Disa valve BMW 528i 1998 E39 Workshop Manual

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This group covers cylinder head and valvetrain service and
repair. Some of the repair procedures described here require
that the cylinder head first be removed as described in
113
Cylinder Head Removal and Installation.
NOTE- For timing chain and
VANOS repair information, see 117
Camshaft Timing Chain.
If it is
determined that the cylinder head will require signif-
icant reconditioning work, a remanufactured cylinder head
may be a good alternative. Remanufactured cylinder
heads are available from an authorized
BMW dealer.
The information given in this repair group is organized ac-
cording to engine code. For engine application information,
see
I00 Engine-General.
For specific repair procedures, refer to the appropriate repair
group:
* 020 Maintenance
100 Engine-General
113 Cylinder Head Removal and Installation
117 Camshafi Timing Chain
= 170 Radiator and Coo!ing System
Special Tools
Special BMW tools are required for most cylinder head ser-
vice described in this repair group. Many of these tools are ex-
pensive and only available through an authorized
BMW
dealer. If the special tools are not available, have the cylinder
head removed and disassembled by an authorized BMW
dealer. Be sure to read each procedure thoroughly before
starting a job to determine which special tools and equipment
will be necessary.
Most of the repairs to a cylinder head require precision
rna-
chine work to specific tolerances. This type of work should be
performed by an authorized BMW repairfacility or an ASE
certified machinist.
71 Torque wrench with flex shaft

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11 6-5
I Cylinder Head and valvetrain1
4 Timing chain tensioner bracket (V-8)
(Tool No. BMW
11 7 380)
CYLINDER HEAD
This section provides the specifications and special recondi-
tioning information necessary to repair the cylinder heads
covered by this manual.
The disassembled cylinder head should be inspected for
warpage and cracks. Check the valve guides and valve seats
for wear before machining a warped head. Always decarbon-
ize and clean the head before inspecting it.
Visually inspect the cylinder head for craclts.
If a cracked cyl-
inder head is suspected and no
craclts are detected through
the visual Inspection, have the head further tested for cracks
by an authorized BMW dealer or an ASE certified machinist.
A cracked cylinder head must be replaced.
NOJE-
When disassembling and inspecting the cylinder head, be
sure to
checlc the camshaft carrier bearing surfaces using a
straight edge for
warpage, and check the lifter bores for wear.
A high-quality straight edge can be used to
checlc for
warpage. A warpage of 0.05 mm (0.002 in.) is acceptable
without machining. A warped cylinder head can be machined
provided no more than 0.3
mm (0.012 in.) of material is re-
moved.
If further machining is required, the head should be
replaced. Removing more than this amount will reduce the
size of the combustion chamber and adversely affect engine
performance. A 0.3 mm
thicker head gasket for machined
heads is available from an authorized BMW parts depart-
ment.

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Cylinder Head and valvetrain1
While counter holding camshaft, remove exhaust camshaft
sprocket bolts
(arrows) from left cylinder head. Remove
sprocltets with chain.
< While counter holding camshaft, remove exhaust camshaft
sprocket bolts
(arrows) from right cylinder head. Remove
sprocltets with chain.
4 Use BMW special tool 11 3 430 to rotate camshaft into disas-
sembly position.
4 Loosen camshaft bearing caps nuts in correct sequence
(1-10) (left cylinder head shown).
NOTE -
Keep camshaft bearing caps in order. Used caps must not be
interchanged.
- Remove exhaust camshaft by repeating process.
0 Remove camshafts from cylinder head.
- Repeat camshaft removal process for right cylinder head.

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Table d. Valve guide specifications
Specifications
All engines (1997-2002)
Valve guide wear, maximum 0.5 mrn (0.020 in)
(valve tilt clearance
measured
with new valve)
Valve guide inside diameter,
installed
(tolerance per IS0 allowance H7)
Standard 6.0 mm (0.236 in)
Oversize
1 6.1 mrn (0.240 in)
Oversize 2 6.2
mm (0.244 in)
Valve stem oil seals
The purpose of the valve stem oil seal is to prevent excess oil
from entering the combustion chamber. The sign of faulty
valve stem oil seals is excessive oil consumption and smoke
from the exhaust immediately after starting and during decel-
eration.
NOTE-
Valve stem oil seals should not be reused. If valves are re-
moved, new valve stem oil seals should be installed.
Valve stem oil seal replacement requires that the cylinder
head be disassembled and the valves removed as described
above under Valves, removing and installing.
NOTE-
BMW special tools are available to remove the valve stem oil
seals. As an alternative, standard valve seal removal tools
are available from most automotive parts stores.
Lubricate new seal and install using hand pressure only. Be
sure to install valve spring
seat(s) before installing seal.

