final drive BMW 540i 2001 E39 Service Manual

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Final Drive
Front final drive mount
4 Remove front final drive mount using BMW special tools 33
3312,333314, 333315,334161
and334162.
I i 4 Coat bearing sleeve in rear axle carrier and rubber mount
with
~ircolight~ anti-friction agent.
Slide rubber mount from side with large diameter into
BMW special tool 33
4 165.
Milled recess
(A) makes firm contact with rear axle carrier
when top rubber mount is tightened down.
The
slolled srde ot r11e rubber mounl must be ar r#ghl angles
lo
rhe groove rn specal roo/ 33 '1 165 and shoulo be lrghrened
I down ~ransversely across the vehicle axis. I
Draw rubber mount in firmly with BMW special tools 33 3
314,333315,334164,334165and334166.
NOTE-
Male sure special tool 33 4 166 is properly seated.
0 Rubber mount must locate flush in rear axle carrier. If nec-
essary, rotate special tool
33 4 164 through 90" and draw
in overlap.
- Remainder of installation is reverse of removal

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Final Drive
Drive axles use constant-velocity (CV) joints on both ends.
For replacement parts, only CV joint boots or complete axles
are offered by BMW. The procedure for drive axle removal
varies for sedan and sport wagon. Follow the appropriate pro-
cedure below.
Drive axle assembly
1. lnner CV joint
2. Drive axle
3. Outer CV joint
4. Collar nut
5. Outer CV boot kit
6. lnner CV boot kit
7. Circlip
8. Dust cover
9. Reinforcement
10. Torx bolt
Drive axle, removing and installing (sedan)
4 With an assistant applying brakes, break free staked collar
nut (arrow) at center of rear wheel hub. Do not remove com-
pletely.
NOTE-
The drive flange collar nut is tightened to a torque of over 300
Nm (221 ft-lb). Male sure the car is firmly on the ground.
- Raise rear of car. Remove rear wheel
WARNING -
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the
jack stands beneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Remove f~nal drrve. See Final drive, removing and install-
ing.

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Final ~rivel
4 Remove staked collar nut and press output shafl out of wheel
hub with special
BMW tool 33 2 111/116/117.
- Remove drive axle.
- Installation is reverse of removal, noting the following:
Use a new collar nut.
a Apply a light coating of oil to contact face of collar nut and
install it loosely.
* Install road wheel and lower car to ground.
- With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening torques
-
Drive axle collar nut to drive flange M27 300 Nrn (221 ft-lb)
Drive axle to differential flange
* M10x20 rnm black Torx bolt
83 Nrn (61 ft-lb)
M10x20 rnrn silver Torx bolt
100 Nrn (74 ft-lb)
Road wheel to hub 120 Nrn f 10 (89 ft-lbf7)
Drive axle, removing and installing
(Sport Wagon)
4 With an assistant applying brakes, brealc free staked collar
nut (arrow) at center of rear wheel hub. Do not remove com-
pletely.
NOJE-
The drive flange collar nut is tightened to a torque of over 300
Nm (221 ft-lb). Make sure the car is firmly on the ground.
WARNING -
Disable airsupply pump (if applicable) by disconnecting elec-
tricalplug before performing any repairs. Pump is located be-
neath a cover under the spare tire
in the floor of the cargo
compartment.
- Raise rear of car. Remove rear wheel.
WARNING -
Malce sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the jack stands beneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Models with rear coil springs: Remove cargo compartment
floor carpet.

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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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331-17
Final ~rivel
4 Remove staked collar nut and press output shaft out of wheel
hub with special
BMW tool 33 2 11 111 161117.
- Remove drive axle
- Installation is reverse of removal, noting the following:
* Use a new collar nut.
- Apply a light coating of oil to contact face of collar nut and
install it loosely.
Install road wheel and lower car to ground.
* With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening
torques
Drive axle collar nut to drive flange M24
300 Nrn (221 ft-lb)
Drive axle collar nut to drive flange M27
300 Nrn (221 ft-lb)
Drive axle to differential flange
M10x20 rnrn blaclc Torx bolt 83 Nrn (61 it-lb)
- M10x20 rnrn silver Torx bolt loo Nrn (74 ft-lb)
Road wheel to hub
120 Nrn+lO (89tt-lbi-7)
CV joint boots
NOTE-
When replacing a CVjoint boot, use a complete CVjoint
boot repair kit. The lit will include a new boot, clamping
bands, special lubricant, and a new inner CV joint circlip.
The lit is available from an authorized
BMW dealerparts
department.
The outer CVjoint cannot be removed from the axle
shaft
In order to replace the outer CV boot, it is necessary to re-
move the inner joint and boot first.
If the
CVjoints are worn or defective, a complete rebuilt
axle shaft is available from an authorized
BMW dealer
parts department.
- Remove appropriate axle shaft. See Drive axle, removing
and installing (sedan), or Drive axle, removing and in-
stalling (Sport Wagon).
- Working with axle shaft at bench, cut off old boot clamps and
remove boot. Clean old grease off joint and shaft. Use new
grease from CV joint boot kit.
4 Remove dust cover from CV joint and remove circlip (arrow)
retaining joint inner hub to axle shaft.

