BMW 3 Series Service Manual (E39)
.pdf-Raise and safely support vehicle
WARNING-
Make sure the car is stable and well supporiedat all times. Usea professionalautomotive /iff orjack stands designedfor 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 transmission. 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. |
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.Bleed clutch hydraulics as described earlier. |
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Tightening toraues |
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Clutch slave cylinder to transmission |
22 Nm (16 R-lb) |
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Fluid line to slave cylinder |
17 Nm (13 ft-lb) |
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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 replaced during a clutch overhaul.
Besuretocheck 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).
210-10
Clutch
Installingthe non-SAC clutch (1997 5281model) requires the use of only a flywheel lock and traditional clutch disc alignment tool.
Installing the self-adjusting clutch (SAC) requires several special tools for aligning and assembling the clutch, as well as locking the flywheel in place. In addition, the procedure for reinstalling a previously used SAC differs from the procedure for installing a new SAC. Be sure to read the SAC installation procedure through before starting the job.
The pressure plate of the SAC uses a spring-loaded wedge rino to cornoensate for clutch disc wear. The wedge ring ad- ;u$s by means of spr'ngtenson, so specal t o o l s h ~ sbet used to appy and relieve spring tension as the c utch pressure plate is installed.
Self adjusting clutch (SAC) and clutch hydraulics
Checlc flywheel location dowel sleeve (arrow) for damage and correct installation.
4 When installing dual-mass flywheel, position dowel sleeve next to two locating notches (arrows).
-Install flywheel using new self-locking bolts,
Tightening torque |
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Flywheel to cranltshaft |
120 Nm (89 ft-lb) |
(use new self-locking bolts) |
Usenewself-lock~ngbolls lo rnslallllylvheel Donotreuse llle |
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oldslrelch-lype bolls Do nor rnsrallbolls wrlh Loct~lo@or srm- |
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I ilar thread licking compound. |
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 112 070. Remove pressure plate and clutch disc as described earlier.
-Use BMW special tool 114 180 (Ton. T60)to loosen and remove flywheel mounting bolts. Remove flywheel.
-Clean flywheel bolt threads in crankshaft
210-14
1Clutch
Check flywheel location dowel sleeve (arrow) for. damage and correct installation.
Dowel sleeve |
I <When installing dual-rnass flywheel, position dowel sleeve |
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next to two locating notches (arrows). |
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- Lightly oil flywheel mounting bolt threads and torque to |
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specification. |
Tightening torque
Flywheel to crankshaft |
105 Nm (77 ft-lb) |
CAUTIOI\C
Do not reinstall flywheelbolls with LoctiteCTJor similar thread locl~ingcompound.
-Install transm~ssionas descr~bedin 230 Manual Transmission.
4 If flywheel was replaced, check pulse sensor (arrow) for cor. rect installation depth.
-Remove pulse sensor.
Clutch
-Remove flywheel locking tool
4 Inspect and clean release bearing lever. Apply a thin coat of grease to release bearing lever lubrication points. Install release bearing. Bearing tabs (A) align with contact points (B) on release lever.
CAUTION-
Do not grease release bearingguide sleeve. Ifguide sleeve isgreased, release bearingmay stick to it.
-Clean and lightly lubricate clutch disc splines and transmission input shaft splines.
-Install transmission. See 230 Manual Transmission
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Transmission to engine |
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MB (Torx) |
22 Nm (16 fl-lb) |
MlO(Torx) |
43 Nm (32fl-lb) |
Clutch, installing (new SAC components)
V-8 models and 1998 and later 6 cylinder models are equipped with the self-adjustingclutch (SAC) pressureplate. The SAC pressure plate, when new, comes from the factory with a lock plate at the center which maintains spring tension on the self-adjusting springs.This loclting ring must not be removed until the pressure plate is securely installed on tlie flywheel with the clutch disk in place.
CAUTION-
Avoidcontaminatingclutchfrictionsurfaces with oilorgrease. Do not touch these surfaces.
<Center clutch disc on flywheel using centering tool.
-5-speed transmission: Special tool 21 2 142
6-speed transmission: Special tool 21 2 141 G6S-3782 transmission: Special tool 21 2 201
CAUTION-
Be sure clutch disc is facing the correct way The disc should be marked "engine side" or "transmissionside':
The large bolt in the clutch disc centering tool is usedto installandremove the tool only. Once the disc is inplace on the eel, remove the bolt to male room for tlie SACpressure