ECT BMW 528i 1998 E39 Owner's Manual

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General
Torque wrench
A torque wrench is used to precisely tighten threaded fasten-
ers to a predetermined value. Many of the repair procedures
in this manual include BMW-specified torque values
in New-
ton-meters (Nm) and the equivalent values in foot-pounds
(ft-
Ib).
4 Several types of torque wrenches are available. An inexpen-
sive beam-type (top) is adequate but must be read visually. A
ratchet-type (bottom) can be preset to indicate (click) when
the torque value has been reached. They all do the same job,
but offer different convenience features at different prices.
The most convenient ones have a built-in ratchet, and can be
preset to indicate when a specific torque value has been
reached. Follow the wrench manufacturer's directions
for use
to achieve the greatest accuracy.
A torque wrench with a range up to about 150 Nm (1 10 ft-lb) BOIBFNG has adequate capacity for most of the repairs covered in this
manual. For recommended torque values of
10 Nm orbelow,
the English system equivalent is given in inch-pounds (in-lb).
These small values may be most easily reached using a
torque wrench calibrated in inch-pounds. To convert
inch-
pounds to foot-pounds, divide by 12.
Digital multimeter
4 Many of the electrical tests in this manual call for the mea-
surement of resistance (ohms) or voltage values. For safe
and accurate tests of sensitive electronic component and
systems, a multimeter or digital
volt/ohm meter (DVOM) with
high input impedance (at least
10,000Sr) should be used.
Some meters have automotive functions such as dwell and
pulse width that are useful for troubleshooting ignition and
fuel injection problems.
CAUTIOI\C
Vehicle electronic systems may be damaged by the high cur-
rent draw of a test light with a normal incandescent bulb. As
a general rule, use a high impedance digital multimeter or an
LED test light for all electrical testing.

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-
General
BMW special tools
Many repairs covered in this manual call for the use of BMW
special tools. Many of the BMW special tools mentioned in
this manual are simply the best thing to use to do the job cor-
rectly. In these cases, the tool is identified with a
BMW parl
number. See your authorized BMW dealer parts department
for information on how to order special tools.
There are some jobs for which expensive special tools are es-
sential, and not a cost-effective purchase for a one time repair
by the do-it-yourself owner. This manual includes such re-
pairs for the benefit of those with the necessary experience
and access to tools. For the do-it-yourselfer, the need for spe-
cial tools is noted in the text, and whether or not BMW dealer
service is recommended.
Changing a tire
- Stop car on as flat a surface as possible, in a place where you
can be easily seen by other drivers. Avoid stopping just over
the crest of a hill.
WARNING -
If a tire goes flat while driving, pull well off the road. Changing
a tire on a busy slreet or liigliway is very dangerous. If
nec-
essag drive a short distance on the flat tire to get to a safe
place. It is much better to ruin a tire or rim than to
risk being
hit.
-
- Turn on emergency flashers, and set out flares or emergency
markers well behind car.
Choclc wheel (wheel chock located
in trunk) diagonally opposite to the one being changed. Pas-
sengers should get out of car and stand well away from road.
- Take jaclc and tools from tool area beneath trunk mat. Re-
move spare tire from tire storage tray.
- Loosen wheel bolts while car is on ground, but leave them a
little snug.
< Place jack in lifting point nearest wheel being changed. Use
a board to provide a firm footing for jack if ground is soft.
Raise car only far enough so that the wheel is fully off ground
and then remove wheel nuts and wheel.
- Install spare wheel. Install wheel nuts and tighten them hand
tight using lug nut wrench.

