1999 BMW 540i wheel bolts

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection
Intake air temperature
([AT) sensor,
testing and replacing
Disconnect harness connector from intake air temperature
sensor
(A) at air filter housing.
Turn ignition on. Using a digital voltmeter, check for
5 volts
between supply voltage wire in connector and ground.
If volt-
age is not present, test ECM
inputs/outputs as described lat-
er.
With harness connector disconnected, test resistance across
sensor terminals. If any faults are found, replace IAT sensor.
IAT test resistance
0 lV *lac (50" i-2°F) 7-1 1.6 k.0.
020' kl°C (68' 322°F) 2.1-2.9 it.0.
080" ?lac (176" i-2°F) 0.27-0.40 itn
Auxiliary throttle valve (ADS)
(M62 and M62 TU engine), replacing
ADS components 540i models with ASC and DSC are fitted with a motor-driv-
en auxiliary throttle valve and housing ahead of the standard Throttle position switch throttle housing. The ADS throttle valve controls engine throt-
tle intervention based on signals from the DME control mod-
ule if road conditions, such as slipping driven wheel, warrant
reduced engine power.
ADS throttle housing
Bowden cable NOTE-
Before replacing the ADS throttle housing, read DME fault
ADS lhroltle actualor codes.
- ADS throttle housing replacement:
Switch off ignition and disconnect electrical connector on
ADS throttle body.
Remove hose from idle control valve.
Loosen hose clamps and remove throttle housing air in-
take boot.
Disconnect cable from ADS throttle body.
- Unscrew 3 bolts and remove ADS throttle body.
Installation is reverse of removal.
- Adjust cable so that no free play is present.

Downloaded from www.Manualslib.com manuals search engine
160-22
Fuel Tank and Fuel Pump
4 Working underneath car, pinch off supply and return fuel hos-
es (arrows), then disconnect hoses from rigid metal lines.
- Remove right rear wheel and wheel housing splash shield.
4 Worlting at right rear wheel housing, loosen hose clamp
(arrow) and disconnect filler pipe from tank.
- Support tank from below. Remove tank strap mounting bolts.
Lower and remove tank, disconnecting right side vent and
other
hoses/electrical connectors as necessary.
Always use new seals, gaskets, O-rings, and hose clamps.
lnspect hoses and replace any that are chafed,
dr~ed out or
cracked.
lnspect heat shield and replace if corroded.
Inspect rubber buffers and
hers on fuel tank, support
straps and on underside of body. Replace rubber parts that
are hardened or damaged.
- After finishing repairs but before starting engine, fill fuel tank
with at least
5 liters (1.5 gallons) of fuel.
CAUTlOI+
The fuelpump will be damaged if run without fuel.
* If the filler neck has been removed from the body, be
sure to reattach the
neck grounding screw (where ap-
plicable). Check electrical resistance between the
ground tab and wheel
hub. The resistance should be
no
hiaher than 0.6f2
Tightening torques
Fuel tank to body 23 Nm (17 ft-lb)
Hose clamp
8 -13 mm dia. 2 Nm (18 in-lb)
Hose clamp 13
- 16 mm dia. 3 Nm (27 in-lb)
Hose clamp 42
- 48 mm dia. 4 Nm (36 in-lb)

Downloaded from www.Manualslib.com manuals search engine
21 0-1 2
Clutch
Release bearing
Release
bearin
- lnspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. If any faults are found, replace flywheel as
described later.
- lnspect transmission pilot bearing in end of crankshaft. The
bearing should rotate smoothly without play. If necessary,
replace as described later.
4 lnspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points (arrows).
Clean and lightly lubricate clutch disc splines and transmis-
sion input
shaft splines.
4 Checlc release bearing ball stud and spring retainer. Replace
if damaged or worn.
CAUTION--
On S6S 420G transmission, always replace release bearing
ball stud and retainer spring.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased,
release bearing may stick to it.
Flywheel, removing and installing
(6 cylinder engine)
- lnspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. Replace flywheel if any faults are found.
Lock flywheel with BMW special tool
11 2 170. Remove
pressure plate and clutch disc as described earlier.
- Loosen and remove flywheel mounting bolts. Remove
flywheel.
- Clean flywheel bolt threads in crankshaft.