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I Final Drive
4 Support inner hub with BMW special tools 26 1 110 and
press axle shaft out of joint using BMW special tool 21 2 120.
- Clean all old lubricant off shaft splines and inner joint splines.
If the CVjoint must be disassembled for cleaning and inspec-
tion, be sure to matchmark inner and outer race and interme-
diate ball cage. This allows reassembly
ofparfs in their
original positions.
NOTE-
To inspect a CVjoint, clean away the grease and loolc forgall-
ing, pitting, and other signs of wear orphysical damage. Pol-
ishedsurfaces or visible ball traclts alone are not necessarily
cause forreplacement. Discoloration due to overheating indi-
cates
laclt of lubrication.
- Slide CV joint boot onto axle shaft
- Apply LoctiteO270 or an equivalent heavy-duty loclting corn-
pound to drive axle splines. Position new CV joint on shaft so
that raised or taller side of hub is facing shaft.
WARNING-
Do not let the locking compound contact the balls in the joint.
Apply only a thin coat to cover the splines.
While supporting axle shaft with BMW special tool
33 2 130
press inner hub of CV joint onto shaft. Install a new circlip.
- Install new boot clamps.
- Use sealing gel to seal dust cover to CV joint prior to reinstal-
lation.
NOTE-
* Do not let the ball hub pivot too far in the outer ring of the
joint.
Tlie balls will fa1 out.
Before installing each small boot clamp be sure to
'burp"the
boot by flexing the CVjoint. A small screwdriver inserted be-
tween the boot and the axle shafl will help the process.
CV joint lubricant capacity
Wheel hub end
80 gram (2.8 oz)
Differential end
85 gram (3.0 oz)

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51 5-4
I Central Locking and Anti-Theft
Driver's door lock
The
lock/unlock signals are sent as input to the door module
from two microswitches on the lockcylinder. The driver's door
module carries out the locking
/ unlocking functions of the
driver's door through its final stage control.
The signal to lock the remaining doors, trunk or tailgate and
fuel flap is sent over the P-Bus to the GM and the passenger
door module. Activation of the passengers door
loclt is carried
out by the passenger door module. The rear doors, trunlt or
tailgate and fuel flap are
locked by the f~nal stage in the GM.
When
locked from the outside, all doors are set to the double
lock position and the GM will not carry out any unlock com-
mands from the central
loclc button or remote trunk release
button.
Selective unlocking
When unlocking with the key or the remote transmitter, the
first unloclcrequestwill only unlock the driver'sdoor. A second
unlock request will unlock the remaining doors, trunk or tail-
gate and fuel flap.
Trunk locking
I
The vehicle can be locked/unlocked from the trunlc loclc cylin-
der. The GM locks the trunk or tailgate, rear doors and fuel fill-
er. The locking command is passed over the P-Bus to the
respective door modules to lock the driver's and passengers
doors.
Locking the trunk and removing the key in the
hor~zontal posi-
tion will set the valet lock and prevent opening of the trunlt
with the central locking system.
Central locking switch
-
< The central locking master control switch (arrow) is located
in the center console behind the shifter.
The central locking button will only single
loclt the doors
and trunk. The filler flap remains unloclted for refueling pur-
poses.
If a door is opened from inside while centrally locked, the
remaining doors remain locked.
The open door can be relocked, when closed, by manually
locking or pressing the central locking button twice. This
synchronizes the door
locks.

