Head BMW 540i 1998 E39 Workshop Manual

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1 Exhaust ~vsteml
NOTE-
The front exhaust manifold must be removed before the rear
manifold.
- Installation is reverse of removal.
Coat exhaust mounting studs with CRC or equivalent cop-
per paste.
Use new gasltets and self-locking nuts.
Tightening torques Exhaust manifold to cylinder head 20 Nm
(15 ft-lb)
Front exhaust pipe to manifold 30 Nm
(22 ft-lb)
Oxygen sensor to manifold 50
Nrn (37 ft-lb)
Exhaust manifolds, removing and installing
(M62 engine)
Always use new retaining nuts and gasltets when removing
and installing the exhaust manifolds.
NOTE-
Access to manifolds is extremely limited. If removing exhaust
manifolds as part of additional engine worlc (such as cylinder
head removal), it may be easier to first remove engine.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work undera lifted car unless it is solidly supported on
jaclt stands designed for the purpose. Never worlc undera car
that is supportedsolely
by a jack.
- Remove exhaust system. See Exhaust system, removing
and installing.
- Removing right side exhaust manifolds (cylinder bank 1-4):
Remove heat baffle plate.
Disconnect plug connection to oxygen sensor.
securing exhaust manifolds to head.
Remove manifolds towards bottom.
- Installation is the reverse of removal.
Coat exhaust mounting studs with CRC or equivalent
copper paste.
Use new gasltets and self-loclting nuts.

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- Removing left side exhaust manifolds (cylinder bank 5-8):
- Remove heat baffle plate on left side.
Remove oxygen sensor using
BMW special tool 11 7 030
or similar oxygen sensor socket.
Install
BMW special tools 00 0 200,OO 0 201,OO 0 202,OO 0
204, and 00 0 208 or other suitable engine lifting support
above engine and attach to lifting eye on left head.
NOTE-
The supports on special tool 00 0 208 must rest on the
screws on the fenders.
- Remove nut at top of engine support on left side
- Raise engine at front suspension lug a maximum of 25 mm
(I
.O in).
Release clamping bolt and nut
(arrow) and slide universal
joint off steering gear.
4 Remove nuts securing left exhaust manifold to head,
Raise front of manifold as high as possible past end posi-
tion of steering gear and feed out towards bottom.
- Installation is reverse of removal.
Coat exhaust mounting studs with CRC or equivalent
copper paste.
Use new exhaust gaskets and self-locking nuts.
Install new self-locking nuts on engine mount and steering
shaft bolt.

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Exhaust System
M52 engine
(5281 1997-1 998)
1. Exhaust manifolds
2. Sealing washer
3. Plug
4. Gasket (manifold to cylinder
head)
5. Clamping sleeve
6. Post-catalytic converter oxygen sensor
7. Pre-catalytic converter oxygen
sensor
8. Hanger
9. Rear muffler
10. Vibration dampener
11. Center support bracket
12. Clamping sleeve
13. Front pipe with catalytic
converters
14. Hanger
15. Center muffler
16. Gasket (front pipe to manifold)

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Clutch, removing
The procedure given here applies to both non-SAC and SAC
clutch assemblies.
- Remove transmission from engine. See 230 Manual Trans-
mission.
4 Loosen 6 clutch mounting bolts (arrows) evenly
- Remove pressure plate and clutch disc.
WARNING-
The clutch disc contains asbestos. Inhaling or ingesting as-
bestos dust can cause severe health problems. Always wear
an approved respiratorandprotective clothing when handling
components containing asbestos. Do not use compressed
air to clean components. Do not
grind, heat, weld, or sand on
or near anv asbestos materials.
Pull release bearing off transmission input shaft. Remove
clutch release lever by sliding it out of spring clip in direction
of arrow.
Clutch components, inspecting
- Inspect clutch disc for wear, cracks, loose rivets, contamina-
tion or excessive
runout (warping). Replace if necessary.
- Measure clutch disc lining thickness at shallowest rivet head. 7
Clutch and pressure plate wear limits
Minimum clutch disc lining thickness (at rivets)
1.0
mm (0.04 in) - Maxtmum lateral runout
(d~aphragm sprtngs to pressure plate) 0 6 mm (0 02 in)

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Manual Transmission
- Thoroughly clean guide sleeve mounting bolts, sealing sur-
faces, and threads. Apply
Loctite8243 or equivalent thread
locking compound to guide sleeve bolts. Reinstall guide
sleeve and
spacer(s).
Tightening torques
Guide sleeve to transmission case
M6 10 Nm (89 in-lb)
* M8 x 22 18 Nm (13 ft-lb)
- Max30 25 Nm (18 ft-lb)
- Reinstall transmission.
TRANSMISSION REMOVAL AND
~NSTALLATION
Removal and installation of the transmission is best accorn-
plished on a lifl using a transmission jack.The engine must be
supported using appropriate support equipment. This allows
the engine to pivot on its mounts to access the upper
Torx-
head bolts at the bellhousing.
WARNING-
Male sure the car is stable and well supported at all times.
Use a professional aulomorive lift or jack slanos des~gned
lor the purpose. A floor jack is nor adequare supporr.
The removal of the transmission may upset the balance
of the vehicle on a
lifl.
Transmission, removing and installing
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 Warnings and Cautions.
V-8 engine: Remove plastic engine cover.
Early models: pry out protective caps (arrows), then re-
move nuts securing cover. Lift off cover.
Later models: depress four studs to release, then
lift off
cover.
- Raise and safely support vehicle
- Remove engine splash shield from underside of vehicle
- Remove exhaust system and heat shields. See 180 Exhaust
System.

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230-1 8
Manual Transmission
- Unbolt clutch slave cylinder from side of transmission. Do not
disconnect fluid hose. Suspend slave cylinder from chassis
using stiff wire.
CA UTIOG
Unbolt clutch slave cylinder slowly to prevent air being
drawn into hydraulic system.
. Do not operate clutch pedal with slave cylinder re-
moved from transmission.
4 Put BMW special tool 11 7 370 or appropriate sized spacer
between engine oil sump and front axle support. Lower trans-
mission until engine is supported on spacer.
0 V-8 vehicle: Turn front wheels to prevent strain from being
placed on center tie rod.
All vehicles: Tilting the engine to lower the transmission
can lead to damage to various components due to lack
of clearance at rear of engine. Lower transmission
slowly
- Support front of engine with floor jack.
4 Disconnect shift rod from selector shaft coupling
- Disconnect shift console from top of transmission. See 250
Gearshift Linkage.
6-cylinder: Remove transrnisslon mounting Torx-head bolts
(arrows). Note length and locatlon of bolts.
Remove
transrnlssion by pulling backward untll transmls-
sion Input shaft clears clutch d~sc spl~nes, then pull down-
wards. Lower
transmlsslon jack to remove transrnlsslon. -
- - -
-

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Manual Transmission
4 V-8 engine: Remove transmission mounting Tom-head bolts
(arrows). Note length and location of bolts.
Remove transmission by pulling backward until transmis-
sion input shaft clears clutch disc splines, then pull down-
wards. Lower transmission jack to remove transmission.
- Installation is reverse of removal, keeping in mind the
following:
When installing a new transmission, be sure to transfer
parts from old transmission
if applicable.
Thoroughly clean input shafl and clutch disc splines. Light-
ly lubricate transmission input shaft before installing.
* Be sure bellhousing alignment dowel sleeves are located
correctly. Replace damaged sleeves.
Center rear of transmission in driveshaft tunnel before
tightening transmission support bracket.
NOTE-
In order to avoid difficulties in transmission removal at a fu-
ture time, use washers with Torx-head mounting bolts.
- Reinstall driveshaft. Use new nuts when mounting driveshaff
to transmission/flex disc. See 260 Driveshaft.
- Refill transmission with appropriate lubricant before starting
or towing car. See Transmission fluid service earlier in this
repair group.

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Manual Transmission
Tightening torques
Flex-disc to transmission output flange
- Mlo (8.8 grade) 48 Nm
(35 ft-lb)
- MI0 (10.9 grade) 60
Nm (44 ft-ib)
MI2 (8.8 grade)
MI2 (10.9 grade) 81
Nm (60 ft-ib) 100 Nm (74 ft-lb)
M14 140 Nm (103 ft-lb)
Rubber mount to transmission or crossmember 21
Nm (15 ft-lb)
(ME)
Slave cylinder to transmission 22 Nm (16
ft-lb)
Transmission crossmember to chassis or transmission
21 Nm
(15 ft-lb)
42 Nm (32 ft-lb)
Transmission to engine
(Towhead)
. M8 22 Nm (16 ft-lb)
MI0 43 Nm (32 ft-lb)
M12 72 Nm (53 It-lb)
Transmission drainlfili plug to transmission 50
Nm (37 It-lb)
case

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240-1 0
Automatic Transmission
TRANSMISSION REMOVAL AND
INSTALLATION
Removal and installation of the transmission is best accorn-
plished on an automotive lift using a transmission jack. Use
caution and safe workshop practices when working beneath
car and lowering transmission.
Torx-head bolts are used to mount the transmission to the
bellhousing.
Besure to have appropriate tools on hand before
starting the job.
WARNING-
Be sure the vehicle is properly supported. The removal of the
transmission may upset the balance of the vehicle on a lift
CAUJION-
Tilting the engine to remove the transmission can lead to
damaae to various components due to
laclc of clearance. 1
Transmission, removing and installing
WARNING -
Allow engine and transmission to cool down before starting
work on the transmission.
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warninas.
4 V-8 engine: Remove plastic engine cover.
Early models: pry out protective caps
(arrows), then re-
move nuts securing cover.
Lift off cover.
Later models: depress four studs to release, then lift off
cover.

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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.