5 Series E34 540i Saloon (M60-2): 2 Repair Instructions
Also for this vehicle: 5 Series E34 518g (M43) TOUR, 5 Series E34 518i (M40) SAL, 5 Series E34 518i (M40) TOUR, 5 Series E34 518i (M43) SAL, 5 Series E34 518i (M43) TOUR, 5 Series E34 520i (M20) SAL, 5 Series E34 520i (M50) SAL, 5 Series E34 520i (M50) TOUR, 5 Series E34 524td (M21) SAL, 5 Series E34 525i (M20) SAL, 5 Series E34 525i (M50) SAL, 5 Series E34 525i (M50) TOUR, 5 Series E34 525ix (M50) SAL, 5 Series E34 525ix (M50) TOUR, 5 Series E34 525td (M51) SAL, 5 Series E34 525td (M51) TOUR, 5 Series E34 525tds (M51) SAL, 5 Series E34 525tds (M51) TOUR, 5 Series E34 530i (M30) SAL, 5 Series E34 530i (M60-1) SAL, 5 Series E34 530i (M60-1) TOUR, 5 Series E34 535i (M30) SAL, 5 Series E34 540i (M60-2) TOUR, 5 Series E34 M5 (S38) SAL, 5 Series E34 M5 (S38) TOUR.
Maintenance
General
Diagnostics
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
0 Maintenance And General Data27 pages
- 1 RA Pre-delivery Check2345
- 2 RA Lifting Vehicle With A Lifting Platform
- 3 RA Notes On Using Repair Instructions, Technical Data, Tightening Torques
- 4 RA Symbols Used And Information In Repair Instructions2
- 5 RA Battery_ Check Display (magic Eye); If Necessary, Recharge Battery
- 6 RA Body And Underbody_ Checking For Corrosion And Damage
- 7 RA Information_warning Labels23
- 8 RA Microencapsulated Screws
- 9 RA Raising BMW Multi-trailer23
- 10 RA Upkeep Measures For Stored Vehicles (new And Used Cars) And Vehicles To Be Laid23
- 11 RA BMW Engine Oil Service (M60 _ M62 _ M73)2
- 12 RA Oil Change In Manual Transmission
- 13 RA Notes On Handling Wiring Harnesses And Cables
- 14 RA Positioning Of Multitrailer Hood For Maintenance And Repair Work2
11 Engine (M60-2)145 pages
12 Cylinder Head With Cover32 pages
- 1 RA Removing And Installing_sealing Both Cylinder Head Covers (M60)234
- 2 RA Removing And Installing Left Cylinder Head (M60)234567891011
- 3 RA Removing And Installing Right Cylinder Head (M60)2345678910
- 4 RA Dismantling And Reassembling Cylinder Head (M60)2
- 5 RA Reworking One Valve Seat (M60)
- 6 RA Checking One Valve Guide For Wear (M60)
- 7 RA Reaming Out One Valve Guide (M60)
- 8 RA Milling Down Cylinder Head Gasketing Face (M60)
- 9 RA Checking Cylinder Head For Water Leaks (M60)
14 Housing Cover15 pages
- 1 RA Removing And Installing _ Sealing Or Replacing Top Left Timing Case Cover (M60)2345
- 2 RA Removing And Installing_sealing Or Replacing Top Right Timing Case Cover (M60)23
- 3 RA Removing And Installing_sealing Or Replacing Timing Case Cover At Bottom (M60)23
- 4 RA Replacing Radial Seal Below Timing Case Cover (M60)
- 5 RA Replacing Crankshaft Radial Sealing Ring (M60)23
- 22 Flywheel › 1 RA Removing And Installing_replacing Flywheel (M60)2
- 24 Connecting Rod With Bearing › 1 RA Replacing All Conrod Bearings2
25 Piston With Rings And Pin7 pages
28 V-ribbed Belt W.tens.-deflect.elemt3 pages
- 40 Oil Supply › 1 RA Checking Engine Oil Pressure2
- 41 Oil Pump With Filter And Drive › 1 RA Removing And Installing_replacing Oil Pump (M60)234
- 51 Water Pump With Drive › 1 RA Removing And Installing Or Replacing Water Pump2
- 52 Fan › 1 RA Removing And Installing Or Replacing Fan Coupling
- 53 Thermostat And Connections › 1 RA Removing And Installing Or Replacing Coolant Thermostat
- 62 Exhaust Manifold › 1 RA Removing And Installing _ Replacing Both Right Exhaust Manifolds (M60)
- 71 Exhaust Gas Recirculation › 1 RA Removing And Installing Or Replacing EGR Cooler (N47)2
- 72 Air Pump, Lines And Control Valves › 1 RA Removing And Installing _ Sealing Or Replacing Tubes For Secondary Air Induction2
- 78 Emission Control, Oxygen Sensor › 1 RA Replacing Oxygen Sensor (M60)
12 Engine Electrical System (M60-2)75 pages
0 Troubleshooting8 pages
- 1 RA Contents Of Engine Electrical System General
- 2 RA Instructions For Disconnecting And Connecting Battery23
- 3 RA Instructions For Removing And Installing Electronic Control Units
- 4 RA Instructions For Working On The Ignition System
- 5 RA Notes On Checking Ignition System
- 6 RA Notes On Handling Wiring Harnesses And Cables
- 12 Ignition Wires, Spark Plugs › 1 RA Replacing All Spark Plugs (M60, M62)
13 Ignition Coil15 pages
- 1 RA Notes On Checking Ignition System
- 2 RA Checking Secondary Signal For Stationary Ignition Distribution
- 3 RA Normal Oscillogram (M, S, W Engines Only)2
- 4 RA Checking Ignition Coils (M60, M62, S62)234
- 5 RA Checking Ignition Coils (secondary Coil)23
- 6 RA Replacing Ignition Coil (M60, M62)23
- 7 RA Replacing A Spark Plug Connector (M60, M62, M54)
14 Electronic Switching Or Contr.units10 pages
- 1 RA Replacing Impulse Sensor (M60)2
- 2 RA Replacing Sensor For Cylinder Recognition (camshaft Sensor) (M60, M62)2
- 3 RA Replacing Right Knock Sensors (cylinder Bank 1 To 4) (M60, M62)2
- 4 RA Replacing Left Knock Sensors (cylinder Bank 5 To 8) (M60, M62)2
- 5 RA Coding Control Module (DME _ DDE)
- 6 RA Programming Control Unit (DME _ DDE)
32 Regulator4 pages
41 Starter With Mounting4 pages
- 51 Engine Wiring Loom › 1 RA Replacing Wiring Harness Section For Engine (M60, M62)23456789
61 Oil Pressure-oil Temperature-oil Gauge3 pages
13 Fuel System (M60-2)40 pages
31 Fuel Pump With Drive And Line6 pages
- 41 Speed Governor › 1 RA Replacing Idle Speed Control Valve (M60, M62)23
- 51 Inj.pump, Regulator, Mixt.regulator › 1 RA Replacing Fuel Pressure Regulator (M60)2
53 Injection Nozzle And Lines4 pages
54 Throttle And Operation9 pages
- 1 RA Removing And Installing_sealing Throttle Body (M60, M62)234
- 2 RA Removing And Installing Or Replacing Throttle Body (ASC-T) (M60, M62)2
- 3 RA Replace Inlet Hose (between Mass Air Flow Sensor And Throttle Body)(M60)
- 4 RA Additional Work With ASC-T (removing And Installing Connections On ASC-T Throttl
- 5 RA Additional Work With ASC-T (removing And Installing Throttle Body ASC-T On Throt
63 Throttle Potentiometer, Fuel Pump Relay4 pages
- 71 Intake Silencer › 1 RA Removing And Installing Suction-filter Housing (M60, M62)2
23 Manual Transmission (MECH)66 pages
0 Complete Transmission19 pages
- 1 RA Oil Change In Manual Transmission
- 2 RA Transmission Designations23
- 3 RA Universal Transmission Bracket
- 4 RA Universal Transmission Retaining Bridge
- 5 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 6 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 7 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 8 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 9 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 10 RA Gearshift Component Arrangement (S5D 260Z _ 310Z _ 320Z)
- 11 RA Gearshift Component Arrangement (S5D 260Z _ 310Z _ 320Z)
- 12 RA Housing Arrangement, Front_rear Section (S5D 260Z _ 310Z _ 320Z)
- 13 RA Transmission Arrangement (S5D 260Z _ 310Z _ 320Z)
- 14 RA Transmission Arrangement (S5D 260Z _ 310Z _ 320Z)
- 15 RA Transmission Arrangement (S5D 260Z _ 310Z _ 320Z)
- 16 RA Transmission Arrangement, Front Section (S5D 260Z _ 310Z _ 320Z)
- 17 RA Transmission Arrangement, Rear Section (S5D 260Z _ 310Z _ 320Z)
- 12 Bearing In Housing, Sealing Ring › 1 RA Replacing Radial Seal For Output Flange (S5D 200G_ 250G)23
21 Transmission Shafts28 pages
