Oil lines BMW 540i 2000 E39 User Guide

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Camshaft Timing chain1
4 Remove oil lines from camshaft supports (arrows).
- Remove radiator cooling fan and fan shroud. See 170 Radi-
ator and Cooling System.
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
- Remove engine drive belts alternator and AlC compressor.
See
020 Maintenance.
4 Remove vibration damper bolts (arrows) and remove
damper.
4 Mount BMW special tool 11 2 450 to crankshaft hub while
aligning damper locator pin with hole (arrow) in special tool.
CAUTION-
Crankshaft center bolt is torqued to 410 Nm (300 ft-lb) use
BMWspecial tool I I 2 450 to secure crankshaft when remov-
ing center bolt.
- Loosen and remove cranltshaff center bolt.

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1 17-76
/camshaft Timing Chain
4 Attach BMW special tool 11 7 380 to right side cylinder head.
Install special tool
11 3 390 and 00 9 250 into 11 7 380. Tight-
en to 0.7 Nm (0.5 ft-lb).
4 Secure sprocket to intake camshaft flange on left cylinder
head.
Repeat for intake sprocket on right cylinder head.
Tightening torque Sprocltet to camshaft flange
15 Nm (1 1 ft-lb)
- Remove BMW special tools 11 2 4441 4431 4411 445 from
right cylinder head.
- Remove BMW special tools 11 2 4441443/421/446 from left
cylinder head.
4 Install oil lines on left and right cylinder head,
Tightening torque
Oil
lines to camshaft bearing caps 6 Nm (4 ft-lb)
- Relieve load on BMW special tool 11 3 390 and remove along
with special tool
11 7 380.
- Remove BMW special tool 11 2 300 from bore at transmis-
sion bellhousing and release crankshaft.

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11 9-1 0
Lubrication System
Oil pan, removing and installing
(6-cylinder)
The engine oil pan removal procedure requires that the en-
gine be supported from the top and the front suspension
sub-
frame be lowered.
- Raise car and place securely on jack stands.
Make sure the car is stable and well supported at all times.
Use a professional automotive
lift orjackstands designed for
- Remove splash shield from under engine.
- Drain engine oil as described in 020 Maintenance.
4 Remove oil dipsticlc guide tube:
Disconnect fuel lines and wiring harness from
bracket (A).
- Disconnect oil separator hose (B) from base of guide tube.
Remove mounting bolt
(C) from left engine mounting
bracket and remove tube from oil pan.
NOTE-
* If necessary, remove air filter assembly for better access to
dipsticlc tube.
The dipstick guide tube is sealed in the block using an
O-
ring. Check that the O-ring comes out with the tube.
4 Lift hood into assembly position:
While supporting the hood, disconnect hood support
struts.
Raise hood and install
loclting bolts (arrow) in right and left
hinges.
WARNING-
Be sure to support hood while disconnecting support struts.

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Lubrication system/
4 Install engine lifting tool at front of engine and raise engine
approximately
5 mm (114 in).
< Remove pinch bolt (arrow) at steering column universal joint
near steering rack. See
320 Steering and Alignment.
- Remove power steering pump, leaving hydraulic lines con-
nected to pump. Suspend pump using strong wire. See
320
Steering and Wheel Alignment.
NOTE-
For better access to power steering assembly, unbolt fluid
reservoir and suspend with wire.
Loosen upper nuts (arrow) in right and lefl engine mounts,
< Remove right and left lower engine mount nuts (arrow)
- On cars with automatic transmission, remove ATF cooler line
brackets from engine oil pan.
- Disconnect electrical harness connector at oil level sensor on
oil pan.

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1 19-1 7
Lubrication System
Disconnect electrical harness connect01
sensor.
. (arrow)
4 Remove lower oil pan bolts (arrows) and pan, oil
level
CAUTION-
If the lowerpan does not separate easily from upperpan, a
few taps with a rubber mallet should break it free. Do not pry
the oil pan loose.
Remove
NC drive belt tensioner.
Remove adjustment bolt
(B).
Remove retaining bolt (A) and remove tensioner from oil
pan.
- Remove power steering pump from engine block, leaving hy-
draulic lines connected. Suspend from chassis using stiff
wire. See
320 Steering and Wheel Alignment.

