW BMW 2 3 Sarvicc Manual: 1996-2002. including 2 3 Roadster, 23 Coupe, M Roadster, M Coupe Be~illq Pi,blislicis ISBN 0-8376-1250-0 BMW 3 Scrics (Ed61 Scrvicc Manual: Mcrcedes-Bcnz Technical C ~ m p a n i o n ' ~ ~ ' Bu,rllu!! P,rlilislio.i ISBN 11-8376-1033-8 Mcrccdcs-Bcnz E-Class (W124) O~vner's BibleT>' : 1986-1995 llu~tilc!~ Pi~lriisiieis ISBN 11-8376-0230-(1 Urlilii-!~ P~~Blisi~~rs ISBN 11-8376-11772

Foreword For the BMW owner with basic mechanical skills and for independent auto service professionals. this manual includes many of the specifications and procedures that were available to an authorized BMW dealer service deoartment as this manual went to Dress. The BMW owner with , no intention of working on his or her car will find that owning and referring to this manual makes it possible to be better informed and to more Itnowledgeably discuss repairs with a professional automotive technician. If you are a BMW owner intending to do maintenance and repair work, make sure you have screwdrivers, a set of metric wrenches and sockets and metric Allen and Torx wrenches, since these basic hand tools are needed for most of the work described in this manual. Many procedures also require a torque wrench to ensure that fasteners are tightened properly and in accordance with specifications. Additional information on basic tools and other tips are in 010 General. In some cases, the text refers to special tools that are recommended or required to accomplish adjustments or repairs. These tools are usually identified by their BMW special tool number and illustrated. Disclaimer We have endeavored to ensure the accuracy of the information in this manual. When the vast array of data presented in the manual is talten into account, however, no claim to infallibility can be made. We therefore cannot be responsible for the result of any errors that may have crept into the text. Please also read the Important Safety Notice on the copyright page at the beginning of this book. Prior to starting a repair procedure, read the procedure, 001 General Warnings and Cautions and the warnigns and cautions that accompany the procedure. Reading a procedure before beginning work will help you determine in advance the need for specific skills, identify hazards, prepare for appropriate capture and handling of hazardous materials, and the need for particular tools and replacement parts such as gasltets. Bentley Publishers encourages comments from the readers of this manual with regard to errors, and/or suggestions for improvement of our product. These communications have been and will be carefully considered in the preparation of this and other manuals. If you identify inconsistencies in the manual, you may have found an error. Please contact the publisher and we will endeavor to post applicable corrections on our website. Posted corrections (errata) should be reviewed before beginning worlc. Please see the following web address: BMW offers extensive warranties, especially on components of the fuel delivery and emission control systems. Therefore, before deciding to repair a BMW that may be covered wholly or in part by any warranties issued by BMW of North America, LLC, consult your authorized BMW dealer. You may find that the dealer can make the repair either free or at minimum cost. Regardless of its age, or whether it is under warranty, your BMW Is both an easy car to service and an easy car to get serviced. So if at any time a repair is needed that you feel is too difficult to do yourself, a trained BMW technician is ready to do the job for you. Bentley Publishers

001 General Warnings and Cautions PLEASE READ THESE WARNINGS AND CAUTIONS BEFORE PROCEEDING WITH MAINTENANCE AND REPAIR WORK. WARNINGS- See also CAUTIONS - Some repairs may be beyond your capability. If you lack the skills, - Catch draining fuel, oil, or brake fluid in suitable containers. Do tools and equipment, or a suitable workplace for any procedure not use foodor beverage containers that might mislead someone described in this manual, we suggest you leave such repairs to into drinking from them. Store flammable fluids away from fire an authorized BMW dealer service department or other qualified hazards. Wipe up spills at once, but do not store the oily rags, shop. which can ignite and burn spontaneously. . Do not reuse any fasteners that are worn or deformed. Many fas- Always observe good worRshop practices. Wear qoqqles when teners are designed to be used only once and become unreliable you operate machine tools or work with battery acid:kloves or and mav fail when used a second time. This includes, but is not other ~rotective clothino should be worn whenever the iob re- limited io, nuts, bolts, washers, self-locking nuts or bolts, clrclips yires' working with harmful substances. and cotter pins. Always replace these fasteners with new parts. Greases, lubricants and other automotive chemicals contain toxic . Never work under a lifted car unless it is solidly supported on substances, many of which are absorbed directly through the stands desiqned for the purpose. Do not supeort a car on cinder skin. Read the manufacturer's instructions and warninos careful- blochs, hollow tiles orotherbrops that may drurnbie undercontin- uous toad. Never work under a car that is supported solely by a iack. Never work under the car while the enqine is runninq. - - If you aregoing to work underacaron the ground, makesure that the ground is level. Block the wheels to keep the car from rolling. Disconnect the battery negative (-) terminal to prevent others from starting the car while you are under it. - Never run the engine unless the work area is well ventilated. Car- bon monoxide kills. Rings, bracelets and other jewelry should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts. - Tie long hair behind your head. Do not wear a necktie, a scarf. loose clothing, or a necklace when you work near machine tools or running engines. if your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result. DO not attempt to work on your car if you do not feel well. You increase the danger of injuryto yourseliand others if you are tired, uDset or have taken medication or anv other substance that mav keep you from being fully alert. Illuminate your work area adequately but safely. Use a portable iy. Use hand and eye protection. Avoid direct skin conGct. Disconnect the battery negative (-) terminal whenever you work on the fuel system orthe electrical system. Do not smokeorwork near heaters or other fire hazards. Keep an approved fire extin- guisher handy. . Friction materials (such as brake pads or shoes or clutch discs) contain asbestos fibers or other friction materials. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing dust. Breathing any friclion material dust can lead to serious diseases and may result in death. Batteries giveoff explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it will ignite gas trapped in the cells and cause the battery to ex- plode. Connect and disconnect battery cables, jumper cables or a battery charger only wilh the ignition switched off. Do not disconnect the battery while the engine is running. 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. . . safety lighiforworking lnsideor under the car. Make sure the bulb - Do not allow battery charging vollage to exceed 16.5 volts. If the is enclosed bv a wire caoe. The hot filament of an accidentallv batten! beoins ~roducina oas or boilino violentiv, reduce the broken bulb can ignite spilled fuel, vapors or oil. , - - - charglng rate. ~oostlng a sutfaled battery at a i g h charging rate can cause an explosion. - Continued on next page

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 repair. 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 o i a frontal or side impact. These are explosive devices. Handled improperly or without 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 area. 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 dealer 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 specifications. Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially 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 temperatures 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, battery cables are not color coded. Disconnectingthe 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 battery'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.

002 Vehicie identification and VlN Decoder Vehicle identification Number (VIN), decoding Some of the information in this manual applies only to cars of a parlicuiar model year or range of vears. For examole. 1999 refers to the 1999 model vear but does not necessarilv malch the caiendsr year in which the car was manufactured or sold. To be sure of the model year of a particular car, checic the Vehicle ldentification Number (VIN) on the car. The VIN is a unique sequence of 17 characters assigned by BMW lo identify each individual car. When decoded, the VIN tells the country and year of manufacture; make, model and serial number: assembly plant and some equipment specifications. The BMW VIN is on a plate mounted on top of the dashboard, on the driver's side where the number can be seen through the windshield, The 10th character is the model year code. The letters I. 0, Q and U are not used for model year designation. Examples: X for 1999, Y for 2000, 1 for 2001,2 for 2002, etc. The table below explains some of the codes in the VIN for 1997 through 2002 BMW E39 5 Series BMWs covered by this manual. Sample VIN: ~ ~ I z ~ o ~ w ~ B ~ w ~ 13 8 9 1 lposition 1 2 3 zi 5 6 7 8 9 10 11 12-17 VIN position Description Decoding information 1-3 Countrv of WBA B I J 1 znan~+q ; BT BMW Molorsporl. Gmon, ~ ; n c hGerrn;!n, Linc 525 (2UU1 - 2003) 528 (2000-2003. 530; 540 i 5 1 Manual belts with dual airbags Manual belts with advanced airbaos Series Body type i engine lype . .. D 5251 (2001 - 2002), 528i (1997 - 2000) E MS. 530i, 540i (1997 - 1998) J 5251 Wagon M 528i (1999 - 2000) N 5401 Sedan (1999 - 2003) 540i wagon (2001) P 528i wagon (1999 - 2000) R 540i waaon 12002 - 20031 6,4 Aulomatic 5,3 Manual Vehicle type 3.4.7 Passenger vehicle Checlr digit Model year Restraint system 1 0 Manual belts 3 Manual belts wilh driver & passenger airbags 4 Manual belts with advanced passenger B driver airbags 0 - 9 or X, calculated by NHTSA V 1997 W 1RRR Assembly plant A, F, K Munich, Germany B, C, D, G Dingolfing. Germany E, J. P Reqensburq. Germany . Serial number Sequential produclion number lor specific vehicle

2002 BMW 540I Service and Repair Manual

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