1998 BMW 540i Transmission

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119-12
Lubrication System 1
4 Support subframe from below using BMW special tool 31 2
220 and appropriate shop lift. Remove
subframe mounting
bolts and lower
subframe as far as possible.
Remove oil pan screws (arrows) at cylinder block and trans-
mission bellhousing. Lower and remove oil pan.
NOTE-
If oil pan will not slide backwards, disconnect stabilizer bar
links and lower front axle support further.
If the oil pan does not separate easily from the engine cylin-
der
block, a few taps with a rubber malletshould breakit free.
Do not
pry the oil pan loose.
When installing oil pan: Thoroughly clean all old gasket material from mating sur-
faces and use a new gasket.
Apply a small amount of non-hardening sealer
(3 Bond
12098 or equivalent) to oil pan gasket directly below joints
(arrows) for end cover and front timing case cover. Apply
a bead
3 mm wide by 2 mm high.
Install all oil pan bolts finger tight. Tighten oil pan bolts to-
ward front of engine first, then pan bolts at transmission
end.
Tightening
torques
Oil drain plug to oil pan (M12) 25 Nm (18 ft-lb)
Oil pan to engine block
MG (8.8 grade)
MG (10.9 grade)
M8 (8.8 grade)
10 Nm (89 In-lb)
12 Nm (9 ft-lb)
22 Nrn (16 R-lb)

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-- . - .. . - Lubrication system]
- Remainder of installation is reverse of removal.
Replace self-locking nuts when reinstalling front suspen-
sion components.
Use new oil dipstick tube sealing O-ring.
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).
NOTE-
BMW does not specify a front end alignment following this
procedure.
Tightening torques Front subfrarne to body rail
(M12, use new bolts)
8.8 grade
10.9 grade
12.9 grade 77 Nrn
(57 ft-lb)
105 Nrn (77 ft-lb)
110 Nrn (81 ft-lb)
Stabilizer bar link to stabilizer bar
65 Nrn (48 ft-lb)
Steering shaft universal joint clamping bolt
(use new bolt)
19 Nrn (14 it-lb)
Lower oil pan, removing and installing (V-8)
- The V-8 engine is equipped with a 2-piece oil pan. The fas-
teners in
V-8 engine oil pump assembly, including the
sprocket retaining nut, are known to loosen and fall off into
the oil pan. Be sure to install these fasteners with Loctite
O
or equivalent thread locking product and torque to specifica-
tions.
CAUTION-
It is recommended that the oil pump retaining bolts and oil
pump drive sprocket retaining nut tightening torque be
checkedany time the
oilpan is removed.
- Raise car and place securely on jack stands.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
- Remove splash shield from under engine.
- Drain engine oil
- On cars with automatic transmission, remove ATF cooler line
brackets from oil pan.

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Lubr~cat~on System r- -
Working at lower rear of engine, remove oil pan retaining
bolts
(arrows).
- If necessary, remove oil cooler bracket from oil pan.
- Remove remaining oil pan bolts. Slide upper section of oil
pan forward to remove.
- Installation is reverse of removal, noting the following:
Clean sealing surfaces of debris.
- Coat joints with Three Bond 1209 O sealant.
Use new gaskets.
Install all oil pan bolts first, installing bolts at transmission
end without preload.
Tighten oil pan bolts at front end, then tighten bolts at rear
of engine.
Be sure to reinstall all oil
pump fasteners, including the
sprocl - 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
AIC drive belt tensloner
M6 10 Nm (7.5 it-lb)
M8 24 Nm (18 ft-lb)
Front axle
subframe to chassis
(Use new fasteners) 77 Nm (57 ft-lb)
Oil drain
line to upper oil pan 30 Nm (22 ft-lb)
Oil pump to crankcase 34 Nm (25 ft-lb)
Oil pan fasteners
(upperllower)
M6 8.8 10 Nm (7.5 ft-lb)
M6 10.9 (replace)
I2 Nm (9 ft-lb)
M8 8.8 22 Nm (16 ft-lb)
Steering column universal joint to
steering box (replace) 19 Nm (14 ft-lb)
Oil pressure warning switch, replacing
(&cylinder and V-8)
- In all models, the oil pressure warning switch is located at the
base of the oil filter housing.

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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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121-8
/Battery, Starter, Alternator
NOTE-
Automatic transmission cars: ambershifier LED willgo out at
consumer cut-off.
4 Attach closed-circuit current measurement adaptor
(BMW special tool
61 2 300):
Connect red clamp (marked A -BATT (+)) to positive bat-
tery terminal.
Connect
black clamp (marked B -CHASSIS) to chassis
ground point.
NOTE-
Green LED will light up to indicate correct installation of
closed-circuit current measurement
adaotor.
< Connect blaclc clamp (marked B - BATT (-)) to negative bat-
tery terminal. Green
LED light will go out.
NOTE-
Any electrical overloading will be indicated at this point by
lighting the red
LED. If the red LED lights up, check the adap-
tor connections.
< Set multimeter (A) to 10 amp measuring range and connect
it to adaptor.
NOTE -
Set multimeter to record average readings.
Ifpossible, turn offpowersaving features of multimeter
which prevent a long term (overnight) test by automatically
powering down
meter.
- Disconnect battery ground strap (B) at chassis mounting
point.
- Measure closed-circuit current using multimeter.
- Typical average closed-circuit current for E39 vehicles is
40 mA. Readings over 50 mA must be further investigated.

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Battery, Starter, Alternator
- Installation is reverse of removal, noting the following:
Replace alternator rubber sealing O-ring.
* Fill and bleed cooling system as described in 170 Radiator
and Cooling System.
Tightening torques
Fan clutch to coolant pump
with
BMW special tool 11 5 040 30 Nm (22 ft-lb)
without
BMW special tool 11 5 040 40 Nm (29 ft-lb)
Terminal 30 (Bc) wire to alternator (ME) 13 Nm (10 ft-lb)
STARTER
Starter troubleshooting
Typical starter wiring terminal identification is shown. Large
wire at terminal
30 (not shown in photo) is direct battery volt-
age. Smaller wire at terminal
50 operates starter solenoid via
ignition switch.
If starter turns engine slowly when ignition is in start position:
Check battery state of charge.
Inspect starter wires, terminals, and ground
connectlons
for good contact. In particular, make sure ground connec-
tions between battery, body and
englne are completely
clean and tight.
If no faults are found, starter may be faulty and should be
replaced.
- If starter fails to operate, check EWS (drive-away protection
system). Try another ignition key.
If no faults can be found,
have the EWS system checked using
BMW scan tool equip-
ment.
Checkclutch pedal operated
starter lock-out switch or gear
position switch (automatic).
NOTE-
* A factory-installed drive-away protection system, also re-
ferred to as
EWS, is used on E39 cars. This system pre-
vents operation of the starter if a specially coded ignition
key is not used.
On cars with automatic transmission, the transmission
gear position switch signals
EWS to prevent the engine
from starting in gear positions other than PARK or NEU-
TRAL.
On cars with manual transmissions, a starter immobiliza-
tion switch
at the clutch pedal is used to prevent the starter
from operating unless the clutch pedal is pushed fully to
the floor.

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Battery, Starter, ~lternatorl
- Disconnect wiring from starter.
4 Note routing for cables. Routing varies depending on model
and transmission. When reinstalling, make sure cables do
not chafe.
- Using a long extension and universal joint from output end of
transmission, remove bolts fastening starter to transmission
bell housing and engine block.
- Remove starter from below
4 Checlc starter pinion gear and flywheel teeth for damage.
- Installation is reverse of removal.
Tightening torques
Starter to engine 47 Nrn (35 It-lb)
Starter sipport bracket to starter 5 Nrn (44 in-lb)
Starter support
bracket to engine 47 Nrn (35 ft-lb)
Wlre terminals to slarter
M5 5 Nrn (44 in-lb)
M6 7 Nrn (62 in-lb)
M8 13 Nrn (10 ft-lb)
Starter, removing and installing
(V-8 engine)
The starter is on the right (passenger) side of the engine, and
is removed from below. Access to starter bolts is difficult. Be
sure to have the proper tools on hand before proceeding.
- Disconnect negative (-) battery cable
CA UTIOW-
Prior to disconnecting the battery, read the battev discon-
nection cautions in
OOlGeneral Cautions and Warnings. -
- Raise vehicle and support safely.
/ WARNING- 1 ~ ~~ ~~ ~~~ ~
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjacltstands designed for
I the purpose. A floor jack is not adequate support I

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-
Battery, Starter, Alternator
- Working underneath car, remove engine splash shield.
- Remove heat shield from starter.
Remove starter wire mounting nuts (arrows). Disconnect
wires from starter terminals and retaining clip.
Disconnect main positive cable and bracket from suspen-
sion.
If necessary for access, remove right side oxygen sensor
harness connector from retaining clip.
Working from end of transmission, use suitable extensions
and universal joint to remove starter mounting bolts (arrows)
at transmission bellhousing.
- Remove starter from below.
- Check starter pinion gear and flywheel teeth for damage.
- Installation is reverse of removal
Tightening torques Starter
to engine 47 Nrn (35
ft-lb)
Wire terminals to starter
M5 5 Nrn (44 in-ib)
M6 7 Nm (62 in-ib)
ME 13 Nrn (10 ft-lb)