top up engine oil BMW 540i 1998 E39 Repair Manual

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Final Drive
Tightening torques
F~nal drive to rear axle carrier 105 Nm (77 it-lb)
Driveshaft CV joint to final drive flange
- MlO (Torx bolt) 70
Nm (51 ft-lb)
- M8 (compression nut) 32 Nm (24
ft-lb)
Drive axle to final drive
ilange
Torx bolts (M10) 83 Nm (61 ft-lb)
Torx bolt with
rlbbed teeth (M10) 64 Nm (47 ft-lb)
Torx bolt
wlth ribbed teeth (MI0 sliver) 80 Nm (59 ft-lb)
Torx
bolt with ribbed teeth (M10 black) 100 Nm (74 ft-lb)
* Torx bolt with ribbed teeth (M12) 135 Nm (100 ft-lb)
Differential oil level, checking
The E39 differential is filled with lifetime oil that ordinarily
does not need to be changed. BMW recommends using only
a specially formulated synthetic gear oil
(SAF-XO) that is
available through an authorized BMW dealer parts depart-
ment. For additional information on this lubricant and any oth-
er lubricants that may be compatible, contact an authorized
BMW dealer service department.
< Check rear differential oil level at filler plug (arrow).
- Check lubricant level with car on a level surface:
Level is correct when fluid just reaches edge of filler hole.
If necessary, top up fluid.
* Replace filler plug sealing ring.
Install and tighten oil filler plug when oil level is correct.
NOTE-
Use either a 14 mm or 17 mm Allen socket to remove the
drain plug.
If car is raised in the air. it should be level when
checkino " or filling final drive fluid level.
- Tightening torque -
Filler plug to final drive housing 70 Nm (52
ft-lb) -

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331-16
I Final Drive
Worlting at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring.
4 Worlting from underneath, position BMW special tool 33 2
301
between 2nd and 3rd spring coil from the bottom.
Make sure tool recess faces upward.
Worlting in cargo compartment, guide BMW special tool
33
2 304
from above and thread into special tool 33 2 301.
4 Worlting in cargo compartment, attach BMW special tools 33
2 302.33
2 303 and 33 2 305 to special tool 33 2 304.
- Use special tool 33 2 306 to compress spring.
Tighten until lower spring end lifts off spring seat on wheel
bearing carrier.
- Model with air springs: Loosen compressed air pipes at air
distribution assembly to release system pressure.
WARNING-
The vehicle will lower when tlie airpipes are loosened.
- Remove final drive. See Final drive, removing and install-
ing.

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Brakes
Warnings and cautions
WARNING-
. E39 cars require special BMWsen/ice equipment toprop-
erly bleed the brake hydraulic system. See Bleeding
Brakes for additional information.
Semi-metallic and metallic brake friction materials in
brake pads or shoes may produce dangerous dust.
Brake fluid is poisonous, corrosive and dangerous to
the environment. Wear safety glasses and rubber
gloves when worliing with
bralie fluid. Do not siphon
brake fluid with your mouth. Dispose of brake fluid
properly
Do not reuse self-locking nuts, bolts or fasteners. They
are designed to be used only once and may fail if re-
used. Always replace them with new self-locliing fas-
teners.
CAUTlOI\C
Immediately clean bralie fluid spilled on painted surfaces
and wash with water, as
bralie fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container.
Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the
braking sys-
tem, and will also lower the fluid boiling point.
. Plug open lines and brake fluid ports to prevent con-
tamination.
Only tighten brake hoses on front wheels
with wheels
in straight ahead position.
If carrying out electric welding
worlc, be sure to discon-
nect electrical harness connector from electronic con-
trol module.
Do not expose electronic control modules to high sus-
tained heat, such as in a paint drying booth. Maximum
heat exposure:-95°C (203
OF) for short periods of time-
85'C (185°F) for Ions periods of time (approx. 2 hours)

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Trunk Lid, Tailgate
Rear window and tailgate, alignment
- Alignment procedures involve adjusting tailgate, window, and
spoiler to have equal space between
iefl and right sides and
to be flush with body. Measurement locations and specific di-
mensions are shown.
- If alignment has been disturbed during repair, adjust fit of tail-
gate to body. Then adjust fit of rear window to tailgate.
Clearance of the rear window is adjusted by adding or re-
moving shims between hinge bracket and rear window
(maximum of three shims).
Adjust spoiler gap to body last.
Height of spoiler is set by alignment of the rear tailgate.
Gap of spoiler to body is set by adjusting spoiler attach-
ment fasteners.
- Lateral and vertical alignment of the window and tailgate is
done using hinge bolts. Fine adjustment of the tailgate to the
body is made using rubber stop buffers and latch assembly.
Spoiler gap specification Rear spoiler to roof 4.25
- 5 mm
(0.167 - 0.197 in)
Max. deviation from parallel 0.5
mm (0.019 in)
Tailgate alignment, preliminary work
- Open rear window and tailgate.
< Remove lower sill trim panel fasteners covers (arrows) and
fasteners.
- Remove rear window and tailgate trim panel.
- Checlc left and right side lateral guides and tailgate latch ful-
crums for wear or damage. Replace
if necessary.