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INDEX 'tl
WARNING
Your common sense, good
judgemenl, and general alertness are
crucial to sale and successiul service
worlr. Belore attempting any work on
your
BMM be sure lo read 001
General Warnings and Cautions
and the
copyriglll page at the front 01
the manual. Review these warnings
and
caulions each lime you prepare
lo work on your BMW. Please also
read any warnings and cautions that
accompany
tile procedures in the
manual.
312-way valve (running losses)
see Fuel tank
Abbreviations, commonly used 600-14
ABS (antilock brake system)
see
Bral(es
A/C air distribution motors
see stepper motors (below)
blower final stage (resistor pack),
replacing
640-16
blower, removinglinslalling
640-1 5
compressor, replacing
640-24 condenser, replacing 64045
control panellmodule, removing1
installing
640-1 1
evaporakr, removinglinstalling 640-29
evaporator temperature sensor
640-12 expansion valve, removinglinstailing
640-27
IHKA/ IHKR system description 640-5
receiveridrier, replacing 640-26
stepper motors 640-1 3 ventilation microiilter, replacing
020-22. 640-17
see also Heating
Accelerator
iinlcage
see Maintenance
Activated carbon canister
see Fuel tank
ADS (auxiliary throttle valve)
130-57
Air compressor
330-44
Air conditioning
see
AIC
Air distribution (flap) motors
seeNC, stepper motors
Air filter see Maintenance
Air spring
300-6, 330-12
Airbag system (SRS)
2-stage
airbag 721-4
control module, replacing 721-7 driver airbag, removinglinstalling
721-8
iiead protection airbag 721-12 components 721-1 1
indicator
lighl721-4
passenger airbag, removinglinstalling
721-9 side-impact airbags crash sensor,
replacing
721-7
Airflow sensor see 130 under appropriate
fuel
injection system
Air pump
see 130 under appropriate fuel
injection system, secondary air
injection system
Air suspension
see Electronic height control
(EHC)
Alarm
see Anti-theft alarm
Alignment see
Wheei alignment
Aluminum suspension components
300-2
Antenna 650-6
Alternator see Battery, starter, alte rnator
Amplifier
650-4
Anti-theft alarm (DWA)
515-24 emergency disarming 515-31
Antifreeze (engine coolant)
see Maintenance
see also Cooling system
Antilock brake system (ABS) see Brakes
ASC see Brakes
ATF (automatic transmission fluid)
see Automatic transmission
see also Cooling systern
Automatic headlight adjustmenl
(LWR) see Lights
Automatic seat belt tensioner
720-4
Automatic shiftloclc
see
Gearshift
Automatic transmission
applications
200-3, 240-4
ATF 020-10, 200-4
capacity 240-8 checking 240-6
drainingifilling 240-7
heat exchanger 170-5
fluid pan and strainer 240-9 gearshift
see Gearshift
ID tag
200-3 range switch 610-6
removaliinstallation 240-10
steptronic see Gearshift
Auxiliary cooling fan
see
Coollng system, electric Ian
Auxiliary throttle valve (ADS)
130-57
Axle joint
see Drive axle
Back-up light switch
automatic transmission see Automatic transmission. range switch
- .~.~~~
manual transmission 230-8 -
- I

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WARNING
Your common sense, good
judgement, and general alertness are
crucial lo sale and
successlul service
work. Belore attempling any work on
your BMW, be sure to read 001
General Warnings and Cautions
and lhe copyright page
a1 llle Iron1 01
the manual. Review lliese warnings
and cautions each time you prepare
lo work on your
BMW Please also
read any warnings and
caulions lhal
accompany the procedures In !he
manual.
Component locations
see Electrical system
Compression test
113-5
Compressor see
AlC
Condenser see
AlC
Constant velocity (CV) joint
see Maintenance
see also
Driveshall
see also Drive axles
Consumer cutoff
600-10
Control arm see Front suspension
see also Rear suspension,
suspension arms
Coolant (antifreeze) see Maintenance
see also Cooling system
Coolant pump
see Cooling system Cooling system
coolant bleeding
170-14 6-cylinder engine, draininglfilling
170-10
V-8 engine, draininglfilling 170-12
coolant pump 170-3
6-cyiinder engine, replacing 170-1 9
V-8 engine, replacing 170-20 cooling fan 170-4
viscous ciutch fan, removingi
installing 170-14
electric fan, removlngiinstailing 170-1 5
expansion tank, removinglinstalling
170-22
electrically heated (ciiaracterislic
map) therrnostat 170-4
radiator, removinglinstaliing 170-22
service
see Maintenance
therrnostat 170-16
transmission fluid heat exchanger
170-5 troubleshooting 170-7
combuslion leal( test 170-10
pressure test
170-9
Crankshaft oil seals
iront
117-6
rear 11 9-6
Crankshaft speed sensor
see Ignition syslem
Crash sensor
see
Airbag system (SRS), side-impact
airbag crasii sensor
Cruise control clutch switch 612-9
CV joint
see Maintenance
see also Driveshalt
see also Drive axles
CV joint boot
see Maintenance
see also Drive axles
Cylinder head removinglinslaliing
M52 engine 113-8
M52 TU / M54 engine 113-22
M62 engine 113-56
Cylinder head and valvetrain
hydraulic lifters, checking and
replacing
116-7 leak test 116-5 valves 11 6-56
see
alsocylinder head Dashboard
513-7
Deck
lid
seeTrunk lid
Diagnostic monitors
OED-4
Diagnostic trouble codes
(DTCs)
080-7
Digital multimetel
010-17
Differential see Final drive
DLC (data
link connector) 020-4, OED-4
DME (digital motor electronics)
see
130 under appropriate fuel
injection system
see also ignition system
DM-TL (detection module-tank leak)
see
Fuel lank, leak deteclion unit
Drive
belts
see Maintenance
Dome light
seeLighls, interior lights
Door
door
check, replacing 411-4
hinge adjustment 41 1-5
loci(
see Door lock see also Central locking
removinglinslaliing 41
1-2
panel, removinglinstaliing 41 1-7 window
see Door window
Door
check
see Door
Door
handle
see Door lock
Door glass
see Door window
Door
lock
handles and loci(s 515-16
see also Central locking
Door
molding
510-13
Door panel see Door

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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan