control valve BMW 528i 2000 E39 Manual PDF

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- .- -
Automatic Transmission
Electronics are used to control the operation of these auto-
matic transmissions. Steptronic transmission functions are
also programmed into the transmission control module
(TCM). The TCM monitors transmission operation for faults
and alerts the driver by illuminating the transmission fault indi-
cator on the instrument panel. Diagnostic trouble codes
(DTCs) stored in the TCM may be downloaded and interpret-
ed by trained technicians using special BMW diagnostic
equipment.
Some minor automatic transmission problems can be cor-
rected by changing the automatic transmission fluid (ATF)
and filter. Begin by checking ATF level and condition.
Checlc
to see if the fluid is dirty or has a burned odor indicating over-
heated fluid. The burned odor may be the results of burned
discs in theclutch paclts. The friction material from the burned
disc can clog valve body passages.
NOTE-
The E39 automatic transmission is not equipped with a dip-
stick.
Checking the ATF level must be done while monitoring
the ATF temperature with the engine idling. The
BMW dealer
is equipped with the special equipment to make this check.

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300-1 0
/Suspension, Steering and Brakes - General
The steering system features variable power assist provided
by an engine-driven hydraulic pump.
Rack and pinion steering
6-cylinder models
(525i, 5281, 5300
Two types of steering systems are used in E39 models. 6-
cylinder (525i, 5281, 530i) models are equipped with a steer-
ing rack system. V-8
(540i) models are equipped with a re-
circulating ball and nut steering gearbox.
Rack-and-pinion steering
Steering components in 6-cylinder models consist of a rack-
and-pinion type steering gear and connecting linltage to the
road wheels.
The steering linkage connects the rack-and-pinion unit
through tie rods to the steering knucltles. The tie rod ends al-
low the wheels to pivot and react to suspension travel.
Recirculating ball and nut steering
V-8 models
(540i)
I
Recirculating ball and nut steering
Recirculating ball and nut steering in V-8 models consists of a
steering box with integrated hydraulic control valve and con-
necting linkage to the road wheels.
Thesteering linkageconnects the steering gearbox through a
pitman arm to the wheels. An idler arm maintains correct toe
angle. The tie rod allow the wheels to pivot and react to sus-
pension travel.
E39 cars are equipped with power disc brakes with integral
antilock brakes (ABS). The parking bralte is a dual-drum sys-
tem integrated with the rear brake rotors.
Power assist is provided by a vacuum booster when the en-
gine is running. The brake pedal
pushrod is connected direct-
ly to the master cylinder, so failure of the vacuum booster
does not normally result in total
bralte failure.
Each disc bralte uses a caliper with a single hydraulic cylin-
der. Brake pads in the left front and right rear contain wear
sensors. When brake pads need replacement, the sensors il-
luminate a light on the dashboard.

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Suspension, Steering and Brakes - ~enerail
The main components of the system are the wheel speed
(pulse) sensors, the
ABSIASC or ABSIDSC control module,
and the hydraulic control unit.
Traction control also comes into operation during decelera-
tion. Decelerating on snowy or icy road surfaces can lead to
rear wheel slip. If a rear wheel starts to drag or lock up, the
ASC system can limit the problem by adjusting throttle, fuel
injection and ignition timing.
4 A switch (arrow) on the center console is used to toggle the
ASC on or off.
NOJE-
Even with the ASC system turned off, if the ASC control mod-
ule senses a difference in wheel speed (one wheel spinning)
the
ASC system applies modulated braling force to the slip-
ping wheel until traction is regained. There is no override of
fuelinjection function.
The ASC system is designed to be maintenance free. There
are no adjustments that can be made. Repair and trouble-
shooting of the ASC system requires special test equipment
and knowledge and should be performed only by an autho-
rized
BMW dealer.
ABSIASC traction
I 1.
control system
Wheel speed sensor
Wheel speed pulse wheel
Brake disk
Brake caliper
ABSIASC hydraulic unit
Brake master cylinder
Pedal operated throttle valve
ASC controlled throttle valve
Engine control module (ECM)
Accelerator pedal
ABSlASC control module

