Gasket BMW 540i 2000 E39 Manual PDF

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Exhaust systeml
M54 engine
(5301 2001-2003)
Clamping sleeve
Front muffler Rear muffler
Hanger
Vibration dampener
Clamping sleeve
Center muffler
Hanger
Gasket (front pipe to manifold)
10. Exhaust
manifold/catalytic
converter assemblies
11. Oxygen sensors, post-catalytic converter
12. Oxygen sensors, pre-catalytic converter

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I Exhaust System
M62 engine
(540i 1997-1 998)
1. Right side catalytic converters
2. Support bracket
3. Support bracket
4. Center muffler
5. Hanger
6. Rear muffler
7. Clamping sleeve
8. Oxygen sensors, post-catalytic
converter
9. Oxygen sensors, pre-catalytic
converter
10. Left side catalytic converter
11. Sealing rings
12. Left front exhaust manifold
13. Left rear exhaust manifold
14. Gasket
15. Exhaust manifold, right front
16. Exhaust manifold, right rear

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Exhaust systeml
M62 TU engine
(540i 1999-2003)
1. Oxygen sensors, pre-catalytic
converter
(2)
2.
Oxygen sensors, post-catalytic
converter
(2)
3.
Hanger
4. Rear muffler
5. Clamping sleeve
6. Hanger
7. Center muffler
8. Clamping sleeve
9. Catalytic converter, left side
10. Catalytic converter, right side
11. Exhaust manifoldlcatalytic
converter,
left side
12. Gasket (2)
13.
Gasket (2)
14.
Exhaust manifoldlcatalytic
converter, right side

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Automatic Transmission
- Raise and safely support vehicle.
CA U JIOG
Male sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A floorjack is not adequate support
4 With engine running and selector lever in PARK, remove filler
plug (arrow)
(A5S 360R transmission shown, refer to other
illustrations for location of filler and drain plugs on other
transmissions).
If a small stream of fluid runs out of the filler hole the level
is correct.
If no fluid
leaks out when plug is removed, fluid level is to
low. Add ATF fluid until it starts to overflow.
Install filler plug using a new sealing ring.
Hot ATF can scald. Wear eye protection and protective cloth-
ing andgloves during
the check. If the tmnsmission was over-
filled, hot ATF will spill from the filler hole when the
fill plug is
removed.
ATF, draining and filling
The procedure given here includes removal and installation of
the fluid strainer (filter). Refer to illustrations in Automatic
transmission fluid
pan and strainer.
Remove ATF drain plug
(1) and drain fluid into container.
WARNING-
ATFshould be warm when draining. Hot ATFcan scald. Wear
eye protection, protective clothing and gloves.
Remove transmission pan mounting bolts and remove pan.
Remove pan gasket and clean
gasket sealing surface.
- Pull ATF strainer from transmission pump housing. If strainer
sealing ring remains in pump housing remove using a seal
puller.
- Installation is reverse of removal.
Always replace seal for drain plug and all
gasket(s)
and O-rings.
Clean sump and sump
magnet(s) using a lint-free cloth.
Tighten transmission pan bolts in sequential order.
Using filler plug
(2), fill transmission with approved ATF.
Check fluid level as described earlier.

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240-9
Automatic Transmission
Automatic transmission
fluid pan and strainer
1. ATF strainer
2. ATF strainer seal
3. Pan gasket
4. Sump magnet
5. ATFpan
6. Filler plug
7. Drain plug

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260-14
Driveshaft
Constant velocity (CV) joint, replacing
The CV joint at the rear of the driveshaft is available from
BMW as a separate part.
- Remove complete driveshaft as described earlier in this
section.
< Clean grease off CV joint. Remove retaining circlip (arrow)
from CV joint end of driveshaft.
- Drive out bolts from CV joint.
4 Remove CV joint from driveshaft:
Pry back protective boot
(A).
- Using BMW special tool 26 1 110 on inner race (B), press
or pull joint off shaft.
- Check protective boot for damage. Replace if necessary.
- lnstall new CV joint:
. Working from both sides of joint, inject approximately 80
grams of
OptimolB grease (or equivalent) into joint.
Install new sealing gasket on joint face that mates with pro-
tective boot. Seal fits in groove on outer race of joint.
Clean grease off driveshaft and mating splines on joint.
Apply
LoctiteO 648 to driveshaft splines.
Press new CV joint onto shaft as far as it will go.
CAUTIOI\C
Only press on inner CVjoint race.
- Install new retaining circlip to end of driveshaft,
- Insert CV joint mounting bolts. Be sure to reuse washers.
- Install driveshaft as described earlier in this section.

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331-12
Final Drive Final drive cover, removing and installing
- Remove final drive. See Final drive, removing and install-
ing.
I 1 4 Remove fasteners (arrows) from rear cover and remove cov-
er.
Clean cover and final drive housing sealing surfaces.
Install new
gasket with cover.
* Installation is reverse of removal.
- Check differential oil level. See Differential oil level, check-
ing.
Tightening
torque
Final drive cover to final drive housing
. M10 (8.8 grade) 45 Nm (33 ft-lb)
M10 (10.9 grade) 90 Nm (66 ft-lb)
Final drive mounts, replacing
- Remove final drive. See Final drive, removing and install-
ing.
Rear final drive mounts
- Remove rear final drive rubber mounts using BMW special
tools333314,333315,334 181, and334 183.
4 Coat new mount with CircolightB anti-friction agent and in-
.
stall, noting the following:
Long bushing on mount must face forward (arrow).
A shows installation position of mounts.

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.
1 Doors
Door hinge assembly
1. Door
2. Spacer ring
3. Upper hinge
4. Hex bolt
5. Spacer ring
6. Lower hinge
7. Door check gasket
8. Doorcheck
9. Pin
10. Torx bolt
11. Gasket
12. Cover

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51 0-6
Exterior Trim, Bumpers
Front bumper assembly
1. Bumper support shock
absorber
2. Bumper support shock absorber seal
3. Bumper mounting bolt
4. Bumper support
5. Bumper to body gasket
6. Bumper cover
7. Grill panel
8. Lower bumper grill
9. Spoiler
10. Towing hinge flap

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540 Sunroof
General . . . . . . . . . . . . . . . . . . . . . . . . . . . ,540-2
Sunroof Adjustments. . . . . . . . . . . . . . . .540-2
Sunroof electronic controls, initializing . . . . ,540-2
Sunroof, normalization. . . . . . . . . . . . . . . . . ,540-3
Sunroof, characteristic curve . . . . . . . . . . . .540-3
Sunroof panel, emergency closing . . . . . . . ,540-4
Sunroof, adiustino . . . . . . . . . . . . . . . . . . . . ,540-5
~unroofwitil steel roof panel, adjusting . . . ,540-5
Sunroof with glass roof panel, adjusting . . . ,540-7
Sunroof Components . . . . . . . . . . . . . . 540-8
Sunroof components (glass)
. . . . . . . . . . . . 540-8
Sunroof panel, removing and
installing (steel or glass)
. . . . . . . . . . . . . . . 540-8
Sunroof panel gasket, replacing
(steel or glass)
. . . . . . . . . . . . . . . . . . . . . . . 540-9
Sunroof motor, replacing
. . . . . . . . . . . . . . 540-10