2000 BMW 540i clutch

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Radiator and Cooling systeml
Tightening torques
Block drain plug to block 25 Nm
(18
it-lb)
Coolant hose clamp (32 - 48 2.
5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator
2-3Nm(l8-27in-lb)
Thermostat housing to cylinder
head 10 Nm (89 in-lb)
I Coolant thermostat housing assmbly- - I
Thermostat, removing and installing
(M52 TU or M54 engine)
4 The electric map-controlled thermostat is part of the thermo-
stat housing at the front of the cylinder head.
1. Bolts (M6)
2 Bolt (ME)
3. Housing with thermostat
4. Gasket
- If a faulty thermostat is suspected, use appropriate scan tool
to interrogate
ECM for stored fault codes.
- Drain radiator and engine block. See Coolant, draining and
filling (6-cylinder models).
CAUTION-
Allow cooling system to cool before opening or draining the
system.
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Disconnect electrical harness connector from thermostat
housina.
4 Lever out retaining clips (arrows) and pull hose fittings off
thermostat housing.
- Unbolt and remove thermostat housing from front of engine.
Loosen nut at top of engine lifting eye to facilitate removal.
- Installation is reverse of removal, noting the following:
Keep sealing faces free of oil.
* Use new sealing gasket.
When reinstalling hose to thermostat housing, install clip
on hose end fitting, then push hose onto housing until it
clicks into place.
Fill system with coolant. See Coolant, draining and fill-
ing (6-cylinder models).

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Tightening torques Block drain plug to block
25 Nm (18 ft-lb)
Radiator drain plug to radiator 2 - 3 Nm (18 - 27 in-lb)
Thermostat housing to
cylinder head 10 Nm (89 in-lb)
Thermostat, removing and installing
(V-8 models)
The electrically-heated thermostat is an integral parl of the
thermostat housing. The operation of the thermostat is moni-
tored by the engine control module (ECM).
- If a faulty thermostat is suspected, use appropriate scan tool
to interrogate ECM for stored fault codes.
- Drain radiator and engine block. See Coolant, draining and
filling
(V-8 models).
WARNING -
Allow cooling system to cool before opening or draining the
system.
- Disconnect mass air flow (MAF) sensor electrical harness
connector. Remove air intake duct together with MAF sensor.
- Remove mechanical cooltng fan and fan shroud. See Me-
chanical (viscous clutch) cooling fan, removing and
in-
stalling.
Disconnect electrical harness connector (arrow) from ther-
mostat housing.
Remove coolant hose from thermostat housing.
NOTE-
M62 engine: Hose is clamped on.
M62 TU engine: Hose is attached with quick-disconnect fit.
ting. Remove clip to disconnect hose.

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170-1 9
Radiator and Cooling System
Coolant pump Remove thermostat housing fasteners
(arrows) and remove
thermostat housing.
Installation is reverse of removal, noting the following:
- Keep sealing faces clean and free of oil.
Use new sealing gasket.
Fill system with coolant. See Coolant, draining and fill-
ing
(V-8 models).
Tightening torques
Block drain plug to block 25 Nm (18 it-lb)
Coolant hose clamp (32
- 48 2. 5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator 2
- 3 Nm (18 - 27 In-lb)
Thermostat cover to
coolant pump 10 Nm (89 in-lb)
Coolant pump, replacing (6-cylinder
models)
< The engine coolant pump is mounted in the front of the en-
gine in the timing chain cover.
- Drain cooling system as described earlier. See Coolant,
draining and filling (6-cylinder models).
WARNING-
Allow cooling system to cool before opening or draining sys-
tem.
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Remove coolant pump drive belt. See 020 Maintenance.
4 Remove coolant pump pulley bolts (arrows) and remove pul-
ley from pump.
- Remove nuts retaining pump to engine block.
NOTE-
The coolant pump is mounted on studs and retained by nuts.

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.," --
Radiator and Cooling System --- 1
insert two M6 screws (arrows) in tapped bores and tighten
uniformly until pump is free from timing chain cover (thermo-
stat and hoses have been removed for purposes of visual
clarity).
Installation is reverse of removal, noting the following:
Be sure to replace sealing O-ring and gaskets.
Coat O-ring with water-based lubricant during installation.
Refill with coolant. See Coolant, draining and filling
(6-
cylinder models).
Tightening torques
-
Coolant pump to timing chain 10 Nm (89 in-lb)
cover
Coolant pump pulley to coolant
10 Nm (89 in-lb
pump
Engine block drain plug to block 25 Nm (1 8 It-lb)
Radiator drain plug to radiator 2 - 3 Nm (I8 - 27 in-lb)
Coolant pump, replacing (V-8 models)
I 1 < The engine coolant pump is mounted in the front of the en-
gine in ;he timing chain cover.
1. Thermostat housing
2. Thermostat
3. Thermostat sealing O-ring
4. Water pump
5. Water pump gasket
- Drain cooling system. See Coolant, draining and filling (V-
8 models).
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Remove engine drive belts: See 020 Maintenance.
NOTE-
Mark direction of drive belt rotation if reusing belt,
- Remove vibration dampener. See 117 Camshaft and Tim-
ing Chain.
- Disconnect mass air flow (MAF) sensor electrical harness
connector. Remove air intake duct together with
MAF sensor.
- Disconnect coolant hoses from thermostat housing and cool-
ant pump housing.

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. --
Radiator and Cooling system/
4 Pry out expansion rivets (A) on left and right side of fan
shroud. Loosen hose clamp
(6) and remove hose from ex-
pansion tank.
Remove expansion tank: Remove expansion tanlc cap, vent plug
(A) and tank retain-
ing clips (arrows).
Lift expansion
tanlc upward and off lower retaining lugs.
Push shroud back to expose expansion tank vent line. Re-
move line.
Using 32 mm wrench
(BMW special tool 11 5 040) on fan
clutch nut (arrow), turn wrench in a clockwise direction
(working from front of car) while counterholding pulley with
BMW special tool 11 5 030. Spin fan off coolant pump.
NOTE-
The radiator cooling fan nut (32 mrn wrench) has left-hand
threads.
Disconnect electrical harnesses from
AUC (air quality) sen-
sor and coolant level sensor.

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This repair group covers general application information for
the clutch, manual and automatic transmissions, shift linkag-
es and driveshaft.
Drivetrain
I ZF manual transmission I
BMW E39 models are equipped with a longitudinal drivetrain.
The transmission is bolted directly to the rear of the engine.
A
driveshaft connects the output shaft of the transmission to the
rear final drive. Individual drive axles with integrated constant
velocity joints transfer rotational power from the final drive
unit to the rear wheels.
4 Due to different power characteristics and performance re-
quirements, various manual transmissions are used in mod-
els covered by this manual. Manual transmission
applications are given in the table below.
For manual transmission specifications or repair procedures,
refer to
230 Manual Transmission.
Manual transmission models use a single disc clutch with
dual-mass flywheel. For further information, see
210 Clutch.
The manual transmission metal ID plate is mounted on side of
transmission. Do not rely on numbers cast on transmission
case for identification.
Manual transmission applications
Model Year Engine Transmission
5251 2001 - 2002 M52TU, M54 Getrag S5D 250G
528i 1997-2002 M52 ZF S5D 3202

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210 Clutch
........................... General .21 0.2
........................ Special tools .21 0.2
Clutch Hydraulics ................. .21 0.4
Clutch hydraulic system.
bleeding and flushing
................. .21 0.4
Clutch master cylinder. replacing
........ .21 0.6
Clutch slave cylinder. replacing ......... .21 0.8 Flywheel. removing
and installing
................... (6 cylinder engine) 210-12
Flywheel. removing and installing
(V-8 engine) ....................... 21 0-1 3
Transmission pilot bearing. replacing .... 210-1 5
Clutch. installing (non-SAC components) . 210-1 6
Clutch. installing (new SAC components)
. 21 0-17
Clutch.
install in^ (used SAC components) 210-19
Clutch Mechanical ................. .21 0.9 self-adjusting crutch (SAC). breaking in : . 210-21
..................... Clutch variations .21 0.9
................... Clutch. removing .21 0.1 1
Clutch components. inspecting
........ .21 0.1 1

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1 Clutch
This repair group covers replacement of clutch mechanical
and hydraulic components.
BMW 5 Series models with manual transmission use a single
disc hydraulically actuated clutch.
Twoversions of the clutch
are used:
1997
5281 (6 cylinder) uses traditional clutch components.
All 540i (V-8) and 1998 and later
6 cylinder models use a
self-adjusting clutch (SAC).
NOTE-
See 200 Transmission-General for transmission applica-
tion information.
Special tools
Some special tools and techniques are required for clutch re-
pairs. Be sure to read a procedure through before beginning a
job.
< Flywheel loclting tool (V-8 models)
1 (Tool NO. 11 2 070)
-
4 Flywheel loclting tool (6 cylinder models)
(Tool No. 1 1 2 170)
- < Pilot bearino removal tools
11 11 2350 < pilot bearing instaation
(Tool No. 11 2 350) tool