Downloaded from www.Manualslib.com manuals search engine
Checlc flywheel location dowel
and correct installation. sleeve (arrow) for
damage
4 When installing dual-mass flywheel, position dowel sleeve
next to two locating notches
(arrows).
- Install flywheel using new self-locking bolts,
Tightening torque Flywheel to cranltshaft
(use new self-locking bolts)
120 Nm (89 ft-lb)
Use new self-lock~ng bolls lo rnslall llylvheel Do not reuse llle
old slrelch-lype bolls Do nor rnsrall bolls wrlh Loct~lo@ or srm-
I ilar thread licking compound. 1
Flywheel, removing and installing
(V-8 engine)
- Inspect flywheel for scoring, hot spots, cracks or loose or
worn guide pins. Replace flywheel if any faults are found.
4 Loclcflywheel with BMW special tool 11 2 070. Remove pres-
sure plate and clutch disc as described earlier.
- Use BMW special tool 11 4 180 (Ton. T60) to loosen and re-
move flywheel mounting bolts. Remove flywheel.
- Clean flywheel bolt threads in crankshaft

Downloaded from www.Manualslib.com manuals search engine
21 0-1 6
Clutch
4 Press new bearing into place using BMW special tool
11 2 350 or equivalent driver.
Clutch, installing (non-SAC)
CAUTIOG
Avoidcontaminating clutch friction surfaces with oilorgrease.
Do not touch these surfaces.
4 Center clutch disc on flywheel using centering tool
Clutch Clutch pressure disc plate
Dual mass flywheel -
5-speed transmission: Special tool 21 2 130
- Install flywheel lock, BMW special tool 11 2 170.
4 Install pressure plate and clutch disc to flywheel. Install and
tighten bolts hand-tight.
CAUTIOG
Be sure clutch disc is facing the correct way The disc should
be
marked 'kngine side" or "transmission side':
- Tighten each clutch bolt one turn at a time until pressure
plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
. M8 (8.8 grade) 24 Nrn (18
ft-lb)
- M8 (10.9 grade) 34 Nrn (25 ft-lb)
- Remove clutch disc centering tool.

Downloaded from www.Manualslib.com manuals search engine
21 0-1 8
Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- Install SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques Clutch to flywheel
- M8 (8.8 grade)
MB 110.9 orade)
24 Nm (1 8 it-lb)
34 Nm (25
ft-lb)
Use 14 mm Allen wrench to unscrew (clocltwise or counter-
clockwise) lock plate in center of pressure plate.
NOTE-
The spring lockplate may make snapping noises while being
unscrewed.
Using large bolt, pull out clutch centering tool
Remove flywheel locking tool
4 Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CAUTIOG
Do not grease guide sleeve. Ifguide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- lnstall transmission. See 230 Manual Transmission.
Tightening torques
- - - Transmlsslon to engine -
. MB (Torx) 22
Nm (16 it-lb)
MI0 (Torx) 43 Nm (32 it-lb)
* M12 (Torx) 72 Nm (53 it-lb)
.-

Downloaded from www.Manualslib.com manuals search engine
1 Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- lnstall SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
- M8 (8.8 grade)
M8 (10.9 grade) 24
Nm (18
ft-ib)
34
Nm (25 ft-lb)
- Slip out clutch centering tool using large bolt.
- Remove flywheel locking tool.
Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- Install transmission. See 230 Manual Transmission
Tightening torques
Transmission to engine
- ME (Torx)
. M1O (Torx)
. M12 (Torx) 22
Nm (16 ft-lb)
43
Nm (32 ft-lb)
72
Nm (53 it-lb)

Downloaded from www.Manualslib.com manuals search engine
Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Break in the SAC gradually, with light to medium loads, to en-
sure correct operation and long life. Fast sports driving ma-
neuvers may destroy a new
clutch.The following break-in
procedure helps to create the correct coefficient of friction.
Drive normally on level grade. Starting speeds on level
grade may be up to 2000 rpm.
Upshift and downshift through all the gears at 3500
- 4000
rpm.
On medium grades (approx. 12% and up), start
off at ap-
prox. 2500 rpm for the first 5 or so times.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade)
M8 (10.9 grade) 24
Nm
(18 ft-lb)
34 Nm (25 ft-lb)