2000 BMW 540i Light

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--. ..
Rear Suspension
4 Remove wheel bearing assembly.
4 Remove inner wheel bearing race with BMW special tools 33
1 312
and 00 7 500 or equivalent.
- Install new wheel bearing assembly. Malte sure mounting
surfaces are free of dirt and grease.
Tightening torques
Wheel bearing to wheel bearing carrier (use new
Tom bolts)
Stage
1 30 Nm (22 ft-lb)
Stage 2 90" torque angle
4 Reinstall wheel hub.
Lightly oil wheel bearing and axle shaft contact surfaces on
wheel hub.
Use BMW special tools
33 2 115,33 2 116 and 33 2 118
or equivalent press tools to press wheel hub to bearing.
CAUTION-
BMWspecifies speclaltools to pull the wheel hub through the
wheel bearing into position. If using alternative tools, be sure
to support the bearing inner race when pressing orpulling the
hub into place.
- Lightly oil the bearing surface of the axle collar nut and install.
Tighten collar nut firmly, but do not fully tighten it at this time.
WARNING-
For safety reasons, the axle collar nut should only be tight-
ened to its final torque with the wheel installed and the car
lowered to the ground. However, loading the bearing without
the nut tightened sufficiently may damage
the bearing.

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331-12
Final Drive Final drive cover, removing and installing
- Remove final drive. See Final drive, removing and install-
ing.
I 1 4 Remove fasteners (arrows) from rear cover and remove cov-
er.
Clean cover and final drive housing sealing surfaces.
Install new
gasket with cover.
* Installation is reverse of removal.
- Check differential oil level. See Differential oil level, check-
ing.
Tightening
torque
Final drive cover to final drive housing
. M10 (8.8 grade) 45 Nm (33 ft-lb)
M10 (10.9 grade) 90 Nm (66 ft-lb)
Final drive mounts, replacing
- Remove final drive. See Final drive, removing and install-
ing.
Rear final drive mounts
- Remove rear final drive rubber mounts using BMW special
tools333314,333315,334 181, and334 183.
4 Coat new mount with CircolightB anti-friction agent and in-
.
stall, noting the following:
Long bushing on mount must face forward (arrow).
A shows installation position of mounts.

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Final Drive
Front final drive mount
4 Remove front final drive mount using BMW special tools 33
3312,333314, 333315,334161
and334162.
I i 4 Coat bearing sleeve in rear axle carrier and rubber mount
with
~ircolight~ anti-friction agent.
Slide rubber mount from side with large diameter into
BMW special tool 33
4 165.
Milled recess
(A) makes firm contact with rear axle carrier
when top rubber mount is tightened down.
The
slolled srde ot r11e rubber mounl must be ar r#ghl angles
lo
rhe groove rn specal roo/ 33 '1 165 and shoulo be lrghrened
I down ~ransversely across the vehicle axis. I
Draw rubber mount in firmly with BMW special tools 33 3
314,333315,334164,334165and334166.
NOTE-
Male sure special tool 33 4 166 is properly seated.
0 Rubber mount must locate flush in rear axle carrier. If nec-
essary, rotate special tool
33 4 164 through 90" and draw
in overlap.
- Remainder of installation is reverse of removal

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Final ~rivel
4 Remove staked collar nut and press output shafl out of wheel
hub with special
BMW tool 33 2 111/116/117.
- Remove drive axle.
- Installation is reverse of removal, noting the following:
Use a new collar nut.
a Apply a light coating of oil to contact face of collar nut and
install it loosely.
* Install road wheel and lower car to ground.
- With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening torques
-
Drive axle collar nut to drive flange M27 300 Nrn (221 ft-lb)
Drive axle to differential flange
* M10x20 rnm black Torx bolt
83 Nrn (61 ft-lb)
M10x20 rnrn silver Torx bolt
100 Nrn (74 ft-lb)
Road wheel to hub 120 Nrn f 10 (89 ft-lbf7)
Drive axle, removing and installing
(Sport Wagon)
4 With an assistant applying brakes, brealc free staked collar
nut (arrow) at center of rear wheel hub. Do not remove com-
pletely.
NOJE-
The drive flange collar nut is tightened to a torque of over 300
Nm (221 ft-lb). Make sure the car is firmly on the ground.
WARNING -
Disable airsupply pump (if applicable) by disconnecting elec-
tricalplug before performing any repairs. Pump is located be-
neath a cover under the spare tire
in the floor of the cargo
compartment.
- Raise rear of car. Remove rear wheel.
WARNING -
Malce sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the jack stands beneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Models with rear coil springs: Remove cargo compartment
floor carpet.

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331-17
Final ~rivel
4 Remove staked collar nut and press output shaft out of wheel
hub with special
BMW tool 33 2 11 111 161117.
- Remove drive axle
- Installation is reverse of removal, noting the following:
* Use a new collar nut.
- Apply a light coating of oil to contact face of collar nut and
install it loosely.
Install road wheel and lower car to ground.
* With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening
torques
Drive axle collar nut to drive flange M24
300 Nrn (221 ft-lb)
Drive axle collar nut to drive flange M27
300 Nrn (221 ft-lb)
Drive axle to differential flange
M10x20 rnrn blaclc Torx bolt 83 Nrn (61 it-lb)
- M10x20 rnrn silver Torx bolt loo Nrn (74 ft-lb)
Road wheel to hub
120 Nrn+lO (89tt-lbi-7)
CV joint boots
NOTE-
When replacing a CVjoint boot, use a complete CVjoint
boot repair kit. The lit will include a new boot, clamping
bands, special lubricant, and a new inner CV joint circlip.
The lit is available from an authorized
BMW dealerparts
department.
The outer CVjoint cannot be removed from the axle
shaft
In order to replace the outer CV boot, it is necessary to re-
move the inner joint and boot first.
If the
CVjoints are worn or defective, a complete rebuilt
axle shaft is available from an authorized
BMW dealer
parts department.
- Remove appropriate axle shaft. See Drive axle, removing
and installing (sedan), or Drive axle, removing and in-
stalling (Sport Wagon).
- Working with axle shaft at bench, cut off old boot clamps and
remove boot. Clean old grease off joint and shaft. Use new
grease from CV joint boot kit.
4 Remove dust cover from CV joint and remove circlip (arrow)
retaining joint inner hub to axle shaft.

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340-6
1 Brakes
Brake system troubleshooting
/symptom I Probable cause 1 Repairs
Brake squeal
Pedal goes to floor when
bralting
Low pedal after system bleeding
Pedal spongy or brakes work
only when pedal is pumped
Excessive braking effort
Brakes pulsate, chatter or grab
Uneven
bralting, car pulls to one
side, rear braltes
loclt
Brakes drag, bind or overheat Brake
pad carriers dirty or corroded or
pads loose (poor fit) in pad carrier
Braite pads heat-glazed or oil-soaked
Wheel bearings worn (noise most
pronounced when turning)
Incorrectly Installed brake pads,
parking bralte shoes, or bralte parts
Brake fluid loss due to system leaks
Master cylinder or traction control
system faulty
Master cylinder faulty
Air in braite fluid
Master cylinder or traction control
system faulty
Brake pads wet
Brake pads
heat-glazedorfluid-soalted
Vacuum booster or vacuum hose
connections to booster faulty
--- Warped brake rotors
Brake pads worn
Brake pads heat-glazed or oil-soaked Remove
brake pads and clean calipers. Use original
equipment pads for proper fit and use BMW anti-squeal
compound during installation,
Replace brake pads. Ciean rotors. Replace leaking caliper:
as required.
Replace worn bearings. See 310 Front Suspension
or33C
Rear Suspension.
Check component installation. Checldreplace anti-rattle
springs.
Checlt fluid level and inspect for signs of leakage.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Replace master cylinder.
Bleed system using factory or compatible diagnostic tool.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Use light pedal pressure to dry pads while driving.
Replace
bralte pads and rotors. Replace leaking calipers.
lnspect vacuum lines. Test vacuum booster and replace as
required. Test vacuum non-return valve for one-way flow.
Resurface or replace rotors.
Replace brake pads.
Clean rotors. Replace leaiting calipers.
Incorrect tire pressures or worn tires
Brake pads on one side of car heat-
glazed or fluid-soaked
Caliper or brake pads binding
Worn suspension components
Brake caliper or brake pads binding
Master cylinder or traction control
system faulty lnspect
tire condition. Checlt and correct tire pressures.
Replace brake pads. Clean rotors. Replace leaking
calipers.
Clean and recondition brakes.
Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Ciean or replace caliper.
Replace master cylinder. Diagnose traction control system
using faclory or compatible diagnostic tool.

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340-1 4
Brakes
4 Apply a thin coating of BMW anti-squeal compound to caliper
contact face
(arrow).
Do not apply grease to brake pad backing plate.
Right Left
CAUTION-
Do not let calliper rubber dust sleeve come in contact with
anti-squeal compound. The rubber will swell and deteriorate.
4 Apply a thin coating of BMW anti-squeal compound to bralte
pad rests (arrows) on pad carrier.
4 When installing directional brake pads, install the marked
pads as shown.
NOTE-
BMW-supplied (OEM) front brake pads may be marked as di-
rectionalpads. Aftermarket brands are generally not labeled
as directional. When installing directional pads, be sure to in-
stall them as indicated in the illustration.
- Where applicable, insert brake pad wear sensor into cutout
in new pad. Push sensor into pad cutout until it locks into
place.
- -
- NOTE-
If brake lining indicator light illuminatedprior to brake pad re-
placement, replace wear sensor.
- Route pad wear sensor wiring through caliper opening and
under bleeder dust cap.

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340-1 5
Brakes
- Remainder of installation is reverse of removal.
- Clean brake caliper mounting bolts (7 mm Allen). Replace
ones which are not in perfect condition. Do not grease.
Top up brake fluid to MAX marking.
- Before driving car, pump bralte pedal several times so that
brake pads contact brake rotors.
Check that brake fluid level is correct. Top up if necessary.
Hold ignition key for at least
30 seconds in accessory po-
sition without starting engine. This clears any fault codes in
memory and turns off brake pad warning light.
Tightening torques Brake caliper to pad carrier
(7 mm Allen)
Front caliper
30 Nm (22 It-lb)
- Rear caliper 28 Nm (21 It-lb)
Road wheel to hub
120i 10 Nm (89i7 ft-lb)
Brake rotors, removing and installing
- Raise car and remove wheels
WARNING-
Male sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
Remove brake caliper carrier bolts (arrows). Suspend brake
caliper from chassis using stiff wire.
NOTE-
Hydraulic brake line remains connected.
4 Remove bralte rotor mounting screw (arrow) and remove ro-
tor.
- Inspect rotor for cracks, signs of overheating and scoring.
- Minimum allowable thickness (MIN TH) is stamped on rotor
hub. Measure rotor braking surface with a micrometer at
eight to ten different points and use the smallest measure-
ment. Compare to specifications in table below.
- If rotor does not pass minimum thickness requirements or is
damaged, replace rotor.