1999 BMW 540i torque

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11 9-2
Lubrication System
This repair group covers lubrication system troubleshooting
as well as oil pan removal and oil pump replacement.
In 6-cylinder models, removal of the oil pan requires the re-
moval of the exhaust system and some front suspension
components. Those procedures are fully covered in:
180 Exhaust System
210 Clutch
230 Manual Transmission
0 240 Automatic Transmission
310 Front Suspension
320 Steering and Wheel Alignment
NOTE-
Oil change procedure and oil filter replacement are covered
in
020 Maintenance.
CAUTIOG
V8 engines: The oil pump fasteners (including the sprocket
retaining nut) are known to vibrate loose. This can result in oil
starvation and engine failure. Be sure to check oil bolts and
nut tightness whenever the
oilpump is accessible. If any fas-
teners are found to be loose, remove them and reinstall with
Loctite
Band torque to specifications.
Special tools
The engine needs to be properly supported while the front
suspension
subframe is lowered to access the oil pan.
A standard oil pressure gauge may be used for measuring oil
pressure.
Engine support bracket
(Tool No, BMW 00 0 20012011202~2041208)
4 6-cylinder crankshalt rear main seal tools
(Tool No. BMW 00 5 50011
1 1 260)

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. .- -
L
- --
- - -. - -- Lubrication ~~stern
- Remove pressure gauge and reinstall pressure switch with
new sealing washer.
Tightening torque
Oil pressure switch to oil filter housing 27 Nm (20 ft-lb)
If testing shows low oil pressure, one or more of the following
conditions may be indicated:
Worn or faulty oil pump or faulty pump pressure relief valve
Worn or damaged engine bearings
Severe engine wear
Any of these conditions indicate the need for major repairs.
Oil pressure warning system, testing
4 When the ignition is turned on, the oil pressure warning light
comes on. When the engine is started and the oil pressure
rises slightly, the oil pressure switch (arrow) contact opens
and the warning light goes out. Make sure the oil level is cor-
rect before making tests.
- Turn ignition switch on.
- Warning light on instrument panel must light up
- Remove connector from oil pressure switch.
Warning light on instrument panel must go out.
NOTE-
If the light does not go out, the wiring to the switch is most
likely grounded somewhere between the switch terminaland
the warning light See
ELE Electrical Wiring Diagrams for
electrical schematics.
- If warning light does not light when ignition is on, remove con-
nector from oil pressure switch and use a jumper wire to
ground connector terminal to a clean metal surface. The oil
pressure warning light should come on.
NOTE-
If there are two wires to the oil pressure switch, ground the
brown/green wire that carries the signal to the warning light.
- If the warning light comes on, check the switch as described
in the next step. If the warning light does not come on, the
wiring to the instrument cluster or to the light itself is faulty.

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Lubrication stern/
Remove remaining seal carrier bolts (arrows) and carefully
remove seal carrier without damaging the oil pan
gasltet.
CAUTION-
After removing seal carrier, checlc oilpan gasket for damage.
If gasket is damaged during removal, remove oil pan (as de-
scribed later) and replace
gasket.
< Remove old seal and install new seal into seal carrier using
BMW special tools
11 1 260 and 00 5 500.
NOTE-
A new radial seal is used from 4/98 production, and is the
only version available from
BMW as a replacement. The
new
sealno longer uses a spring to support the sealing lip.
Do not
lcinlc or damage the sealing lip. Do not touch with
fingers.
* BMW offers the rear main seal carrier and seal in a lit A
plastic support bushing, required for sliding the seal over
the crankshaft, is included with the
lcit.
I CAUTION- 1
Do not use BMW special tool 1 I 2 213 (mstallation guide)
with the new style seal. Use only the special tool
supphed
with the seal lcit.
When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace
gasltet between rear main seal carrier and crank-
case.
Apply thin coat of
3 Bond 8 1209 or equivalent sealant to
oil pan gasket sealing surfaces.
* Lubricate crankshaft seal contact surface.
Use plastic support bushing
(A) that comes with seal ltit as
an installation
quide, fittina seal over end of crankshaft. Use - -
care to push seal carrier and support bushing on straight,
without tilting sideways. Remove support bushing.
- lnstall seal carrier bolts and torque to specifications.
4 Use new bolts (arrows) at base of seal carrier. Coat threads
with sealing compound before installing.
- Install and tighten oil pan bolts.

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I Lubrication System -
- Remainder of assembly is reverse of disassembly.
Install flywheel, clutch or torque converter and
transmission.
Fill engine with oil.
- Run engine and check for leaks.
Tightening torques
Oil
drain plug fo oil pan (MI21 25 Nm (18 ft-lb)
Oil pan to engine
block
M6 (8.8 grade) 10 Nm (89 in-ib)
M6 (1 0.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (1 6 it-lb)
Rear main seal carrier to crankcase
M6 10 Nm (89 in-lb)
ME 22 Nm (16 ft-lb)
Crankshaft rear main seal, replacing (V-8)
- Remove transmission. See 230 Manual Transmission or
240 Automatic Transmission.
- Manual transmission vehicles: Remove clutch pressure plate
and disc. See
210 Clutch.
- Remove flywheel. See 210 Clutch.
- Drain engine oil.
4 Remove bolts (A) retaining rear main seal carrier, including
bolts at (arrows) oil pan.
Carefully separate seal carrier from oil pan gasket and re-
move carrier.
CAUTION-
Do not damage oil pan gasket.
< Remove old seal and reinstall new seal into seal carrier using
) BMW special tools 11 1 230 and 00 5 500.

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- When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace gasitet between rear main seal carrier and
cranlt-
case.
Apply thin coat of
3 Bond 8 1209 or equivalent sealant to
oil pan
gasltet sealing surfaces.
* Lubricate crankshaft and seal contact surfaces.
4 Use BMW special tool 11 2 390 as an installation guide in fit-
ting seal over end of cranltshaft. Use care to push seal carrier
and support bushing on straight, without tilting. Remove in-
stallation guide carefully.
- Replace sealing washers under seal carrier mounting bolts.
- Install seal carrier mounting bolts and torque to specilica-
tions.
- lnstall oil pan bolts.
- Remainder of assembly is reverse of disassembly.
Install flywheel using new bolts,
Install clutch or torque converter and transmission.
* Fill engine with oil.
Run engine and
checlt for leaks.
Tightening torques Flywheel to crankshaft (use new bolts)
120 Nm (89 ft-lb)
011 dra~n plug to 011 pan (M12) 25 Nm (18 ft-lb)
Oil pan to
eng~ne block
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (1 0 9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Rear main seal carrier to crankcase
M6 10 Nrn (89 in-lb)
ME 22 Nm (16 ft-lb)

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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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.
[Lubrication System
< Disconnect electrical harness connector (arrow) at oil level
sensor.
< Remove lower oil pan mounting bolts (arrows)
CAUTIOI\C
If the lowerpan does not separate easily from upperpan, a
few taps with a rubber mallet should break it free. Do
notpry
the oil pan loose.
- When installing oil pan:
Thoroughly clean all old
gasltet material from mating sur-
faces and use a new gasket.
4 Install threaded guide studs at locations marked by arrows
to guide new oil pan
gasltet and oil pan into position and to
prevent damage to sealing lip.
- Install new oil pan mounting bolts (threads coated with
sealer).
Remove guide studs and install remainder of oil pan bolts.
- Remainder of reassembly is reverse of disassembly
- 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 Lower oil pan to upper
oil pan
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (10.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Oil drain plug to oil pan (M12) 25 Nm (18 ft-lb)