flywheel torque BMW 525i 2001 E39 User Guide

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- When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace gasitet between rear main seal carrier and
cranlt-
case.
Apply thin coat of
3 Bond 8 1209 or equivalent sealant to
oil pan
gasltet sealing surfaces.
* Lubricate crankshaft and seal contact surfaces.
4 Use BMW special tool 11 2 390 as an installation guide in fit-
ting seal over end of cranltshaft. Use care to push seal carrier
and support bushing on straight, without tilting. Remove in-
stallation guide carefully.
- Replace sealing washers under seal carrier mounting bolts.
- Install seal carrier mounting bolts and torque to specilica-
tions.
- lnstall oil pan bolts.
- Remainder of assembly is reverse of disassembly.
Install flywheel using new bolts,
Install clutch or torque converter and transmission.
* Fill engine with oil.
Run engine and
checlt for leaks.
Tightening torques Flywheel to crankshaft (use new bolts)
120 Nm (89 ft-lb)
011 dra~n plug to 011 pan (M12) 25 Nm (18 ft-lb)
Oil pan to
eng~ne block
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (1 0 9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Rear main seal carrier to crankcase
M6 10 Nrn (89 in-lb)
ME 22 Nm (16 ft-lb)

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Battery, Starter, ~lternatorl
- Disconnect wiring from starter.
4 Note routing for cables. Routing varies depending on model
and transmission. When reinstalling, make sure cables do
not chafe.
- Using a long extension and universal joint from output end of
transmission, remove bolts fastening starter to transmission
bell housing and engine block.
- Remove starter from below
4 Checlc starter pinion gear and flywheel teeth for damage.
- Installation is reverse of removal.
Tightening torques
Starter to engine 47 Nrn (35 It-lb)
Starter sipport bracket to starter 5 Nrn (44 in-lb)
Starter support
bracket to engine 47 Nrn (35 ft-lb)
Wlre terminals to slarter
M5 5 Nrn (44 in-lb)
M6 7 Nrn (62 in-lb)
M8 13 Nrn (10 ft-lb)
Starter, removing and installing
(V-8 engine)
The starter is on the right (passenger) side of the engine, and
is removed from below. Access to starter bolts is difficult. Be
sure to have the proper tools on hand before proceeding.
- Disconnect negative (-) battery cable
CA UTIOW-
Prior to disconnecting the battery, read the battev discon-
nection cautions in
OOlGeneral Cautions and Warnings. -
- Raise vehicle and support safely.
/ WARNING- 1 ~ ~~ ~~ ~~~ ~
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjacltstands designed for
I the purpose. A floor jack is not adequate support I

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-
Battery, Starter, Alternator
- Working underneath car, remove engine splash shield.
- Remove heat shield from starter.
Remove starter wire mounting nuts (arrows). Disconnect
wires from starter terminals and retaining clip.
Disconnect main positive cable and bracket from suspen-
sion.
If necessary for access, remove right side oxygen sensor
harness connector from retaining clip.
Working from end of transmission, use suitable extensions
and universal joint to remove starter mounting bolts (arrows)
at transmission bellhousing.
- Remove starter from below.
- Check starter pinion gear and flywheel teeth for damage.
- Installation is reverse of removal
Tightening torques Starter
to engine 47 Nrn (35
ft-lb)
Wire terminals to starter
M5 5 Nrn (44 in-ib)
M6 7 Nm (62 in-ib)
ME 13 Nrn (10 ft-lb)

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Checlc flywheel location dowel
and correct installation. sleeve (arrow) for
damage
4 When installing dual-mass flywheel, position dowel sleeve
next to two locating notches
(arrows).
- Install flywheel using new self-locking bolts,
Tightening torque Flywheel to cranltshaft
(use new self-locking bolts)
120 Nm (89 ft-lb)
Use new self-lock~ng bolls lo rnslall llylvheel Do not reuse llle
old slrelch-lype bolls Do nor rnsrall bolls wrlh Loct~lo@ or srm-
I ilar thread licking compound. 1
Flywheel, removing and installing
(V-8 engine)
- Inspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. Replace flywheel if any faults are found.
4 Loclcflywheel with BMW special tool 11 2 070. Remove pres-
sure plate and clutch disc as described earlier.
- Use BMW special tool 11 4 180 (Ton. T60) to loosen and re-
move flywheel mounting bolts. Remove flywheel.
- Clean flywheel bolt threads in crankshaft

