Pressure plate BMW 528i 1998 E39 User Guide

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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.

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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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Clutch
- Remove flywheel locking tool
4 Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. Install re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
CAUTION-
Do not grease release bearing guide sleeve. If guide sleeve
is greased, release bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- Install transmission. See 230 Manual Transmission
.
Transmission to engine
MB (Torx) 22 Nm (16 fl-lb)
MlO(Torx) 43 Nm (32 fl-lb)
Clutch, installing (new SAC components)
V-8 models and 1998 and later 6 cylinder models are
equipped with the self-adjusting clutch (SAC) pressure plate.
The SAC pressure plate, when new, comes from the factory
with a lock plate at the center which maintains spring tension
on the self-adjusting springs. This
loclting ring must not be re-
moved until the pressure plate is securely installed on tlie fly-
wheel with the clutch disk in place.
CAUTION-
Avoidcontaminating clutch friction surfaces with oilorgrease.
Do not touch these surfaces.
< 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-3782 transmission: Special tool 21 2 201
CAUTION-
Be sure clutch disc is facing the correct way The disc should
be marked "engine side" or "transmission side':
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 the
eel, remove the bolt to male room for tlie
SACpressure

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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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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.

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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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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.

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SCA subsystem
1. Battery power (term. 30)
2. Battery power (term. 30)
3. SCA actuator
4. Ground (term. 31)
5. Feedback OPEN
6. Ground (term. 31)
7. General Module (GM)
8. Trunk contact switch
9. Trunk opening switch
502515990
SCA operation
Three microswitches are used to operate trunk latching sys-
tem.
Microswitch mounted on lock cylinder. Pushing lock cylin-
der in will signal GM to activate actuator and open trunk.
Q Microswitch in actuator signals GM when trunlc has re-
leased. Actuator shuts off.
When closing trunk, third microswitch (on trunk latch) sig-
nals GM to activate actuator. Cam turns to pull lid closed.
Foroverload protection,
ON duration of actuator is limited to a
max.
5 seconds.
Emergency opening of trunk is provided by a mechanical link
from the lockcylinder.
If the trunlc has been opened by the
emergency release, it can be
reclosed as a conventional lid
with normal pressure.
Tailgate and rear window locks
The Sport Wagon tailgate can be opened from:
0 Remote lkey (FZV)
Interior tailgate release button at driver's lkick panel
Unlock microswitch above rear license plate

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INDEX 7
WARNING
Your common sense, good
judgement, and general alertness are
crucial to safe and successful service
work. Before
attempting any work on
your BMW, be sure to read 001
General Warnings and Cautions
and the copyright page at the front of
the manual. Review these warnings
and cautions each time you prepare
to
work on your BMW. Please also
read any warnings and
caulions that
accompany
/he procedures in the
manual.
Jack stands
010-16
Jump starting 010-19
Keys
515-1 1
Knock sensor
see Ignition system
Leak detection,
fuel tanlr
see Fuel tank, leak detection unit
Leather upholstery
see Maintenance, leather
upholstery and trim
LDP
(leak detection pump)
see Fuel
tanir, leal( detection unit
Level sender
see Fuel tank
see also Fuel pump
License
plate iight
630-1 1
Lifters see Cylinder head and vaivetrain
Lifting the car
010-5 Lights
bulb applications
630-2
control module (LCM) 630-3
foglights 630-8 headiighls 630-4
automatic headlight adjustment
(LWR)
630-7
vertical aim system 630-8 interior lights 630-12
bulb applications 630-13
side turn signal 630-9
taillight 630.10 trunk light bulb 630-14
turn signals, taillights 630-12
LOClCS see Central loci(ing
see also Door loclrs
Lubrication system
oil
level warning switch, replacing
119-20
oil pan, removinglinstalling
6-cylinder 119-10
V-E lower 119-13 V-8 upper 119-15
oil pressure
checiring 11
9-4
warning system, testing 119-5 warning switch, replacing 119-20
oil pressure
reliel valve
6-cylinder 119-26
V-8 11 9-27
oil pump, removinglinstalling
6-cylinder
119-22
V-8 1 19-4
troubieshooting 119-3
Luggage compartment
seeTrunk
MAF (mass air flow) sensor
see 130 under appropriate fuel
injection system Maintenance
accelerator linkage
020-14 air filter 020-14
automatic transmission 020-29
battery 020-22
body lubrication 020-31 body and interior 020-31
braire fluid 020-24
brake padlrotor wear 020-24
brake system 020-25 clutch fluid 020-26
cooling system 020-15
CV ioint boots 020-27
differential oil level 020-26
drive bells 020-16 engine comparlmenl 020-14
engine cooling system 020-16
engine oil 020-1 1 exhaust system 020-27
exterior washing 020-31
fluid and lubricant specifications 020-9
fuel lilter 020-27 fuel lanir and fuel lines 20-28
idle speed 020-19
inspection 020-5
interior care 020-31
lealher upholslery and trim 020-31
maintenance tables 020-6
manual transmission oil 020-30
microiilter 020-22 oxygen sensors 130-72, 180-8
parlcing brake 020-25
power steering fluid level 020-20
seat belts
020-32 service indicator 020-3
spark plugs 020-20
special cleaning 020-32 suspension, front 020-29
suspension, rear 020-29
tires 020-29
washing
020-32
waxing 020-32 windshield wiper blade 020-33
wheels, aligning 020-30
Malfunction indicator iight (MIL)
OED-2
Manifold, exhaust
see Exhaust system
Manifold,
intake
see Intake maniiold