- 1 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 2 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 3 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 4 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 5 RA Gear Train Arrangement (S5D 260Z _ 310Z _ 320Z)
- 6 RA Removing And Installing Complete Drive And Output Shafts (S5D 260Z _ 310Z _ 320Z23456789101112131415161718
- 7 RA Replacing Bearings On All Transmission Shafts (S5D 260Z _ 310Z _ 320Z)2345
- 23 Synchromesh › 1 RA Disassembling And Assembling All Synchronizing Mechanisms (S5D 260Z _ 310Z _ 32023456789101112
- 31 Inner Gearshift Components › 1 RA Replacing Arrester Balls On Shift Rods (S6S 420G)2
24 Automatic Transmission (AUT)92 pages
0 Transmission Assembly38 pages
- 1 RA Transmission Designations23
- 2 RA Universal Transmission Bracket
- 3 RA Universal Transmission Retaining Bridge
- 4 RA Removing And Installing Automatic Transmission (A5S 310Z)2345678
- 5 RA Installing Replacement Transmission (A5S 310Z)2
- 6 RA Dismantling And Assembling Automatic Transmission (A5S560Z)234567891011121314151617181920212223
- 11 Transmission Case, Oil Sump › 1 RA Removing And Installing_sealing Or Transmission Oil Sump23
12 Torque Converter Bearing, Seal6 pages
13 Extension Housing, Bearings, Seal3 pages
23 Release Clutches9 pages
- 30 Hydr-el Control Components-elements › 1 RA Removing And Installing Or Replacing Shift Control Unit (A5S 310Z)23
- 35 Wiring Harness, Shift Elements And Senso › 1 RA Replacing Wire Harness In Automatic Transmission
- 40 Torque Converter › 1
- 61 Electronic Control Unit › 1 RA Removing And Installing Or Replacing Control Unit2
- 26 Propeller Shaft › 11 Propeller Shaft Assembly › 1 RA Replacing Rubber Gaiter For Constant Velocity Joint
- 31 Front Axle › 1 RA Microencapsulated Screws
32 Steering And Wheel Alignment13 pages
- 0 Electronic Chassis Alignment › 1 RA Test Conditions For Chassis_wheel Alignment Check
34 Steering Wheel For Airbag11 pages
- 41 Pump And Oil Supply › 1 RA Servotronic Troubleshooting
33 Rear Axle39 pages
34 Brakes11 pages
41 Body (SAL)53 pages
0 Body52 pages
- 1 RA Contents Of Body, General2
- 2 RA Bonding Plastic Parts
- 3 RA Bonding Steel Parts2
- 4 RA Corrosion Protection2
- 5 RA General Cementing Instructions
- 6 RA Grinding Steel Parts
- 7 RA Handling Airbags And Restraint Systems
- 8 RA Handling Electrical And Electronic Equipment
- 9 RA Information _ Warning Labels
- 10 RA Information On Hazards
- 11 RA Information On Vehicle Protection
- 12 RA Installation Of A Cavity Seal With Cavity Foam2
- 13 RA Installing A Cavity Bulkhead (expanded)
- 14 RA Installing A Cavity Bulkhead (not Expanded)
- 15 RA Materials Science23
- 16 RA Opening Adhesive Bonds
- 17 RA Opening Weld Joints
- 18 RA Quality Standard
- 19 RA Riveting Aluminium Parts2
- 20 RA Riveting Steel Parts
- 21 RA Safety At Work2
- 22 RA Spot-weld Bonding Steel Parts
- 23 RA Straightening Steel Parts2
- 24 RA Use Of Materials In Outer Shell2
- 25 RA Vehicle Identification Number, General
- 26 RA Welding And Soldering Steel Parts23
- 27 RA Welding In Reinforcement Plate (steel Plate)2
- 28 RA Workshop Equipment2
- 29 RA Replacing Unfinished Body Shell
- 30 RA Installation Solution For Straight Shank_hexagon Rivet Nut23
- 31 RA Repair Solution For Straight Shank_hexagon Rivet Nut23
- 32 RA Notes On Cavity Foam2
- 33 RA General Instructions On Painting
- 14 Wheel Wells › 1 RA Vehicle Identification Number, General
- 52 Seats › 1 RA Microencapsulated Screws
- 54 Slide-tilt Sunroof And Convertible Top (SAL) › 10 Sunroof › 1 RA Repair Instructions For Bonded Seals23
61 General Electrical System81 pages
0 Troubleshooting12 pages