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210-1 4
1 Clutch
Dowel sleeve I
Check flywheel location
and correct installation. dowel sleeve
(arrow)
for . damage
< When installing dual-rnass flywheel, position dowel sleeve
next to two locating notches (arrows).
- Lightly oil flywheel mounting bolt threads and torque to
specification.
Tightening torque
Flywheel to crankshaft 105 Nm (77 ft-lb)
CAUTIOI\C
Do not reinstall flywheel bolls with LoctiteCTJ or similar thread
locl~ing compound.
- Install transm~ssion as descr~bed in 230 Manual Transmis-
sion.
4 If flywheel was replaced, check pulse sensor (arrow) for cor.
rect installation depth.
- Remove pulse sensor.

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21 0-1 6
Clutch
4 Press new bearing into place using BMW special tool
11 2 350 or equivalent driver.
Clutch, installing (non-SAC)
CAUTIOG
Avoidcontaminating clutch friction surfaces with oilorgrease.
Do not touch these surfaces.
4 Center clutch disc on flywheel using centering tool
Clutch Clutch pressure disc plate
Dual mass flywheel -
5-speed transmission: Special tool 21 2 130
- Install flywheel lock, BMW special tool 11 2 170.
4 Install pressure plate and clutch disc to flywheel. Install and
tighten bolts hand-tight.
CAUTIOG
Be sure clutch disc is facing the correct way The disc should
be
marked 'kngine side" or "transmission side':
- Tighten each clutch bolt one turn at a time until pressure
plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
. M8 (8.8 grade) 24 Nrn (18
ft-lb)
- M8 (10.9 grade) 34 Nrn (25 ft-lb)
- Remove clutch disc centering tool.

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21 0-1 8
Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- Install SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques Clutch to flywheel
- M8 (8.8 grade)
MB 110.9 orade)
24 Nm (1 8 it-lb)
34 Nm (25
ft-lb)
Use 14 mm Allen wrench to unscrew (clocltwise or counter-
clockwise) lock plate in center of pressure plate.
NOTE-
The spring lockplate may make snapping noises while being
unscrewed.
Using large bolt, pull out clutch centering tool
Remove flywheel locking tool
4 Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CAUTIOG
Do not grease guide sleeve. Ifguide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- lnstall transmission. See 230 Manual Transmission.
Tightening torques
- - - Transmlsslon to engine -
. MB (Torx) 22
Nm (16 it-lb)
MI0 (Torx) 43 Nm (32 it-lb)
* M12 (Torx) 72 Nm (53 it-lb)
.-

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1 Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- lnstall SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
- M8 (8.8 grade)
M8 (10.9 grade) 24
Nm (18
ft-ib)
34
Nm (25 ft-lb)
- Slip out clutch centering tool using large bolt.
- Remove flywheel locking tool.
Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- Install transmission. See 230 Manual Transmission
Tightening torques
Transmission to engine
- ME (Torx)
. M1O (Torx)
. M12 (Torx) 22
Nm (16 ft-lb)
43
Nm (32 ft-lb)
72
Nm (53 it-lb)

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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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240-1 3
Automatic ~ransmissionl
- Blow out oil cooler lines with low-pressure compressed air
and flush cooler with clean ATF twice before reattaching lines
to transmission.
CA UTIOG
Wear safety glasses when worling with compressed air:
@ Do not reuse ATF used for flushing.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Reinstall driveshafl using new nuts.
Install new sealing washers on transmission cooling line
banjo bolts.
Install new O-rings on transmission cooler lines, where
applicable.
Inspect engine drive plate (flywheel) for cracks or elongat-
ed holes. Replace
if necessary.
Be sure bellhousing alignment dowel sleeves are located
correctly. Replace damaged sleeves.
Checlc to be sure torque converter is seated correctly in
transmission during final installation.
Use
BMW special tool 24 2 300 to align three mounting
tabs on torque converter with indentations on drive plate
(flywheel).
Fill transmission with clean ATF until oil level is even with
fill hole. Then check fluid level as described earlier.
Adjust gearshift mechanism. See
250 Gearshift Linkage.
NOTE-
In order to avoid difficulties in transmission removal at a fu-
ture time, use washers with Torx-head mounting bolts.