Crankshaft bolt BMW 540i 2000 E39 Repair Manual

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Lubrication System
To test switch, connect an ohmmeter between terminal in
switch body (arrow) and ground. With engine off, there
should be continuity. With engine running, oil pressure
should open switch and there should be no continuity. Re-
place a faulty switch.
CAUTION-
Keep in mind that low oil pressure may be preventing the
switch from turning the light out
If the light remains on while
the engine is running, check the oil pressure as described
earlier. Do not drive the car until the problem is corrected. The
engine may be severely damaged.
Crankshaft rear main seal replacement requires removal of
the transmission and flywheel.
Crankshaft rear main seal, replacing
(&cylinder)
- Remove transmission. See 230 Manual Transmission or
240 Automatic Transmission.
- Manual transmission vehicles: Remove clutch pressure plate
and disc. See
210 Clutch.
- Remove flywheel. See 210 Clutch or 240 Automatic Trans-
mission.
- Drain engine oil.
4 Remove seal carrier bolts from oil pan (arrows). Loosen all
oil pan bolts.

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Lubrication stern/
Remove remaining seal carrier bolts (arrows) and carefully
remove seal carrier without damaging the oil pan
gasltet.
CAUTION-
After removing seal carrier, checlc oilpan gasket for damage.
If gasket is damaged during removal, remove oil pan (as de-
scribed later) and replace
gasket.
< Remove old seal and install new seal into seal carrier using
BMW special tools
11 1 260 and 00 5 500.
NOTE-
A new radial seal is used from 4/98 production, and is the
only version available from
BMW as a replacement. The
new
sealno longer uses a spring to support the sealing lip.
Do not
lcinlc or damage the sealing lip. Do not touch with
fingers.
* BMW offers the rear main seal carrier and seal in a lit A
plastic support bushing, required for sliding the seal over
the crankshaft, is included with the
lcit.
I CAUTION- 1
Do not use BMW special tool 1 I 2 213 (mstallation guide)
with the new style seal. Use only the special tool
supphed
with the seal lcit.
When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace
gasltet between rear main seal carrier and crank-
case.
Apply thin coat of
3 Bond 8 1209 or equivalent sealant to
oil pan gasket sealing surfaces.
* Lubricate crankshaft seal contact surface.
Use plastic support bushing
(A) that comes with seal ltit as
an installation
quide, fittina seal over end of crankshaft. Use - -
care to push seal carrier and support bushing on straight,
without tilting sideways. Remove support bushing.
- lnstall seal carrier bolts and torque to specifications.
4 Use new bolts (arrows) at base of seal carrier. Coat threads
with sealing compound before installing.
- Install and tighten oil pan bolts.

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I Lubrication System -
- Remainder of assembly is reverse of disassembly.
Install flywheel, clutch or torque converter and
transmission.
Fill engine with oil.
- Run engine and check for leaks.
Tightening torques
Oil
drain plug fo oil pan (MI21 25 Nm (18 ft-lb)
Oil pan to engine
block
M6 (8.8 grade) 10 Nm (89 in-ib)
M6 (1 0.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (1 6 it-lb)
Rear main seal carrier to crankcase
M6 10 Nm (89 in-lb)
ME 22 Nm (16 ft-lb)
Crankshaft rear main seal, replacing (V-8)
- Remove transmission. See 230 Manual Transmission or
240 Automatic Transmission.
- Manual transmission vehicles: Remove clutch pressure plate
and disc. See
210 Clutch.
- Remove flywheel. See 210 Clutch.
- Drain engine oil.
4 Remove bolts (A) retaining rear main seal carrier, including
bolts at (arrows) oil pan.
Carefully separate seal carrier from oil pan gasket and re-
move carrier.
CAUTION-
Do not damage oil pan gasket.
< Remove old seal and reinstall new seal into seal carrier using
) BMW special tools 11 1 230 and 00 5 500.

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- When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace gasitet between rear main seal carrier and
cranlt-
case.
Apply thin coat of
3 Bond 8 1209 or equivalent sealant to
oil pan
gasltet sealing surfaces.
* Lubricate crankshaft and seal contact surfaces.
4 Use BMW special tool 11 2 390 as an installation guide in fit-
ting seal over end of cranltshaft. Use care to push seal carrier
and support bushing on straight, without tilting. Remove in-
stallation guide carefully.
- Replace sealing washers under seal carrier mounting bolts.
- Install seal carrier mounting bolts and torque to specilica-
tions.
- lnstall oil pan bolts.
- Remainder of assembly is reverse of disassembly.
Install flywheel using new bolts,
Install clutch or torque converter and transmission.
* Fill engine with oil.
Run engine and
checlt for leaks.
Tightening torques Flywheel to crankshaft (use new bolts)
120 Nm (89 ft-lb)
011 dra~n plug to 011 pan (M12) 25 Nm (18 ft-lb)
Oil pan to
eng~ne block
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (1 0 9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Rear main seal carrier to crankcase
M6 10 Nrn (89 in-lb)
ME 22 Nm (16 ft-lb)

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ignition System
Crankshaft speed sensor, replacing (M62 and M62TU
engines)
The crankshaft speed sensor reads a toothed pulse wheel
mounted on the flywheel.
If the Engine Control Module(ECM)
does not receive an impulse signal from the crankshaft speed
sensor during
cranking, the engine will not start. If the OBD II
system misfire detection protocol detects a catalyst damag-
ing fault due to a malfunction in the crankshaft speed sensor
components, the Check Engine light (Malfunction
Indicator
Light or MIL) will be Illuminated.
4 The crankshaft speed sensor (arrow) is mounted in the right
lower side of the bell housing.
- Remove speed sensor by disconnecting electrical harness
connector and unbolting sensor from bell housing. Do not
discard shims, if present.
- Installation is the reverse of removal. Clean mounting surface
before installing new sensor, and install shims, if present.
< If the flywheel was replaced, the speed sensor must be
checked for correct installation depth.
* Crank engine in direction of rotation using crankshaft bolt
until a full pulse tooth is centered in the opening for the re-
moved speed sensor.
Measure depth ro top of tooth from speed sensor p~lse
generator mounting s~rface on transmission.
4 Measure length of pulse generator from mounting surface to
end (A).
- Subtract length of pulse generator (A) from distance to pulse
tooth from mounting area on transmission. This measure-
ment is the gap between the pulse sensor and flywheel. Use
shims available from BMW to increase gap as needed to
reach specification.
Pulse sensor
gap
End of sensor to flywheel teeth 0.55 + 0.2 rnrn
(0.0217 t 0.008 in)

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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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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

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210-1 4
1 Clutch
Dowel sleeve I
Check flywheel location
and correct installation. dowel sleeve
(arrow)
for . damage
< When installing dual-rnass flywheel, position dowel sleeve
next to two locating notches (arrows).
- Lightly oil flywheel mounting bolt threads and torque to
specification.
Tightening torque
Flywheel to crankshaft 105 Nm (77 ft-lb)
CAUTIOI\C
Do not reinstall flywheel bolls with LoctiteCTJ or similar thread
locl~ing compound.
- Install transm~ssion as descr~bed in 230 Manual Transmis-
sion.
4 If flywheel was replaced, check pulse sensor (arrow) for cor.
rect installation depth.
- Remove pulse sensor.

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21 0-1 5
Clutch
Use crankshaft pulley bolt to rotate engine in direction of ro-
tation until a full pulse tooth
(arrow) is centered in pulse sen-
sor opening.
Measure depth from pulse sensor mounting surface on trans-
mission to top of tooth.
Q Measure length (A) of pulse sensor from mounting surface to
end.
- Subtract length of pulse sensor (A) from distance to pulse
tooth from mounting area on transmission. This resulting
measurement is the pulse sensor air gap. Use shims avail-
able from
BMW to adjust air gap to specification.
Pulse air sensor gap
End of sensor to flywheel teeth 0.55 i-0.2 rnrn
(0.0217 i0.0079 in)
Transmission input shaft pilot bearing,
replacing
- Remove clutch as described earlier.
4 Remove pilot bearing from end of crankshaft using BMW
special tool 11 2 340 or equivalent puller.

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Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Break in the SAC gradually, with light to medium loads, to en-
sure correct operation and long life. Fast sports driving ma-
neuvers may destroy a new
clutch.The following break-in
procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level
grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500
- 4000
rpm.
On medium grades (approx. 12% and up), start
off at ap-
prox. 2500 rpm for the first 5 or so times.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade)
M8 (10.9 grade) 24
Nm
(18 ft-lb)
34 Nm (25 ft-lb)