1998 BMW 540i wheels

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1 16-36
I Cylinder Head and Valvetrain
4 Preload exhaust camshaft spring plate by pressing on im-
pulse wheel while tightening mounting nuts (arrows)
fingel
tight.
4 Install BMW special tool 11 6 150 (VANOS setup bracket) to
front of cylinder head timing case. Install nuts (arrows) finger
tight, then tighten down uniformly until special tool is in full
contact with cylinder head.
CAUTION--
Male sure aNgas1ef material Is removed from face of cyiin-
der head. Clean sealing face and keep free of oil.
4 Secure camshaft sprockets and impulse wheels:
Tighten mounting screws (A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Tighten mounting nuts (B) on exhaust and intake sprocket
assemblies to approx.
5 Nm (44 in-lb).
Torque down mounting screws (A) and nuts (B) to final
specifications.
Tightening torques Sprocket assembly to camshaft initial torque
5 Nm (44 in-lb)
Sprocket assembly wheel to carnshaft
M7 tom screws (A) 20 Nm (15 ft-lb)
M6 mounting sciew (6) I0 Nm (8 ft-lb) - - -
- - Remove crankshaft locking tool from crankcase.
- Remove camshaft locking tools from cylinder head.

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1 17-34
1 Camshaft Timing Chain
DOUBLE VAMOS SYSTEM
(M52 TU AND M54 ENGINES)
Double VANOS system function
The M52TU and M54 6-cylinder engines are equipped with a
Double VANOS system that varies intake and exhaust cam-
shaft timing.
The main components of the Double VANOS system are:
lntalte and exhaust camshafts with helical spline inserts.
Camshaft sprockets with adjustable gears.
VANOS actuators (two position piston housing with
inter-
nallexternal helical spline cup).
Three-way solenoid switching valves.
Camshaft position impulse wheels.
Hall effect camshaft position sensors.
Camshaft position
IS varied based on engine rpm, throttle po-
sition signal, intake air and coolant temperature.

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-
I Camshaft Timing Chain - --
Install BMW special tool 11 6 150 (VANOS setup bracket) to
front of cylinder head timing case. Tighten nuts
(arrows) by
hand, and then tighten down uniformly until special tool is in
full contact with cylinder head.
CAUTION-
Male sure all gasket material is removed from face of cylin-
der head. Clean
sealins face and keep free of oil.
Secure camshaft impulse sprockets and wheels:
Pretighten Torx screws
(A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Pretighten mounting nuts
(B) on exhaust and intake
sprocket assemblies to approx.
5 Nm (44 in-lb).
- Torque down Torx screws (A) and nuts (8) to flnal
specifications.
Tightening torques Sprocket assembly
to camshaft
initial torque
5 Nm (44 in-lb)
Sprocket assembly to camshaft
M7 Torx screw (A) 20 Nm (15 fl-lb)
ivl6 mounting nut (B) 10 tdm (89 in-lb)
- Remove flywheel locking tool from transmission bellhousing
so that crankshaft is no longer locked.
- Remove camshaft locking tools from rear of cylinder head.
- Crank engine over twice by hand in direction of rotation until
cylinder
1 intake and exhaust camshaft lobes face each other - again.
- Secure crankshaft with BMW special tool 11 2 300.
4 Place BMW special tool 11 3 240 over camshaft ends and
measure clearance of tool to cylinder head surface.
NOJE-
If the exhaust side of the tool (A) is not flush with the head,
camshaft timing
Is incorrect. Repeat camshaft timing pro-
cedure.
* Due to flexible sprocket design and VANOS control unit tol-
erances and play, the
intake side of special tool 11 3 240
(6) may be up to 1 mm (0.04 in) above the sudace of the
cylinder head. This is normal. Otherwise, repeat camshaft
timing procedure.

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Cp-- Camshaft -- Timing Chain
Secure camshaft sprockets and impulse wheels:
Tighten mounting screws
(A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Tighten mounting nuts
(6) on exhaust and intake sprocket
assemblies to approx.
5 Nm (44 in-lb).
Torque down mounting screws (A) and nuts
(6) to iinal
specifications.
Tightening torques Sprocket assembly
to camshaft
initial torque
5 Nrn (44 in-lb)
Sprocket assembly to camshaft
M7 Torx screw (A) 20 Nm (I5 it-lb)
M6 mounting nut (8) 10 Nm (89 in-lb)
- Remove flywheel locking tool from transmission bellhousing
so that crankshaft is no longer secured.
- Remove camshaft loclting tools from rear of camshafts.
4 Crank engine over by hand twice in direction of rotation until
cylinder
1 intake and exhaust camshaft lobes (arrows) face
each other.
- Secure crankshaft in TDC position with BMW special tool
11 2 300.
4 Place BMW special tool 11 3 240 over camshaft ends and
measure clearance of tool to cylinder head surface.
NOTE-
* If the exhaust side of the tool is not flush with the head (gap
A), retime the camshafts as described laler in this repair
group.
Due to flexible sprocket design and VANOS control unit tol-
erances and play, the
intake side of special tool 71 3 240
may be up to
I mm (0.04 in) above the suriace of the cyl-
inder head (gap
B). This is normal. Otherwise, retime the
camshafts as described in
VANOS timing, checking and
adjusting (M52 TU and 11154 engines).
- Remove VANOS setup bracket from front of cylinder head
- Install VANOS control unit. See VANOS control unit, in-
stalling
(01152 TU and M54 engines).
- Install intake camshaft oil baffle

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This repair group covers general application information for
the clutch, manual and automatic transmissions, shift linkag-
es and driveshaft.
Drivetrain
I ZF manual transmission I
BMW E39 models are equipped with a longitudinal drivetrain.
The transmission is bolted directly to the rear of the engine.
A
driveshaft connects the output shaft of the transmission to the
rear final drive. Individual drive axles with integrated constant
velocity joints transfer rotational power from the final drive
unit to the rear wheels.
4 Due to different power characteristics and performance re-
quirements, various manual transmissions are used in mod-
els covered by this manual. Manual transmission
applications are given in the table below.
For manual transmission specifications or repair procedures,
refer to
230 Manual Transmission.
Manual transmission models use a single disc clutch with
dual-mass flywheel. For further information, see
210 Clutch.
The manual transmission metal ID plate is mounted on side of
transmission. Do not rely on numbers cast on transmission
case for identification.
Manual transmission applications
Model Year Engine Transmission
5251 2001 - 2002 M52TU, M54 Getrag S5D 250G
528i 1997-2002 M52 ZF S5D 3202

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230-1 8
Manual Transmission
- Unbolt clutch slave cylinder from side of transmission. Do not
disconnect fluid hose. Suspend slave cylinder from chassis
using stiff wire.
CA UTIOG
Unbolt clutch slave cylinder slowly to prevent air being
drawn into hydraulic system.
. Do not operate clutch pedal with slave cylinder re-
moved from transmission.
4 Put BMW special tool 11 7 370 or appropriate sized spacer
between engine oil sump and front axle support. Lower trans-
mission until engine is supported on spacer.
0 V-8 vehicle: Turn front wheels to prevent strain from being
placed on center tie rod.
All vehicles: Tilting the engine to lower the transmission
can lead to damage to various components due to lack
of clearance at rear of engine. Lower transmission
slowly
- Support front of engine with floor jack.
4 Disconnect shift rod from selector shaft coupling
- Disconnect shift console from top of transmission. See 250
Gearshift Linkage.
6-cylinder: Remove transrnisslon mounting Torx-head bolts
(arrows). Note length and locatlon of bolts.
Remove
transrnlssion by pulling backward untll transmls-
sion Input shaft clears clutch d~sc spl~nes, then pull down-
wards. Lower
transmlsslon jack to remove transrnlsslon. -
- - -
-

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240-2
/ ~utomatic Transmission
This section covers maintenance and replacement of the
automatic transmission for
E39 models.
Automatic transmission internal repairs are not covered.
Such repairs require special service equipment and knowl-
edge. If it is determined that transmission internal
sewice is
required, consult an authorized BMW dealer about a factory
reconditioned unit or a transmission rebuild.
CAUTION-
ATF does not circulate unless the engine is running. When
towing an automatic transmission vehicle, use a flat bed truck
or raise the rear wheels off the ground.
Special tools
Some special tools are required for the removal and installa-
tion of an automatic transmission on the
E39 BMW models.
While these tools are not absolutely necessary, they are es-
pecially helpful when dealing with the removal and replace-
ment of the torque converter.
4 Engine support bracket
(Tool No. BMW
00 0 200.00 0 208)
4 Transmission jack
(Tool No.
BMW 00 2 030)
4 Engine support block (V-8 models) 11 7310 (Tool No. BMW 11 7 310)

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-.- .
/ Driveshaft Driveshaft, removing
CAUTION-
. Be sure the wheels are off the ground before removing the
driveshak Set the parl(ing brake before removing the
driveshaft.
Once the driveshaft has been removed, the vehicle can
roll regardless of whether the transmission is in gear or
not.
The driveshaft is mounted to the transmission and final
drive
with self-locliing nuts. These nuts are designed to
be used only once and should be replaced during reas-
sembly.
Remove complete exhaust system. See
180 Exhaust
System.
- Remove exhaust heat shields.
- Support transmission with transmission jack.
< Loosen transmission mount nuts (arrows) on real
transmission support crossmember.
- Release wiring harness retainers from rear transmission
support crossmember.
< Remove mounting bolts (arrows) for rear transmission sup-
port crossmember. Slide crossmember rearward to remove.
- Matchmark front and rear driveshaft halves to corresponding
transmission output and final drive input flanges.
4 Remove nuts securing driveshaft mounting bolts at transmis-
sion output flange. Counterhold bolts (arrows) at transmis-
sion flex-disc. Discard old nuts.
- Hang driveshaft front section from body using stiff wire.