2000 BMW 540i Bolt Torque

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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

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210-1 4
1 Clutch
Dowel sleeve I
Check flywheel location
and correct installation. dowel sleeve
(arrow)
for . damage
< When installing dual-rnass flywheel, position dowel sleeve
next to two locating notches (arrows).
- Lightly oil flywheel mounting bolt threads and torque to
specification.
Tightening torque
Flywheel to crankshaft 105 Nm (77 ft-lb)
CAUTIOI\C
Do not reinstall flywheel bolls with LoctiteCTJ or similar thread
locl~ing compound.
- Install transm~ssion as descr~bed in 230 Manual Transmis-
sion.
4 If flywheel was replaced, check pulse sensor (arrow) for cor.
rect installation depth.
- Remove pulse sensor.

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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.

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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)
.-

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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)

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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)

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230-9
Manual ~ransmissionl
Carefully pry out selector shaft oil seal with BMW special tool
23
0 210, or with a narrow seal remover or small screwdriver.
Coat new selector shaft seal with transmission fluid. Drive
new seal in flush with housing. Use
BMW special seal instal-
lation tool
23 0 220 or equivalent and a soft-faced (plastic)
hammer.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new
loclc nuts.
Check transmission oil level, topping up as necessary.
Tightening torques Aluminum driveshaft to flex-disc
. MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft CV joint to final drive flange
MI 0 (Torx bolt) 70
Nm (51 ft-lb)
M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
MI0 (8.8 grade) 48 Nm (35 ft-lb)
MI0 (10.9 grade) 60
Nm (44 it-lb)
MI2 (8.8 grade) 81
Nm (60 ft-lb)
MI2 (10.9 grade) lo0 Nm (74 ft-lb)
- MI4 140 Nm (103 ft-lb)
Transmission crossmember
to transmission (ME) 21 Nm (15 ft-lb)
. to chassis (M10) 42 Nm (30 ft-lb)

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230-1 1
Manual ~ransmissionl
Coat new seal with transmission fluid. Use seal installation
drift (see table below) to drive seal into position until it is flush
with housing.
Output seal drives
Transmission
BMW special tool
Getrag S5D 250G 240110
ZF S5D 3202 23 2 300
inspect sealing surface on output flange. Replace if flange
surface is worn or damaged.
Heat output flange to about 176"
F (80" C) to aid in installa-
tion. This can be done by placing flange in hot water. Rein-
stall output flange to output shaft.
- Coat flange nut with LoctiteB243 and reinstall. Torque in two
stages.
Tightening torques Output flange to output shaft
Stage I 190 Nm (140 ft-lb)
Stage II (after loosening) 120
Nm (89 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Check transmission fluid level, topping up as necessary
Tightening torques Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
. MI0 (Torx bolt) 70
Nm (51 ft-lb)
. M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
- MI0 (8.8 grade) 48
Nm (35 ft-lb)
- MI0 (10.9 grade) 60
Nm (44 It-lb)
. MI2 (8.8 grade) 81 Nm (60 ft-lb)
. MI2 (10.9 grade) I00 Nm (74 It-lb)
M14 140 Nm (103 It-lb)
Transmission crossmember
- to transmission (ME) 21 Nm (15 It-lb)
- to chassis (M10) 42 Nm (30 It-lb)