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General
Cars with discharged or dead batteries can be jump-started
using the good battery from another car. See owner's manual
for proper instruction on jump starting. When jump-starling
the engine, always note the following warnings.
4 Lower car. With all wheels on ground, fully tighten nuts in a
WARNING-
* Battery acid (electrolyte) can cause severe burns, and will
damage the
cal; clothing, and you. If electrolyte is spilled,
wash the surface with large quantities of water.
M itgets into
eyes, flush them with water for several minutes and call a
doctor.
B4
5
43
2 BOOIFNG.
Batteries produce explosive and noxious gasses.
Keeps sparks and flames away. Do not smoke near
batteries.
Do notjump-start the engine
ifyou suspect that the bat-
tery is frozen. Trappedgas may explode. Allow the bat-
tery to thaw first.
Do not quick-charge the battery (for boost starting) for
longer than one minute, and do not exceed
16.5 volts
at the battery with the boosting cables attached. Wait at
least one minute before boosting the battery a second
time.
crisscross pattern.
Torque wheel nuts when installing wheel.
Check inflation pressure of spare tire.
Tightening torque
Wheel to wheel hub 120 Nm (89 ft-ib)
Jump starting
Indicator and warning lights
Many vehicle systems are self-monitored for faults while driv-
ing. Generally,
a red warning lamp that comes on during driv-
ing should be considered serious. If you cannot immediately
determine the seriousness of the warning light, stop the vehi-
cle in a safe place and turn the engine off as soon as possible.
Consult the owner's manual for additional information on the
warning lamp and the recommended action.
If the Malfunction Indicator Lamp (MIL)
(Check Engine or Ser-
vice Engine Soon warning light) comes on orflashes, it indi-
cates that an emissions-related fault has occurred. Faults
such as a bad oxygen sensor or a dead fuel injector can
cause the exhaust or evaporative emissions to exceed a
specified limit. When these limits are exceeded, the MIL will
be turned on. The engine can be safety driven with the light
on, although the emission systems should be
checked as
soon as possible. See OBD On-Board Diagnostics for

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020 Maintenance
General ........................... .02 0.2
Special tools ........................ .02 0.2
Service Interval Indicator (Sll) ........... .02 0.3
Service Interval Indicator (Sll), resetting ... .02 0.3
Inspection I, Inspection 11 ............... .02 0.5
Maintenance Tables ................ .02 0.6
Fluid and Lubricant Specifications .. .02 0.9
Fluids and lubricants ................. .02 0.10
Engine Oil Service ................ .02 0.1 I
Engine oil. checking level ............. .02 0.12
Engine oil and filter. changing .......... .02 0-13
Engine Compartment Maintenance . .02 0.14
Accelerator and linkage ............... .02 0.14
Air filter. replacing ................... .02 0.1 4
Cooling system service ............... .02 0.15
Engine drive belt service .............. .02 0.16
Idlespeed .......................... 020-19
Catalytic converter and oxygen sensors .. .02 0.19
Power steering fluid, checking level ..... .02 0.20
Spark plugs ........................ .02 0.20
Spark plugs, replacing ................ .02 0.21
Interior ventilation microfilter, replacing ... .02 0.22
Other Mechanical Maintenance ..... .02 0.22
Battery, checking. cleaning. and replacing .02 0-22
Brake fluid. replacing ................. .02 0-24
Brake pad 1 rotor wear. checking ........ .02 0.24
Brake system, inspecting ............. .02 0.25
Parking brake. checking ............... 020-25
Clutch fluid. checking ................. 020-26
Differential oil level. checking ........... 020-26
Drive axle joint (CV joint) boots. inspecting 020-27
Exhaust system. inspecting ............ 020-27
Fuel filter. replacing .................. 020-27
Fuel tank and fuel lines. inspecting ...... 020-28
Suspension. front. inspecting ........... 020-29
Suspension. rear. inspecting ........... 020-29
Tires. checking inflation pressure ........ 020-29
Tires. rotating ....................... 020-29
Transmission service. automatic ........ 020-29
Transmission service. manual .......... 020-30
Transmission fluid. checking and filling
(manual transmission)
................ 020-30
Wheels. aligning ..................... 020-30
Body and Interior Maintenance ..... 020-31
Body and hinges. lubricating ........... 020-31
Exterior washing ..................... 020-31
Interior care ........................ 020-31
Leather upholstery and trim ............ 020-31
Polishing ........................... 020-32
Seat belts .......................... 020-32
Special cleaning ..................... 020-32
Washing chassis ..................... 020-32
Waxing ............................ 020-32
Windshield wiper blade maintenance ..... 020-33

