20 pin BMW 525i 2001 E39 Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
Exhaust systeml
M62 TU engine
(540i 1999-2003)
1. Oxygen sensors, pre-catalytic
converter
(2)
2.
Oxygen sensors, post-catalytic
converter
(2)
3.
Hanger
4. Rear muffler
5. Clamping sleeve
6. Hanger
7. Center muffler
8. Clamping sleeve
9. Catalytic converter, left side
10. Catalytic converter, right side
11. Exhaust manifoldlcatalytic
converter,
left side
12. Gasket (2)
13.
Gasket (2)
14.
Exhaust manifoldlcatalytic
converter, right side

Downloaded from www.Manualslib.com manuals search engine
4 Tom T60 socket for V-8 flywheel bolt removal
(Tool No. 1 1 4 180)
4 Hose clamping tool
(Tool No. 13 3
01 0)
4 Clutch disc lining gauge
(Tool No. 21 2 080)
4 Clutch disc centering mandrels (non-SAC clutch)
(Tool No. 21 2
141,21 2 142,21 2 200,21 2 201)
4 Clutch disc alignment tools (SAC clutch)
(Tool No. 00 5 500 (handle). 21 2 130 (drift))
4 SAC tensioning tool
(Tool No. 21 2 170)
4 SAC locating ring
(Tool No. 21 2 180)

Downloaded from www.Manualslib.com manuals search engine
21 0-7
Clutch
- Remove brake fluid reservoir cap. Using a clean syringe.
remove brake fluid from reservoir to below level of clutch
hydraulic supply hose.
- Detach clutch hydraulic supply hose from brake fluid reser-
voir. Plug reservoir outlet and hose.
4 Remove lower dash trim panel fasteners (A) and (B).
Lower trim panel and disconnect wiring harnesses on back
side of panel.
Remove trim panel.
4 Working under dash, remove clutch master cylinder pushrod
retaining clip (arrow) and pin from clutch pedal.
4 Remove master cylinder mounting bolts (arrows)

Downloaded from www.Manualslib.com manuals search engine
21 0-8
Clutch
4 Remove hydraulic line locking clip (1) and pull line (2) off
master cylinder.
CAUTION-
. To prevent brake fluidspill, wrap clutch master cylinder with
shop rags when removing hydraulic fluid lines from master
cylinder.
* Brake fluid damages paint andstains carpets. Clean off
any brake fluid on or
in the car immediately.
- Remove master cylinder with supply hose
4 Remove switch module from master cylinder.
Press locking button
(A) to release harness connector.
Pull harness connector
(8) off switch module.
Use screwdriver to lever
off switch module (C).
- Installation is reverse of removal.
CA UTlON-
Switch module must snap firmly into place on the master cyl-
inder during installation.
Tightening torques
Clutch master cylinder to pedal cluster
10 Nm (89 in-lb)
Fluid line
to master cylinder or slave cylinder 17 Nm (13 ft-lb)
- Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as
described earlier.
Clutch slave cylinder, replacing
4 Working inside engine compartment, remove left interiorven-
tilation filter housing:
Release
3 plastic taps (A) on duct. Early models: release
latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Release spring lock (B) on interior ventilation housing and
remove housing.
- Pinch off brake fluid supply hose to clutch master cylinder us-
ing BMW special tool
13 3 01 0 or equivalent hose clamping
tool.

Downloaded from www.Manualslib.com manuals search engine
- Raise and safely support vehicle
WARNING-
Make sure the car is stable and well supporied at all times.
Use a professional automotive /iff orjack stands designed for
the
ournose. A floor jack is not adeouate suooort.
- If necessary, remove transmission splash shield.
- Disconnect fluid line from slave cylinder on lefl side of trans-
mission. Place pan under hose to catch dripping fluid.
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder.
- Installation is reverse of removal, noting the following:
Check for wear on slave cylinder. Any wear except on tip is
caused by misalignment of clutch components.
Lightly coat
pushrod tip with molybdenum disulfide grease
(MolyltoteIB Longterm or equivalent).
. During installation be sure pushrod tip engages recess in
clutch release lever.
Fill fluid reservoir with clean fluid.
. Bleed clutch hydraulics as described earlier.
Tightening
toraues - -.
Clutch slave cylinder to transmission 22 Nm (16 R-lb)
Fluid line to slave cylinder 17 Nm (13 ft-lb)
The transmission must be removed from the engine to access
the clutch mechanical components. It is recommended that
the clutch disc, pressure plate and release bearing be re-
placed during a clutch overhaul.
Besure tocheck the bottom of the bellhousing foroil. If engine
oil is found, check for a faulty rear crankshaft main oil seal.
See
119 Lubrication for rear main seal replacement.
Clutch variations
Two versions of the clutch are used:
1997 528i (6 cylinder) uses traditional clutch components.
All
540i (V-8) and 1998 and later 6 cylinder models from
use a self-adjusting clutch (SAC).

Downloaded from www.Manualslib.com manuals search engine
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)

Downloaded from www.Manualslib.com manuals search engine
21 0-1 2
Clutch
Release bearing
Release
bearin
- lnspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. If any faults are found, replace flywheel as
described later.
- lnspect transmission pilot bearing in end of crankshaft. The
bearing should rotate smoothly without play. If necessary,
replace as described later.
4 lnspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points (arrows).
Clean and lightly lubricate clutch disc splines and transmis-
sion input
shaft splines.
4 Checlc release bearing ball stud and spring retainer. Replace
if damaged or worn.
CAUTION--
On S6S 420G transmission, always replace release bearing
ball stud and retainer spring.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased,
release bearing may stick to it.
Flywheel, removing and installing
(6 cylinder engine)
- lnspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. Replace flywheel if any faults are found.
Lock flywheel with BMW special tool
11 2 170. Remove
pressure plate and clutch disc as described earlier.
- Loosen and remove flywheel mounting bolts. Remove
flywheel.
- Clean flywheel bolt threads in crankshaft.

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
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)
.-

Downloaded from www.Manualslib.com manuals search engine
Clutch
Clutch, installing (used SAC components)
When reinstalling a previously used self-adjusting clutch
(SAC), special tools are needed to reset the self-adjusting
ring to its original position.
CAUTIOI\C
Avoidcontaminating clutch friction suifaces with oilorgrease.
Do not touch these
suifaces.
- Place SAC pressure plate on clean worlc suriace.
4 Place BMW special tool 21 2 180 on pressure plate
Note that locating hoolts of special tool engage pressure
plate adjusting ring openings
(inset).
Grip tool firmly and squeeze special tool handles together.
Tighten down special tool knurled screws (arrows).
- SAC adjustment ring is now in its original position.
4 Install BMW special tool 21 2 170 on SAC pressure plate.
Fit fingers of special tool in slots above dowel pin bores.
Tighten down knurled nut (arrow) finger-tight.
Screw in T-handle until pressure plate diaphragm spring is
pretensioned to stop.
< Center clutch disc on flywheel using centering tool.
5-speed transmission: Special tool 21 2 142
6-speed transmission: Special tool 21 2 141
G6S-3762 transmission: Special tool 21 2 201
CAUTION--
Be sure clutch disc is lacing the correct way The disc should
be
marked 'kngine side" or 'Transmission side':
NOTE-
The large bolt in the clutch disc centering tool is used to in-
stalland remove the tool only Once the disc is in place on tlie
flywheel, remove the bolt to male room for the SACpressure
plate.