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... -.
Camshaft Timing chain1
Timing chains, removing
(M52 TU and M54 engines)
Camshaft timing chain removal requires that the oil pan be re-
moved. See
119 Lubrication System. Also required is re-
moval of the VANOS control
unit and disassembly of the
intake and exhaust camshaft sprocket assemblies as de-
scribed earlier in this repair group.
Special BMW
service tools are needed for timing chain re-
moval and installation. The special tools assure proper timing
of the valvetrain. Precise
marlts to set the timing on the cam:
shafts are not provided for reassembly. Read the procedures
through before beginning the job.
CA
UTION-
If the camshafts are not properly timed, the pistons can con-
tact the valves.
- D~sconnect negative (-) cable from battery.
CAUTION-
* Disconnecting the battery may erase fault code@) stored in
control module memory. Check for fault codes using spe-
cial
BMW diagnostic equipment.
Prior to disconnecting the battery, read the battery dis-
connection
cautfons given in 001 General Cautions
and
Warninqs.
- Remove VANOS control unit. See VANOS control unit, re-
moving
(M52 TU and M54 engines).
Remove sealing plug from crankcase below starter and se-
cure crankshaft with
BMW special tool ll 2 300.
Drain engine cooling system. See 170 Radiator and Cool-
ing System.
Remove belt driven cooling fan, fan shroud, and thermostat
housing. See
170 Radiator and Cooling System.
Remove drive belts. See
020 Maintenance.
NOTE-
Mark direction of belt rotation if reusing belt.
- Remove water pump pulley fasteners and pulley.
- Drain engine oil and remove oil pan as described in 119
Lubrication System.

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11 9-26
/Lubrication System
< Use Allen wrench to adjust chain slaclc (B) by turning thread-
ed spacer
(A).
Oil pump chain adjustment
Slack
10 52 mrn (0.394i0.079 in)
- Coat remaining oil pump mounting fastener with Loctite 03. In-
stall and tighten.
- Remainder of assembly is reverse of disassembly.
- After adding engine oil, start and run engine. Raise engine
speed to
2,500 rpm until oil pressure warning light goes out
(about
5 seconds).
Tightening torques
Lower oil pan to upper oil pan
M6 (8.8 grade) 10
Nm (89 in-ib)
M6 (10.9 grade) 12
Nm (9 ft-lb)
M8 (8.8 grade) 22
Nrn (1 6 ft-lb)
Oil drain plug to oil pan (M12) 25 Nm (I8 ft-lb)
Oil pump cover to oil pump
(M6) 10 Nrn (89 in-lb)
Oilpump sprocket to shaft TKO) 45 Nm (33 it-lb)
Oil pump to engine bloclc
M8 (8.8 grade) 22 Nrn (16 ft-lb)
Oil pressure relief valve (&cylinder)
Remove oil
pump as described earlier. The oil pump pressure
relief valve is held in the side of the
oil pump with a circlip.
< Inspect oil pump relief valve components and bore for scor-
4. Sleeve
5. Circlip
- Install using a new circlip.
Oil
pressure relief valve assembly
,- ..., !~. -.-~. - ~- -~!~~-% h. .- .,, /to-cy~~noer engrnej ing or other damage.
1. Control plunger
2. Spring
3. Sealing O-ring

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.-
ignition System
Disabling ignition system
The ignition system operates in a lethal voltage range and
should be disabled any time engine service or repair work is
being done that requires the ignition to be switched on.
The engine management system can be disabled by remov-
ing the DME main relay. The relay is located in the electronics
box (E-box) in the left rear of the engine
compartment, be.
neath the interior microfilter housing.
CAUTION- Relay locations may
vary. Use care when identifying relays.
See
610 Electrical Component Locations.
Checking for spark
CAUTION-
If
a spark test is done incorrecth damage to the Engine Con-
trol Module
(ECM) or the ignition coils may result.
NOTE-
Spark plug replacement is covered in 020 Maintenance.
Check~ng for spark is d~fflcult on englnes wlth d~str~butorless
ignition systems.
Try removing the spark plugs and inspecting for differences between them.
A poor-firing plug may be wet with fuel and/or ~. - ~
black and sooty, but not always. If a coil is not operating, the
engine management system will electrically disable the fuel
injector to that cylinder. The key is to look for differences be-
tween cylinders.
Ignition coil assembly, testing and
replacing
C4 UTION-
Use a digital multimeter for the following tests. I
- Remove plastic engine cover from top of valve cover by pry-
ing off bolt covers and removing cover mounting bolts.
- Raise car slowly while constantly checking position of jack
and car.
- Disconnect harness connector from coil. Connect multimeter
between terminal 15
(+) in connector and ground.
4 Terminal identification are typically molded into connector. In
photo, terminals are from left to right: 1,
4a, 15.

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On-Board Diagnostics
Catalyst monitoring. Thisstrategy monitors the outputofthe
precatalyst and post-catalyst oxygen sensors, comparing the
oxygen content going into the catalytic converter to the
oxygen leaving the converter.
The diagnostic executive
lknows that most of the oxygen
should be used up during the oxidation phase. If it detects
higherthan programmed values, afault is set and the MIL
illuminates.
Misfire detection. This strategy monitors crankshaft speed
fluctuations and determines if an enoine misfire occurs bv
monitoring variations in speed between each crankshaft
sensortrigger point. This strategy is so finely tuned that it can
determine the severity of the misfire.
The system determines
if a misfire is occurring, as well as
other pertinent misfire
information such as:
Specific
cylinder(s)
Severity of the misfire event
Emissions relevant or catalyst damaging
Misfire detection is an on-going monitoring process that is
only disabled under certain limited conditions.
Secondary air injection monitoring. Secondary air
injection is used to reduce HC and CO emissions during
engine warm up. Immediately following a cold engine start
(-1 0" to 40°C), fresh air (and therefore oxygen) is pumped
directly into the exhaust
manifold. By injecting additional
oxygen into the exhaust manifold, catalyst warm-up time is
reduced.
Secondary air system components are:
Electric air injection pump
* Electric pump relay
* Non-return valve
Vacuum
I vent valve
- Stainless steel air injection pipes
Vacuum reservoir
The secondary air system is monitored via the use
of the pre-
catalyst oxygen sensors. Once the air pump is active and air
is injected into the system, the signal at the oxygen sensor
reflects a lean condition. If the oxygen sensor signal does not
change, a fault is set and the faulty
bank(s) identified. If after
completing the next cold startafault is again present, the MIL
illuminates.

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On-Board ~ia~nosticsl
I I
PO340 1113 I Camshaft Position Sensor 'A' Circuit (Bank 1 or Single Sensor)
Engine
diagnostic trouble codes:
M62 engine (continued)
P-code
PO342
PO343
PO345
PO347
PO348
PO363
PO370
PO41 2
PO335 I111 I Crankshaft Position Sensor 'A' Circuit
BMW-FC
I I -
I I -
PO445 1 98 1 Evaporative Emission System Purge Control Valve Circuit Shorted
Explanation
113
113
114
114
114
62 112
85
PO41 3
PO41 8
PO420
PO430
PO440
PO442
PO442
PO443
PO444
Camshaft Position Sensor 'A' Circuit Low (Bank 1 or Single Sensor)
Camshaft Position Sensor
'A' Circuit High (Bank 1 or Single Sensor)
Camshaft Position Sensor
'A' Circuit (Bank 2)
Camshaft Position
Sensor'A' Circuit Low (Bank 2)
Camshaft Position Sensor 'A' Circuit High
(Banic 2)
Misfire Detected
- Fueling Disabled
Timing Reference High Resolution Signal
'A'
Secondary Air lniection System Switchinq Valve A Circuit
PO41 4 / 85 I Secondary Air Injection System Switching Valve A Circuit Shorted
85
84
40
45 93 183
188
98
98
PO450
PO452
PO453
PO455
PO456
PO491
PO492
PO500
PO506
I I
PI102 1163 I Idle Control System, Adaptation of Unmetered Air Mass Too Low
Secondary
Air Injection System Switching Valve A Circuit Open
Secondary Air Injection System Control
'A' Circuit
Catalyst System Efficiency Below Threshold (Bank 1)
Catalyst System Efficiency
Below Threshold (Bank 2)
Evaporative Emission System
Evaporative Emission System Leak Detected (small
leak)
Evaporative Emission System Leak Detected (small leak)
Evaporative Emission System Purge Control Valve Circuit
Evaporative Emission System Purqe Control Valve Circuit Open
I
I
185
185
185
183
187
80
81 120
32
PO507
Evaporative Emission System Pressure SensorISwitch
Evaporative Emission System Pressure SensorISwitch Low
Evaporative Emission System Pressure
SensorISwitch High
Evaporative Emission System
Leaic Detected (large leak)
Evaporative Emission System
Leal$ Detected (very small leak)
Secondary Air Injection System Insufficient Flow (Bank
1)
Secondary Air Injection System insufficient Flow (Bank 2)
Vehicle Speed Sensor
'A'
idle Air Control System RPM Lower Than Expected
PI103
PI130
PI131
PO600 1 220 I Serial Communication Link
32
idle Air
Control System RPM Higher Than Expected
163
17
23
Idle Control System, Adaptation of Unmetered Air Mass Too Large
02 Sensor Circuit Dynamic Test (Bank
1 Sensor 2)
02 Sensor Circuit Dynamic Test (Bank 2 Sensor 2)