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020-2
Maintenance
The information given in this repair group includes the routine
checlts and maintenance steps that are both required by
BMW under the terms of the vehicle warranty protection and
recommended by BMW to ensure long and reliable vehicle
operation.
NOTE-
Aside from keeping your car in the best possible condition,
proper maintenance plays a role in maintaining full protection
under
BMW's new car warranty coverage. If in doubt about
the terms and conditions of your car's warranty, an autho-
rized BMW dealer should be able to explain them to you.
Special tools
Some special tools are required for performing engine main-
tenance tasks. Be sure to have the necessary equipment on
hand before starting any job.
4 Hand pump for manual transmission lifetime oil
71 (Tool No. BMW 002 080)
4 Cooling fan counterhold wrench
(Tool No. BMW 11 5 030)
I I 4 Coolina fan wrench
I
4 Service position hood props
(Tool No. BMW 51 2 160)

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Maintenance
Service Interval lndicator (Sll)
The BMW Service Interval lndicator (SII) notifies the driver
when oil change and other service is required. The
Sll dis-
plays the phrase "OIL SERVICE"
or"INSPECTI0N" and 7
light emitting diodes (LEDs) in the Instrumentcluster: 5green,
one yellow and one red.
For the
1997 and later 5 Series, BMW introduced an oil
change interval based on fuel consumption. The advantages
of this system are:
Fuel consumption is an accurate method of determining
engine load and the need for service.
The processing electronics are simple.
Resetting of indicator before the scheduled time will not
affect the time to the next service.
4 The Sll is programmed to measure a set volume of con-
sumed fuel. This volume varies between models, dependent
on vehicle and engine size. The
Sil control unit receives a
signal from the engine control module (ECM) when the vehi-
cle is in use. As
20% of the programmed fuel volume is con-
sumed, one of the green LEDs will go out. Each successive
20% of fuel consumption will cause the next LED to go out
until
100% of the measured volume has been consumed. At
this point the yellow LED will come on, indicating that service
is due. When
108% of the measured volume has been con-
sumed, the red LED will illuminate, indicating that service is
overdue.
Service Interval Indicator (SII), resetting
After the specified maintenance has been carried out, the Sll
memory should be reset.
NOTE-
For reference, the BMW oil service requirements are approx-
imately equivalent to the maintenance tliat other European
manufacturers specify at intervals with a maximum of every
15.000 miles or I2 months.

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020-4
Maintenance
1997 to 2000 models
1997 to 2000 models are equipped with a data link connector
(DLC) plug in the right side engine compartment:
Reset
SII using BMW service and scan tool (DISplus or MoD-
iC, GTI) or a specialty tool from another manufacturer. Plug
tool (arrow) into DLC.
CAUTION-
Follow the manufacturer's directions when resetting the Sll. If
the reset procedures are done
incorrect& the tool or the elec-
tronic Service Interval Indicator
may be damaged.
Aftermarket reset tools that can reset all models with the DLC
can be purchased from one of the following suppliers:
Specialty tool suppliers
Assenmacher Specialty Tools
6440
Odell Place
Boulder, CO 80301
303-530-2424
sales@asttool.com http://www.asttool.com
Baum Tools Unlimited,
Inc.
P.O. Box 5867
Sarasota, FL 34277-5867
800-848-6657
sales@baumtools.com
http://www.baumtools.com
Peake Research. Automotive Products Division
P.O. Box 28776
San Jose, CA 95159
408-369-0406
support @peakeresearch.com
http://www.peal~eresearch.com
2001 and later models
On vehicles without the data link connector (DLC) in the en-
gine compartment (2001 and latercars), the reset tool can not
be used. Instead, the
Sll can be reset with the trip odometer
reset button in the instrument cluster.
Make sure ignition key is in OFF position.
* Press and hold trip odometer button in instrument cluster,
and turn ignition key to ACCESSORY position.
Keep
button pressed for approximately 5 seconds until
either of following appear in display: OIL SERVICE or
INSPECTION, with RESET.
Press button again and
hold for approximately 5 seconds
until RESET flashes.