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Lubrication System
- Lower front suspension and remove oil pan, as described
earlier, to gain access to oil pump.
Remove oil pump
sprocket mounting nut (left-hand thread)
(arrow). Lift sprocket off together with drive chain.
Engines produced to 9/98: Remove oil pump with pick-up
tube. Pick-up tube is bolted to side of oil pump.
Engines produced from 9/98 to 01/00: Remove pick-up
tube, scraper tray and oil pump as a unit.
Engines produced from 01/00: Remove oil pump pick-up
tube bolts and remove pick-up tube before removing pump.
Remove mounting bolts from oil pump. Withdraw pump.
NOTE-
Record location of any spacers between pump and engine
bloclc Note positions of locating dowels.
- Remove cover from oil pump and check for wear or scoring.
Spin oil pump shaft and
check that gears turn smoothly. Re-
place pump if gears spin with difficulty
orany wear is present.
- Inspect oil pressure relief valve as described later.
- Installation is reverse of removal, noting the following:
Replace pick-up tube O-ring (if applicable).
- Align sprocket splines to oil pump shaft spl~nes before
tightening sprocket nut.
- After adding engine oil, start and run engine. Raise engine
speed to 2,500 rpm until oil pressure warning light goes out
(about 5 seconds).
Tightening torques Oil drain plug to oil pan 25
Nm (18 ft-lb)
Oil pan to engine
bloclc
M6 (8.8 grade)
M6 (10.9 grade)
M8 (8.8 grade)
10 Nm (89 in-lb)
12
Nrn (9 ft-lb)
22 Nm (16 ft-lb)
Oil pump sprocket to oil pump shait
(M10 x 1) (left hand thread)
25 Nm (1 8 it-lb)
Oil pump to crankcase (ME) 22 Nm (1 6 it-lb)
Oil pump pickup tube to cranltcase (M6) 10 Nm (89 in-lb)

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130-36
[~uel Injection
4 Remove nuts and bolts (arrows) retaining wiring harness to
throttle housing.
- Working at throttle housing, turn harness plug countercloclc
wise and remove.
4 Working at side of intake manifold, disconnect electrical bar-
ness connectors:
Idle control valve (A)
Intake manifold resonance valve (B)
- Disconnect electrical harness connectors at oil pressure
sender and oil temperature sender at base of oil filter hous-
ing.
4 Remove dipstick guide tube:
Disconnect wiring harness brackets from tube
(A)
Unclip fuel lines from tube (B).
Remove lower guide tube mounting bolt (C).
Pull out dipstick guide tube.

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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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Automatic Transmission
4 Remove transmission cooler line clamp mounting nut (ar-
row) from transmission bell housing. Disconnect cooler lines
from transmission.
- Disconnect both transmission cooler fluid lines from trans-
mission.
CAUTION-
Place a pan under transmission fluid lines to catch dripping
fluid.
4 Remove access plug in cover plate below engine oil pan
(V-8 models) or left side of bellhousing (6-cylinder models).
Remove torque converter bolts. Turn
cranltshaft to access
bolts.
V-8 models: Place BMW special tool 23 3 030 between
engine oil pan and front
subframe (arrows).
- 6-cylinder models: Place BMW special tool 11 7 370
between engine oil pan and front subframe.
- Support transmission with transmission jack.
4 Remove transmission crossmember bolts A, B and C and re-
move transmission support crossmember
(V-8 model shown,
6-cylinder models are similar).
- Remove bellhousing-to-engine mounting bolts.
- Use appropriate selection of BMW special tools 24 4 130 to
hold torque converter in place during transmission removal.
CAUTION-
Do not allow the torque converter to fall off the transmission
input shaft
- Remove transmlsslon by pull~ng back and down. Lower jack
to allow transmiss~on to clear vehicle.
rrs corn-hi8 Rniiti Riranrd

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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.