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INDEX 'tl
WARNING
Your common sense, good
judgemenl, and general alertness are
crucial to sale and successiul service
worlr. Belore attempting any work on
your
BMM be sure lo read 001
General Warnings and Cautions
and the
copyriglll page at the front 01
the manual. Review these warnings
and
caulions each lime you prepare
lo work on your BMW. Please also
read any warnings and cautions that
accompany
tile procedures in the
manual.
312-way valve (running losses)
see Fuel tank
Abbreviations, commonly used 600-14
ABS (antilock brake system)
see
Bral(es
A/C air distribution motors
see stepper motors (below)
blower final stage (resistor pack),
replacing
640-16
blower, removinglinslalling
640-1 5
compressor, replacing
640-24 condenser, replacing 64045
control panellmodule, removing1
installing
640-1 1
evaporakr, removinglinstalling 640-29
evaporator temperature sensor
640-12 expansion valve, removinglinstailing
640-27
IHKA/ IHKR system description 640-5
receiveridrier, replacing 640-26
stepper motors 640-1 3 ventilation microiilter, replacing
020-22. 640-17
see also Heating
Accelerator
iinlcage
see Maintenance
Activated carbon canister
see Fuel tank
ADS (auxiliary throttle valve)
130-57
Air compressor
330-44
Air conditioning
see
AIC
Air distribution (flap) motors
seeNC, stepper motors
Air filter see Maintenance
Air spring
300-6, 330-12
Airbag system (SRS)
2-stage
airbag 721-4
control module, replacing 721-7 driver airbag, removinglinstalling
721-8
iiead protection airbag 721-12 components 721-1 1
indicator
lighl721-4
passenger airbag, removinglinstalling
721-9 side-impact airbags crash sensor,
replacing
721-7
Airflow sensor see 130 under appropriate
fuel
injection system
Air pump
see 130 under appropriate fuel
injection system, secondary air
injection system
Air suspension
see Electronic height control
(EHC)
Alarm
see Anti-theft alarm
Alignment see
Wheei alignment
Aluminum suspension components
300-2
Antenna 650-6
Alternator see Battery, starter, alte rnator
Amplifier
650-4
Anti-theft alarm (DWA)
515-24 emergency disarming 515-31
Antifreeze (engine coolant)
see Maintenance
see also Cooling system
Antilock brake system (ABS) see Brakes
ASC see Brakes
ATF (automatic transmission fluid)
see Automatic transmission
see also Cooling systern
Automatic headlight adjustmenl
(LWR) see Lights
Automatic seat belt tensioner
720-4
Automatic shiftloclc
see
Gearshift
Automatic transmission
applications
200-3, 240-4
ATF 020-10, 200-4
capacity 240-8 checking 240-6
drainingifilling 240-7
heat exchanger 170-5
fluid pan and strainer 240-9 gearshift
see Gearshift
ID tag
200-3 range switch 610-6
removaliinstallation 240-10
steptronic see Gearshift
Auxiliary cooling fan
see
Coollng system, electric Ian
Auxiliary throttle valve (ADS)
130-57
Axle joint
see Drive axle
Back-up light switch
automatic transmission see Automatic transmission. range switch
- .~.~~~
manual transmission 230-8 -
- I