1998 BMW 540i lug bolts

Downloaded from www.Manualslib.com manuals search engine
General
Much of the necessary maintenance and minor repairthat an
automobile will need can be done with ordinary tools. Below
you'll find important information on how to work safely, a dis-
cussion of what tools will be needed and how to use them.
Safety
Although an automobile presents many hazards, common
sense and good equipment can help ensure safety. Many ac-
cidents happen because of carelessness. Pay attention and
stick to the safety rules in this manual.
Lifting the car
4 The proper jacking points should be used to raise the car
safely and avoid damage. The
jack supplied with the car can
only be used at the four side points (arrows) just behind the
front wheels or just in front of the rear wheels.
WARNING-
. Never work under a lifted car unless it is solidly supported
on
jack stands that are intended for that purpose.
When raising the car using a floorjack or hydraulic lift,
carefully position the jack pad to prevent damaging the
car body.
* Watch the jack closely. Male sure it stays stable and
does not shift or tilt.
As the car is raised, it may roll
sliahtlv and the
jack mav shift.
Raising car
- Park car on flat, level surface.
- If changing a tire, loosen lug bolts before raising car. See
Changing
a tire.
Place jack into position.
Malte sure jack is resting on flat, sol-
id surface. Use a board or other support to provide a firm sur-
face for jack, it necessary.
- Raise car slowly while constantly checking position of jack
and car.
- Once car is raised, bloclc wheel that is opposite and farthest
from jack to prevent car from unexpectedly rolling.

Downloaded from www.Manualslib.com manuals search engine
Sockets Socltets are used with a ratchet handle for speed and conve-
nience and can be combined with extensions and universal
joints (swivels) to reach fasteners more easily. The most
common socket drive sizes are
114 inch, 318 inch and 112 inch.
Sockets come in
6 point and 12 point styles. The 6 point offers
a better grip on tight nuts and bolts.
6 mm to 19 mm socltets
are the most needed sizes. Below is a list of typical bolt
diarn-
eters and the corresponding wrench sizes.
Common bolt diameters and wrench sizes
M5 8 rnrn
M6
10 rnm
M8 12rnrnor13rnrn
MI 0 17 rnrn
MI2 19 rnrn
M14 22 mm
Spark plug socket
4 A 518" deep-well socket for sparlt plugs includes a rubber in-
sert to both protect the spark plug from damage and grip it for
easier removal.
Pliers
There are many types of pliers including snap-ring,
needle-
nose, adjustable-joint, slip-joint (Channel-lock@), and locking
(Vice-Grip@) most of which are used for holding irregular ob-
jects, bending, or crimping. Some have special applications.
Needlenose pliers are used for gripping small and poorly ac-
cessible objects, and are useful forwiring and other electrical
work. Locking pliers such as the Vise-Grip@ are useful be-
cause of their tight grip.
Snap-ring and circlip pliers with special tipped jaws are used
to remove and install snap-rings or circlips. Channel-lock@ or
water pump pliers have adjustable jaws that can be quicltly
changed to match the size of the object being held to give
greater leverage,

Downloaded from www.Manualslib.com manuals search engine
-
General
BMW special tools
Many repairs covered in this manual call for the use of BMW
special tools. Many of the BMW special tools mentioned in
this manual are simply the best thing to use to do the job cor-
rectly. In these cases, the tool is identified with a
BMW parl
number. See your authorized BMW dealer parts department
for information on how to order special tools.
There are some jobs for which expensive special tools are es-
sential, and not a cost-effective purchase for a one time repair
by the do-it-yourself owner. This manual includes such re-
pairs for the benefit of those with the necessary experience
and access to tools. For the do-it-yourselfer, the need for spe-
cial tools is noted in the text, and whether or not BMW dealer
service is recommended.
Changing a tire
- Stop car on as flat a surface as possible, in a place where you
can be easily seen by other drivers. Avoid stopping just over
the crest of a hill.
WARNING -
If a tire goes flat while driving, pull well off the road. Changing
a tire on a busy slreet or liigliway is very dangerous. If
nec-
essag drive a short distance on the flat tire to get to a safe
place. It is much better to ruin a tire or rim than to
risk being
hit.
-
- Turn on emergency flashers, and set out flares or emergency
markers well behind car.
Choclc wheel (wheel chock located
in trunk) diagonally opposite to the one being changed. Pas-
sengers should get out of car and stand well away from road.
- Take jaclc and tools from tool area beneath trunk mat. Re-
move spare tire from tire storage tray.
- Loosen wheel bolts while car is on ground, but leave them a
little snug.
< Place jack in lifting point nearest wheel being changed. Use
a board to provide a firm footing for jack if ground is soft.
Raise car only far enough so that the wheel is fully off ground
and then remove wheel nuts and wheel.
- Install spare wheel. Install wheel nuts and tighten them hand
tight using lug nut wrench.