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Maintenance
0 Service due is shown with RESET if the measured con-
sumption limit has been reached and resetting is possible.
If RESET is not shown, the minimum limit has not been
reached and resetting is not possible.
While display is flashing, press button briefly to reset
Sll.
After display has shown new interval, the following will
appear in display for approximately
2 seconds: END SIA.
NOTE-
The system can only be reset again after the vehicle has
been driven approximately 50 to
75 miles (consumes at
least2.5gallons of fuel). If the display shows RESETwhen
resetting, the minimum driving distance has been fulfilled
and the system can be reset again.
0 It is possible to interrupt and end the reset procedure by
changing the position of the ignition
ley.
lnspection I, lnspection II
The Service Interval Indicator (SII) signals the need for main-
tenance and inspection. There are two sets
of inspection re-
quirements, alternating throughout a car's maintenance
history. If the last inspection interval was lnspection I, the next
inspection interval (following an oil service) will be lnspection
11, the next after that will be lnspection I, and so on.
lnspection
I tasks are listed in Table b. lnspection I Service.
lnspection
II includes most of the tasks from lnspection I with
additional lnspection
II tasks. A complete listing of lnspection
II tasks is in Table c. lnspection I1 Service.
NOTE-
For reference, the BMW lnspection I and lnspection I1 re-
quirements are approximately equivalent to the maintenance
requirements that other European manufacturers specify.
ln-
spection I is normally due at intervals with a maximum of
30,000 miles or
24 months. lnspection I1 is normally due at
intervals with a maximum of 60,000 miles or
48 months.

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Maintenance
The intervals for most tasks listed in the maintenance tables
below are determined by the Sll.
NOTE-
BMW is constantly upgrading recommended maintenance
procedures and requirements.
The information contained
here is as accurate as possible at the time of publication. if
there is any doubt about what procedures apply to a specific
model or year, or what intervals should be followed, remem-
ber that an authorized
BMW dealer has the latest information
on factory-recommended maintenance.
Except where noted, the maintenance items listed apply to all
models and model years covered by this manual. The num-
ber in the "additional repair information" column refers to the
repair group in this manual where additional information can
be found.
Table a.
Oil Service
I I I I I Additional
( New parts (Tools Required requrred
Under car maintenance
1 I I I I
I I - I I
Engine compartment maintenance
Check overall thickness of front and rear
bralte pads.
If replacement is necessary:
Examine
braite disc surface.
Clean brake pad contact points in calipers.
Grease wheel centering hubs.
Checlc thickness of parking braite linings
only when replacing rear brake pads.
Checlc operation of parking brake and
adjust as necessary.
spare
Table b.
Inspection I Service
I 1 I I [Additional
020
020
020
New parts Warm engrne Dealer service Irepair , /Tools Required (required (required . (recommended lnformatlon
Change oil and oil filter
Reset Service Interval indicator [Sli)
Replace interior ventilation microfilter
*
A
*
*
*
I I I I I
Undercar maintenance
Checlc engine drive belt condition 020
ri: * Change oil and oil filter. 020 *

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Table b. Inspection I Service (continued)
Checlt transmission and differential for
external lealts.
Check CV joint boots for damage or leaks.
Visually
check fuel tank, fuel lines, and
connections for
leaks.
New parts
Tools Required required
Check condition, position, and mounting
ol
exhaust system. Visually check and adjusl
if necessary.
Check power steering system for lealts.
Check power steering
fluid level and adjust
if necessary.
Check steering racidbox and tie rods for
tightness. Checit condition of front axle
joints, steering
linkage, and steering shaft
joints.
Check overall thickness of front and rear
bralte pads using
BMW special tool. If
replacement is necessary:
Examine brake disc surface.
Clean brake pad contact points in calipers
Grease wheel centering hubs.
Checlt thickness of parking brake linings
only when replacing rear brake shoes.
Checit operation of pariting brake and
adjust as necessary.
Checlt front control arm bushings for
damage or wear.
Check brake system connections and
lines
for leaks, damage, and incorrect
positioning Warm
engine
(~ealer service Irepair , required recommended lnformat~on
Check parking braite actuator. Adjust if
necessary
Check ail tire pressure (including spare)
and correct if necessary.
Checlt condition of tires (outer tread
surface), tread wear pattern: in case of
uneven wear, perform wheel alignment.
inspect entire body according to terms of
rust oerforation limited warrantv. (Must be
*:
4:
2 ~ perfdrmed at least every two years). I
Read out on-board diagnostic (OBD 11) fault
codes.
Checkengine coolant
system1 heater hose
connections for
leaks.
Checit coolant level and antifreeze
protection level. Add coolant as necessary.
* 100113010BD
I
170