1999 BMW 525i Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
200 Transmission-Genera!
General ........................... .20 0.2 Automatic Transmission
Drivetrain .......................... .20 0.2 Transmission Lubricants
Manual Transmission
.............. .20 0.2

Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine
Different automatic transmissions are used, depending on
model and model year
and/orproduction date. All of the auto-
matic transmissions are electrohydraulically controlled with
five forward speeds. Automatic transmission applications are
given in the table below.
Automatic transmission applications Model Year Engine Transmission
526 from 911 999 M52 TU ASS 360R
5251 from 312001 M54 ASS 3252
5301 to 312001 M54 ASS 390R
530i from 312001 M54 ASS 3252
540i
from 111 997 M62 TU ASS 4402
Automatic transmission identification metal ID plate is mount-
ed to body of transmission.
4 GM transmission ID tag (arrow) is on left side of transmission
housing, behind transmission selector cable, just above
transmission pan.
< ZF transmission ID tag (arrow) is on left rear of transmission,
just above transmission pan.

Downloaded from www.Manualslib.com manuals search engine
The lubricant used varies, depending on transmission and
model year. Fluid application information is clearly marked on
a label on transmission.
On manual transmission, either ATF (orange label reads
ATF-Oil) or a special BMW lubricant (yellow label reads MTF-
LT
I) is used. See 230 Manual Transmission.
Automatic transmission is filled with either Dexron
Ill ATF
(black transmission ID plate reads ATF-Oil), or special life-
time oil (green transmission ID plate reads Life-Time Oil). See
240 Automatic Transmission.
CAUTION--
If in doubt as to the type of fluid installed in a particular trans-
mission, consult an authorized
BMW dealer service depari-
ment for the latest in operating fluids.

Downloaded from www.Manualslib.com manuals search engine
210 Clutch
........................... General .21 0.2
........................ Special tools .21 0.2
Clutch Hydraulics ................. .21 0.4
Clutch hydraulic system.
bleeding and flushing
................. .21 0.4
Clutch master cylinder. replacing
........ .21 0.6
Clutch slave cylinder. replacing ......... .21 0.8 Flywheel. removing
and installing
................... (6 cylinder engine) 210-12
Flywheel. removing and installing
(V-8 engine) ....................... 21 0-1 3
Transmission pilot bearing. replacing .... 210-1 5
Clutch. installing (non-SAC components) . 210-1 6
Clutch. installing (new SAC components)
. 21 0-17
Clutch.
install in^ (used SAC components) 210-19
Clutch Mechanical ................. .21 0.9 self-adjusting crutch (SAC). breaking in : . 210-21
..................... Clutch variations .21 0.9
................... Clutch. removing .21 0.1 1
Clutch components. inspecting
........ .21 0.1 1

Downloaded from www.Manualslib.com manuals search engine
1 Clutch
This repair group covers replacement of clutch mechanical
and hydraulic components.
BMW 5 Series models with manual transmission use a single
disc hydraulically actuated clutch.
Twoversions of the clutch
are used:
1997
5281 (6 cylinder) uses traditional clutch components.
All 540i (V-8) and 1998 and later
6 cylinder models use a
self-adjusting clutch (SAC).
NOTE-
See 200 Transmission-General for transmission applica-
tion information.
Special tools
Some special tools and techniques are required for clutch re-
pairs. Be sure to read a procedure through before beginning a
job.
< Flywheel loclting tool (V-8 models)
1 (Tool NO. 11 2 070)
-
4 Flywheel loclting tool (6 cylinder models)
(Tool No. 1 1 2 170)
- < Pilot bearino removal tools
11 11 2350 < pilot bearing instaation
(Tool No. 11 2 350) tool