Downloaded from www.Manualslib.com manuals search engine
020-21
Maintenance
Spark plugs, replacing
E39 engines use a coil-over-spark plug configuration, with
one ignition coil above each spark plug. Sparks plugs should
be removed only after the engine has cooled.
Remove engine
cover(s) over ignition coils:
Remove acoustic cover over fuel injectors
I intake
manifold.
6-cylinder engine: Remove oil filler cap.
Remove plastic trim covers (arrows).
Remove cover hold-down bolts. Remove coil
cover(s)
6-cylinder engine: Temporarily reinstall oil filler cap to
keep out contaminants.
Remove ignition coil grounding harnesses (arrows). 6-cylin-
der coils shown,
V-8 engine is similar.
< Remove ignition coils:
Pull up on spring clips to disconnect ignition coil harness
connectors.
Remove coil mounting bolts. Pull coils up and off spark
plugs.
- Remove spark plugs.

Downloaded from www.Manualslib.com manuals search engine
11 0-20
Engine Removal and Installation
Working at right side of transmission bellhousing, disconnect
electrical harness connections (arrows) from starter. Re-
move starter retaining bolts and remove starter from trans-
mission mount.
M62 TU engine: Disconnect electrical harness connector
for right oxygen sensor from retaining clip and remove re-
taining clip from transmission.
- Working underneath engine compartment at left side:
Unclip positive battery cable from oil pan.
. Remove alternator cooling duct.
4 M62 engine: Remove fastener A and plug connector B from
alternator.
- M62 TU engine: Remove electrical harness connectors from
front of water cooled alternator.
- Remove exhaust system and transmission. See 180 Ex-
haust System and 230 Manual Transmission or 240 Auto-
matic Transmission.
- Working at front of engine:
Remove upper and lower hoses from radiator.
D~sconnect expansion tank hose from coolant pump.
- Remove belt-driven cooling fan:
Counterhold fan with special tool
11 5 050.
Turn fan mounting nut (32 mm) clockwise (left hand
threads) to loosen.
Rotate fan clockwise to remove.
Remove cooling fan shroud:
Disconnect electrical connectors from coolant level sensor
(B) and coolant temperature sensor (C).
. Remove expansion rivets (A) from each side of shroud
Remove coolant hose
(D).
Slide fan shroud with expansion tank up. Remove radiator
overflow tube from spout of expansion tank. Remove radi-
ator fan shroud with expansion tank.
Remove radiator. See
170 Radiator and Cooling System.

Downloaded from www.Manualslib.com manuals search engine
--
-- Engine Removal and installation' -
Remove polyribbed A/C compressor belt:
Mark direction of belt travel if belts are to be reused.
Loosen bolts
(A).
Turn adjusting lug (B) clocltwise to release belt tension.
Working beneath car, remove power steering pump and air
conditioner compressor. Suspend from body using stiff wire.
Remove exhaust manifolds. See
180 Exhaust System.
< lnstall engine lifting device (BMW 11 0 000 or equivalent) to
front and rear engine supports and raise engine until it's
weight is supported. Detach engine mounts.
a Watch carefully for hoses and electrical wires that might
snag.
- installation is reverse of removal:
Replace all gaskets, O-rings and seals.
V-8 engine mounts have two sets of mounting holes. E39
cars use front most mounting holes.
* On cars with automatic transmission, use new O-rings at
ATF cooler lines.
Use new alignment sleeves when installing transmission.
Be sure engine drive belts properly engage pulley grooves.
When installing belt, preload tensioner to stop (toward
belt), then tighten tensioner clamping nut.
lnstall front exhaust pipes using new gasltets and copper
paste and new mounting hardware. See
180 Exhaust
System.
Change engine oil and filter. Check all other fluid levels as
described in
020 Maintenance.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
CAUTION-
Do not interchange knoclc sensor harness connectors. Seri-
ous engine damage may result

Downloaded from www.Manualslib.com manuals search engine
11 3-1 4
Cylinder Head Removal and Installation
4 Secure camshafts in TDC position using BMW special tool
set
11 3 240.
4 Remove access plugs from VANOS control unit in front of
exhaust camshaft sprocket.
Remove
4 bolts (arrows) from exhaust camshaft sprocket
(Torx E10).
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
eninq or tiqhteninq sprocl(et mounting fasteners. r
Press down on secondary chain tensioner and lock into place
using
BMW special tool 11 3 292 or a similar size pin.
NOTE-
Some tensioners may have a single hole for special tool.
Remove secondary chain tensioner.
Disconnect harness connector and oil line fitting from bottom
of VANOS control unit.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
Remove VANOS control unit mounting nuts and bolt at front
of cylinder head.

Downloaded from www.Manualslib.com manuals search engine
- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Install intake camshaft cover and cylinder
head cover.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in 020 Mainte-
nance.
If necessary, adjust accelerator cable.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl