2000 BMW 540i warning

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Exhaust system1
Exhaust manifold removal procedures are organized accord-
ing to engine code. If necessary, see
100 Engine-General
for engine code and application information.
Exhaust manifolds, removing and installing
(M52 engine)
4 Exhaust manifolds for the M52 engine.
Always use new retaining nuts and gaskets when removing
and installing the exhaust manifolds.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work under a lined car unless it is solidly supported on
jack stands designed for that purpose. Never work under a
car that is supported solely by a jack.
- Disconnect secondary air check valve and pipe from exhaust
manifold.
- Unbolt front exhaust pipe@) from exhaust rnanifold(s)
- Remove exhaust support bracket from transmission.
- Loosen and remove nuts from exhaust manifolds and remove
manifolds. Discard nuts and gaskets.
NOTE-
On cars with oxygen sensors mounted in the exhaust mani-
folds, use care when removing manifolds.
To be safe, remove
the sensors from the manifolds before removing manifolds.
- Installation is reverse of removal
Coat exhaust manifold mounting studs with copper paste
before installing new nuts.
Install manifold gaskets with arched side facing manifolds.
Tightening torque
Exhaust manifolds
to cylinder head 20 Nm (15 ft-lb)

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180-6
Exhaust System
Exhaust manifolds, removing and installing
(M52 TU and M54 engines)
I Exhaust manifolds with converters I 4 The exhaust manifolds incorporate the catalytic converters.
Two precatalyst and two post-catalyst oxygen sensors are
mounted in the exhaust manifold assembly.
Under normal conditions, the catalytic converters do not re-
quire replacement unless damaged. Always use new retain-
ing nuts and gaskets when removing and installing the
exhaust manifolds.
I\
1 4 Using engine support equipment (BMW special tools 00 0
200. 00 0 201. 00 0 202.00 0 204.00 0 208 or equivalent).
connect to
lifting eye on front of engine. Rhise engine approx.
/I 1
5 mm (IH in).
With exhaust system cold, raise and support car for access
to exhaust system.
WARNING-
Do not worlc undera liftedcar unless it is solidly supported on
jack stands designed for that purpose. Never worlc under
a
car that is supported solely by a jaclc.
in order to avoid damaging oxygen sensors:
- Detach oxygen sensor harness connectors,
Remove oxygen sensors from exhaust manifolds as de-
scribed later in this group.
Unbolt and remove secondary air
checkvalve and pipe from
right front of cylinder headlexhaust manifold.
Working underneath car, unbolt front exhaust pipes from ex.
haust manifolds.
With engine supported from above, remove right engine
mount
bracket and right engine mount (arrow).
Loosen and remove nuts from exhaust manifolds and remove
manifolds. Discard nuts and gaskets.
CA UTIOG
Take care tliat the front and rear oxygen sensor connectors
are not mixed up.
-

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1 Exhaust ~vsteml
NOTE-
The front exhaust manifold must be removed before the rear
manifold.
- Installation is reverse of removal.
Coat exhaust mounting studs with CRC or equivalent cop-
per paste.
Use new gasltets and self-locking nuts.
Tightening torques Exhaust manifold to cylinder head 20 Nm
(15 ft-lb)
Front exhaust pipe to manifold 30 Nm
(22 ft-lb)
Oxygen sensor to manifold 50
Nrn (37 ft-lb)
Exhaust manifolds, removing and installing
(M62 engine)
Always use new retaining nuts and gasltets when removing
and installing the exhaust manifolds.
NOTE-
Access to manifolds is extremely limited. If removing exhaust
manifolds as part of additional engine worlc (such as cylinder
head removal), it may be easier to first remove engine.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work undera lifted car unless it is solidly supported on
jaclt stands designed for the purpose. Never worlc undera car
that is supportedsolely
by a jack.
- Remove exhaust system. See Exhaust system, removing
and installing.
- Removing right side exhaust manifolds (cylinder bank 1-4):
Remove heat baffle plate.
Disconnect plug connection to oxygen sensor.
securing exhaust manifolds to head.
Remove manifolds towards bottom.
- Installation is the reverse of removal.
Coat exhaust mounting studs with CRC or equivalent
copper paste.
Use new gasltets and self-loclting nuts.

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-- -
Exhaust System
Oxygen sensors (precatalyst), replacing
(M52 TU and M54)
The precatalyst oxygen sensors are installed at the top of the
exhaust manifolds.
WARNING-
Allow components to cool before servicing.
- Using BMW scan tool DlSplus (Diagnostic Information Sys-
tem) or equivalent, read out and clear ECM fault codes.
Working at right side of engine above exhaust manifolds,
remove front or rear oxygen sensor harness connector
(arrows) from bracket, then separate plug.
NOTE-
In photo, secondary air pump has been removed for clarity.
Remove oxygen sensor using special oxygen sensor
removal socket.
Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing a sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
- -.
Oxygen sensor to manifold 50 Nm (37 ft-lb)
Oxygen sensors (post-catalyst), replacing
(M52 TU and M54)
The post-catalyst oxygen sensors are installed at the rear of
the catalytic converters.
WARNING-
Allow components to cool before servicing
- Using BMW scan tool DlSplus or equivalent, read out and
clear ECM fault codes.
- Remove large cover from above fuel raillintake manifold.

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Exhaust System
Label and disconnect sensor harness connectors (arrows).
CAUTlOI\C
Label connectors so that front and rear connectors are not
mixed up.
- Detach harness from guides and brackets.
- Remove oxygen sensor from exhaust manifold using special
tool
11 7 030 or equivalent.
- Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing old sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
Oxygen sensor to manifold 50 Nm (37 ft-lb)
Oxygen sensor, replacing
(M52 and M62 engine)
The sensors are installed at the front and rear of the catalytic
converters.
I WARNING- I
I Allow components to cool before servicing. I
Using BMW scan tool DlSplus or equivalent, read out and
clear
ECM fault codes.
Detach harness from guides and brackets.
Remove oxygen sensors (arrows) from exhaust using spe-
cial tool
ll 7 030 or equivalent.
Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing a sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
Oxvaen sensor to manifold 50 Nm (37 it-lb)

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Anach pressure brake bleeder to fluid reservoir and pump
bleeder a few times to pressurize hydraulic fluid system.
CAUTION-
* Do not exceed 2 bar (29 psi) pressure at the fluid resenfoil
when bleeding or flushing the hydraulic system.
Brake fluid is poisonous, highly corrosive and danger-
ous to the environment. Wear safety glasses and
rub-
bergloves when working with brake fluid. Do not siphon
brale fluid with your mouth. Immediately clean away
any fluid spilled on painted surfaces and wash with wa-
ter, as brale fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container.
Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the clutch and
brake hydraulic systems, ;nd will also lower the brake
fluid boiling point. Dispose of brale fluid properly.
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor
iack is not adequate support.
- If necessary, remove transmission splash shield.
Hydraulic system, bleeding
Worlting underneath transmission, connect a hose from
clutch slave cylinder bleeder valve
(arrow) to a container.
Open bleeder valve and allow bralte fluid to expel until
clean fluid comes out, free of air bubbles.
Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly operate clutch pedal about
10 times. Fill reservoir
with clean fluid as necessary.
CR* .,,, .rP,ll,h.:I,,~,~mn.lI","i,,i"

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- Raise and safely support vehicle
WARNING-
Make sure the car is stable and well supporied at all times.
Use a professional automotive /iff orjack stands designed for
the
ournose. A floor jack is not adeouate suooort.
- If necessary, remove transmission splash shield.
- Disconnect fluid line from slave cylinder on lefl side of trans-
mission. Place pan under hose to catch dripping fluid.
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder.
- Installation is reverse of removal, noting the following:
Check for wear on slave cylinder. Any wear except on tip is
caused by misalignment of clutch components.
Lightly coat
pushrod tip with molybdenum disulfide grease
(MolyltoteIB Longterm or equivalent).
. During installation be sure pushrod tip engages recess in
clutch release lever.
Fill fluid reservoir with clean fluid.
. Bleed clutch hydraulics as described earlier.
Tightening
toraues - -.
Clutch slave cylinder to transmission 22 Nm (16 R-lb)
Fluid line to slave cylinder 17 Nm (13 ft-lb)
The transmission must be removed from the engine to access
the clutch mechanical components. It is recommended that
the clutch disc, pressure plate and release bearing be re-
placed during a clutch overhaul.
Besure tocheck the bottom of the bellhousing foroil. If engine
oil is found, check for a faulty rear crankshaft main oil seal.
See
119 Lubrication for rear main seal replacement.
Clutch variations
Two versions of the clutch are used:
1997 528i (6 cylinder) uses traditional clutch components.
All
540i (V-8) and 1998 and later 6 cylinder models from
use a self-adjusting clutch (SAC).

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Clutch, removing
The procedure given here applies to both non-SAC and SAC
clutch assemblies.
- Remove transmission from engine. See 230 Manual Trans-
mission.
4 Loosen 6 clutch mounting bolts (arrows) evenly
- Remove pressure plate and clutch disc.
WARNING-
The clutch disc contains asbestos. Inhaling or ingesting as-
bestos dust can cause severe health problems. Always wear
an approved respiratorandprotective clothing when handling
components containing asbestos. Do not use compressed
air to clean components. Do not
grind, heat, weld, or sand on
or near anv asbestos materials.
Pull release bearing off transmission input shaft. Remove
clutch release lever by sliding it out of spring clip in direction
of arrow.
Clutch components, inspecting
- Inspect clutch disc for wear, cracks, loose rivets, contamina-
tion or excessive
runout (warping). Replace if necessary.
- Measure clutch disc lining thickness at shallowest rivet head. 7
Clutch and pressure plate wear limits
Minimum clutch disc lining thickness (at rivets)
1.0
mm (0.04 in) - Maxtmum lateral runout
(d~aphragm sprtngs to pressure plate) 0 6 mm (0 02 in)