- 1 RA Instructions On Starting Aid
- 2 RA Battery
- 3 RA Notes On Handling Wiring Harnesses And Cables
- 4 RA Repairing Airbag Cables2
- 5 RA Safety Instructions For Handling Vehicle Battery
- 6 RA Unlocking And Disconnecting Different Plug Connections23
- 7 RA Opening Plug Housings And Removing Contacts Of Different Plug Systems23
- 11 Wiring Harness › 1 RA Notes On Handling Wiring Harnesses And Cables
13 Plug Connection, Terminal, Fuse Box41 pages
- 1 RA Notes On Handling Wiring Harnesses And Cables
- 2 RA Repairing Airbag Cables2
- 3 RA Butt Connector For Repairing A Plug Connection234
- 4 RA Crimping Stop Parts234
- 5 RA Installing Fan Connector For Retrofitting_repairs2345
- 6 RA Special Tools For Wiring Harness Repairs23
- 7 RA Unlocking And Disconnecting Different Plug Connections23
- 8 RA Antenna Elbow Plug On Radio Receiver23
- 9 RA Base Of Tab Connector Housings
- 10 RA Crimping Micro Power Quadlock Contacts (MPQ)
- 11 RA Crimping Micro Quadlock System Contacts (MQS)2
- 12 RA Crimping Annular Contacts
- 13 RA Cutting To Length And Stripping Insulation From Cables
- 14 RA In-line Plugs, 30-pin, Hybrid System MQS_MPQ2
- 15 RA Opening Plug Housings And Removing Contacts Of Different Plug Systems23
- 16 RA Relay Carrier
- 17 RA Retaining Bracket
- 18 RA Socket Housing (radio Plug), Hybrid System MQS_MPQ23
20 Battery15 pages
- 1 RA Instructions For Disconnecting And Connecting Battery23
- 2 RA Instructions On Starting Aid
- 3 RA Battery
- 4 RA Repairing Airbag Cables2
- 5 RA Safety Instructions For Handling Vehicle Battery
- 6 RA Threshold Values For Battery Inspection Of All Battery (telephone Except For Tel
- 7 RA AGM Battery234
- 8 RA Battery Charging
- 9 RA Battery Open-circuit Current Test
35 ECUs, Modules4 pages
- 36 Relays › 1 RA Relay Carrier
- 61 Windscreen Wipers › 1 RA Checking Or Adjusting Contact Angle Of Wiper Arms On Windshield
64 Heating And Air Conditioning31 pages
- 11 Heater With Operation › 1 RA Installing Servodrive
50 Air Conditioning System19 pages
- 1 RA Air Conditioner Test (R 134a)
- 2 RA Instructions For Handling Refrigerant R 134a
- 3 RA Instructions For Handling Refrigerant Oil (for Refrigerant R 134a)2
- 4 RA Leak Testing With Ultraviolet Additives (UV Additives) (BMW Leak-testing Case)23
- 5 RA Leak-testing With Leak Tester Device2
- 6 RA Safety Instructions For Handling Refrigerant R134a
- 7 RA Safety Instructions For Handling Refrigerant Oil2
- 8 RA Troubleshooting By Pressure Measurement (R 134a)23
- 9 RA Drawing Off, Evacuating And Filling A_C System (R 134a)2
- 10 RA Instructions For Opening And Replacing Parts In Refrigerant Circuit2
- 51 AC Housing-evaporator, Switching Elemts › 1 RA Instructions For Opening And Replacing Parts In Refrigerant Circuit2
53 Condenser And Dryer With Lines3 pages
- 65 Audio, Navigation And Information System › 20 Aerial-antenna › 1 RA Antenna Elbow Plug On Radio Receiver23
- 67 Electrical Drives › 65 Drive, Sun Roller Blind-sun Visor › 1 RA Removing And Installing Or Replacing Drive For Sun Roller Blind23
72 Parts - Accessories (Body)26 pages
12 Airbag Generator-airbag Unit For Pass16 pages
- 1 RA Repairing Airbag Cables2
- 2 RA Safety Precautions And General Information
- 3 RA Safety Regulations For Handling Airbag System Components2
- 4 RA Safety Regulations For Handling Components With Gas Generators2
- 5 RA Procedure After Airbag Triggering As Result Of An Accident23
- 6 RA Safety Regulations For Handling Airbag Modules, Airbag Components And Pyrotechni
- 7 RA Scrapping Vehicles With Passenger Airbag And Pyrotechnic Belt Tensioners
- 8 RA Unlocking_locking Airbag Plug Connections234
