Head removal BMW 540i 1998 E39 Workshop Manual

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Exhaust system1
Exhaust manifold removal procedures are organized accord-
ing to engine code. If necessary, see
100 Engine-General
for engine code and application information.
Exhaust manifolds, removing and installing
(M52 engine)
4 Exhaust manifolds for the M52 engine.
Always use new retaining nuts and gaskets when removing
and installing the exhaust manifolds.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work under a lined car unless it is solidly supported on
jack stands designed for that purpose. Never work under a
car that is supported solely by a jack.
- Disconnect secondary air check valve and pipe from exhaust
manifold.
- Unbolt front exhaust pipe@) from exhaust rnanifold(s)
- Remove exhaust support bracket from transmission.
- Loosen and remove nuts from exhaust manifolds and remove
manifolds. Discard nuts and gaskets.
NOTE-
On cars with oxygen sensors mounted in the exhaust mani-
folds, use care when removing manifolds.
To be safe, remove
the sensors from the manifolds before removing manifolds.
- Installation is reverse of removal
Coat exhaust manifold mounting studs with copper paste
before installing new nuts.
Install manifold gaskets with arched side facing manifolds.
Tightening torque
Exhaust manifolds
to cylinder head 20 Nm (15 ft-lb)

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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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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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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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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.

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Driveshaft
- Road test vehicle to check for noise or vibration
CAUTION-
Do not reuse self-locking nuts. These nuts are designed to
be used only once.
Avoid stressing the flex-disc when torquing the bolts.
Do this by counterholding the bolts and turning the nuts
on the flange side.
Tightening torques
Alunlinum driveshaft to flex-disc
- MI2 (use coated washers)
90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
Mi0 (Tom bolt)
70 Nm (51 ft-lb)
M8 (compression nut) 32 Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
MI0 (8.8 grade) 48 Nm (35 ft-lb)
MI 0 (1 0.9 grade) 60 Nm (44 ft-lb)
- Mi2 (8.8 grade)
81 Nm (60 ft-lb)
- MI2 (10.9 grade) I00 Nm (74 ft-lb)
MI4 140 Nm (103 ft-lb)
Transmission
crossmember
to transmission (ME) 21 Nm (15 ft-lb)
. to chassis (M10) 42 Nm (30 ft-lb)
NOTE-
Boltgrade is marked on the bolt head. When replacing bolts,
only use bolts of the same strength and hardness as the orig-
inals installed.
Flex-disc, replacing
- Checlc flex-disc between front section of driveshafl and trans-
mission output flange for craclts, tears, missing pieces, or
distortion. Check for worn bolt hole bores in flange.
- If flex-disc needs replacement, remove driveshafl as de-
scribed earlier.
- Unbolt flex-disc from driveshaft.
NOTE-
Removal andinstallation of the bolts may be made easier by
placing a large hose clamp around the flex-disc, and tighten-
ing the clamp slightly to compress the rubber.

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320-7
Steering and Wheel ~liqnmentl
STEERING WHEEL
Steering wheel, removal and installation
WARNING -
The BMWairbag system (Supplemental Restraint System or
SRS) is complex. Special precautions must be observed
when servicing. Serious injury may result if
SRS system serv-
ice is
attempted by persons unfamiliar with the BMW SRS
and its approved service procedures. BMW specifies that all
inspection andservice should be preformed by an authorized
BMW dealer.
E39 cars may come with either one of two different styles of
steering wheel:
Multifunction (MFL) steering wheel
* Sport steering wheel
4 Multifunction (MFL) steering wheel components:
1. Cruise control 1 radio 1 telephone electrical harness
2. Horn button electrical harness
3. Airbag electrical harness
4. Radio / telephone control switch set
5. Air bag
6. Cruise control switch set
Sport steering wheel
3
5 0021413
4 Sport steering wheel components:
1. Switch carrier
2 Steering wheel switch set electrical harness
3. Airbag
4. Lower cover
5. Horn button and airbag electrical harness
- Center steering wheel. Make sure front wheels are pointed
straight ahead.
- Disconnect negative (-) cable from battery.
CA UTIOP&
Prior to disconnecting the battern read the battew discon-
nection cautions given in
001 General Cautions and
Warnings.
-

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Steering and Wheel Alignment
4 Release lock (A) and pull up on harness connector (6) to dis-
connect ignition switch harness.
. Remove wire harness bracket fastener (C).
4 Remove shear bolts (arrows) using a chisel or punch.
NOTE-
The shear bolts can be drilled and then removed using an
easy-out.
- Remove steering column lock housing.
- Installation is reverse of removal.
Tighten new shear bolts until bolt heads shear off.
ignition interlock cable, removing and
installing (models
with automatic
transmission)
- Remove steering column trim panels as described earlier.
4 Loosen and disconnect interlock cable (arrow) from ignition
lock assembly.
- Remove center console trim panel.