- 84 Communication Systems › 1 RA Notes On Handling Wiring Harnesses And Cables
86 Trailers107 pages
10 Loading Platform71 pages
- 1 RA Body And Underbody_ Checking For Corrosion And Damage
- 2 RA Raising BMW Multi-trailer23
- 3 RA Adjusting Brake System23
- 4 RA Adjusting Spring Force Accumulator
- 5 RA Disassembly Of Camlock Retaining Cam
- 6 RA Disassembly Of Base Plate
- 7 RA Disassembly Of Bracket On Platform Base
- 8 RA Disassembly Of Front Apron
- 9 RA Disassembly Of Front Protection Bar
- 10 RA Disassembly Of Jockey Wheel Or Jockey Wheel Mount
- 11 RA Disassembly Of Left And Right Aprons
- 12 RA Disassembly Of Left And Right Lamp Housings
- 13 RA Disassembly Of Left And Right Wheel Boxes
- 14 RA Disassembly Of Licence Plate Mounting Plate
- 15 RA Disassembly Of Loading Ramp Frame_disassembly Of Rail, Left_right
- 16 RA Disassembly Of Rear Apron
- 17 RA Disconnecting Plug Connection, Wiring Harness, Front_rear
- 18 RA Installation Position Of BMW Lettering
- 19 RA Positioning Of Multitrailer Hood For Maintenance And Repair Work2
- 20 RA Removing Camlock Retaining Cam On Loading Ramp
- 21 RA Removing Camlock Screw Cap
- 22 RA Removing And Installing Or Replacing Left Or Right Coil Spring2
- 23 RA Removing Bolt On Loading Ramp
- 24 RA Removing Brake Shoes2345
- 25 RA Removing Entry Profile Section On Loading Ramp, Left, Right And Center
- 26 RA Removing Left Or Right Shock Absorber
- 27 RA Removing Loading Ramp Lock2
- 28 RA Removing Mounting Bracket Sealing Cap
- 29 RA Removing Mounting Bracket, Center, Left And Right
- 30 RA Removing Outer Pull Rod Mount, Left And Right
- 31 RA Removing Overrunning Equipment_maintaining Or Replacing Guide Bush_installing Ov2345
- 32 RA Removing Plastic Bush_metal Bush
- 33 RA Removing Rear Supports And Bracket
- 34 RA Removing Reflecting Rear Light
- 35 RA Removing Rest On Loading Ramp, Left, Right And Center
- 36 RA Removing Shock Absorber From Overrunning Equipment
- 37 RA Removing Trailing Arm, Removing And Installing Or Replacing Mounting23
- 38 RA Removing Wheel Bearing2
- 39 RA Removing Wooden Rest On Loading Ramp, Left, Right And Center
- 40 RA Repair Work On GFP Components With Gelcoat Surface
- 41 RA Replacing 12 Volt Socket2
- 42 RA Replacing Bar
- 43 RA Replacing Drawbar Members, Left And Right2
- 44 RA Replacing Gaiter
- 45 RA Replacing Holder For Chock
- 46 RA Replacing Lashing Plate And Lashing Eye
- 47 RA Replacing License Plate Light
- 48 RA Replacing Position Light
- 49 RA Replacing Rear Light
- 50 RA Troubleshooting On Multi-trailer2
21 Hood36 pages
- 1 RA Positioning Of Multitrailer Hood For Maintenance And Repair Work2
- 2 RA Adjusting Hood Pretension - Camloc Fastener With Spacers23
- 3 RA Adjusting Rear Lid To Fit2
- 4 RA Adjusting Rotary Striker Lock
- 5 RA Adjusting Side Lid To Fit2
- 6 RA Attaching_replacing BMW Badge2
- 7 RA Fitting BMW Logo
- 8 RA Installing Hood Seal
- 9 RA Installing Rubber Roof Strip
- 10 RA Installing Seal For Rear Lid And Side Lid
- 11 RA Installing Sponge Rubber Seal
- 12 RA Removing Ball Pivot
- 13 RA Removing Centering Pin From Mounting Bracket
- 14 RA Removing Gas Spring
- 15 RA Removing Gas Spring Retaining Bracket
- 16 RA Removing Hinge Bracket On Rear Lid
- 17 RA Removing Lid
- 18 RA Removing Lock Barrel
- 19 RA Removing Lock Striker Fixture On Rear Lid
- 20 RA Removing Plug For Inside Light2
- 21 RA Removing Roof Railing
- 22 RA Removing Roof Railing Adapter2
- 23 RA Removing Rotary Striker Lock2
- 24 RA Removing Side Lid Hinge
- 25 RA Replacing Inside Light
- 26 RA Replacing Inside Light Power Cable2
99 Paintwork2 pages