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I Steerina and Wheel Alianment
Steering
system
Two types of steering gear are used in the E39 series models.
6-cylinder
(5251, 528i and 530i) models are equipped with
rack and pinion steering. The steering rack is mounted to
an aluminum subframe.
V-8
(540i) models are equipped with a recirculating ball
and nut steering gearbox mounted to a steel subframe.
At low speeds, maximum power assist is provided to ease
parking and city driving. At high speeds, assist is reduced to
ensure stability. The power steering system varies assist
based on engine speed.
Power boost for the steering is provided by an engine-driven
hydraulic pump. A hydraulic control valve is used to control
boost pressure.
The steering wheel connects to the steering gear via an ad-
justable steering column which incorporates a rubber cou-
pling ("guibo") to dampen vibration and noise.
Power steering fluid is supplied from the fluid
reservoir to the
pump and to the steering gear via rubberlmetal hoses.
The return line from the steering gear to the
reservoir loops
into the airstream in front of the radiator and connects to the
steering fluid cooler. The fluid cooler is attached to a cassette
which also includes cooling coils for engine oil, transmission
fluid and AIC condenser.
The steering gear requires no maintenance other than align-
ment and periodic inspection for worn components. Inspect
rubber rack boots
(rack and pinion system) and tie-rod end
boots periodically for tears or damage. Replace
if necessary.
-
NOTE-
The airbag system is traditionally referred to as Supplemen-
tal Restraint System (SRS). The
BMW versfon of SRS used
m the E39 models is known as the Multiple Restraint System - (MRS). - -

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i Steering and Wheel Alignment
RACK AND PINION STEERING
(6-CYLINDER MODELS)
Refer to the steering components illustration when perform-
ing the procedures below.
Rack and pinion steering
components
(6-cylinder models)
1. Power steering fluid reservoir
2. Fluid supply line
3. Power steering pump
4. Copper sealing ring
5. Banjo bolt MI4
6. Banjo bolt MI6
7. Power steering rack
8. Fluid return line
9. Pressurized fluid line
10. Steering fluid cooler
11. Rack boot components
12. Tie rod nut
13. Washer
14. Outer tie rod end
15. Tie rod locking ring
16. Outer tie rod end loclc nut
17. Inner tie rod
18. Hydraulic control valve
Steering rack, removing and installing
- Remove steering wheel as described earlier.
- Raise front of car, and remove front wheels.
WARNING -
Male sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do
not place jack stands under suspension
parts.
- Remove splash shield from under engine.
- Remove right and lefl engine mount fasteners
-" ., - , . ,

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General ........................... .34 0.2
Special Tools
....................... .34 0.2
E39 brake system
.................... .34 0.4
Electronic braking and stability control
.... .34 0.4
Troubleshooting
..................... .34 0.5
Warnings and cautions
................ .34 0.7
Bleeding Brakes ................... .34 0.8
Brakes, bleeding
..................... .34 0.9
Brake Pads, Calipers and Rotors ... .34 0.1 1
Braking system components .......... .34 0.11
Brake pads,
checking and replacing ..... .34 0.12
Brake rotors, removing and installing
.... .34 0.15
Master Cylinder .................. .34 0.16
Master cylinder, removing and installing
. .34 0.17
Brake Booster .................... .349 0.1
Brake booster check valve
............ .34 0.19
Brake booster, removing and installing
.. .34 0.20
Parking Brake .................... .34 0.22
Parking brake components
............ .34 0.22
Parking
brake, adjusting .............. .34 0.22
Parking bralte shoes, removing
and installing
....................... .34 0.23
Parking
brake cable, replacing ......... .34 0.24
ABS Component Replacement ..... 340-26
Wheel speed sensor. replacing
......... 340-26
ABS impulse wheel
.................. 340-27
DSC lateral acceleration or
rotational rate (yaw) sensor. replacing
... 340-27
DSC steering angle sensor.
removing and installing
............... 340-28
DSC precharge pump.
removing and installing (1998 models)
... 340-29
DSC pressure sensor
(1 999 - 2002 models) ................ 340-30
ABS /traction electronic control
module
(1 997 -1 998 models) .......... 340-31
ABS
/ DSC control module
(1 999
- 2002 models) ................ 340-31
ABS
/ traction control hydraulic unit.
removing and installing
............... 340-31

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340-6
1 Brakes
Brake system troubleshooting
/symptom I Probable cause 1 Repairs
Brake squeal
Pedal goes to floor when
bralting
Low pedal after system bleeding
Pedal spongy or brakes work
only when pedal is pumped
Excessive braking effort
Brakes pulsate, chatter or grab
Uneven
bralting, car pulls to one
side, rear braltes
loclt
Brakes drag, bind or overheat Brake
pad carriers dirty or corroded or
pads loose (poor fit) in pad carrier
Braite pads heat-glazed or oil-soaked
Wheel bearings worn (noise most
pronounced when turning)
Incorrectly Installed brake pads,
parking bralte shoes, or bralte parts
Brake fluid loss due to system leaks
Master cylinder or traction control
system faulty
Master cylinder faulty
Air in braite fluid
Master cylinder or traction control
system faulty
Brake pads wet
Brake pads
heat-glazedorfluid-soalted
Vacuum booster or vacuum hose
connections to booster faulty
--- Warped brake rotors
Brake pads worn
Brake pads heat-glazed or oil-soaked Remove
brake pads and clean calipers. Use original
equipment pads for proper fit and use BMW anti-squeal
compound during installation,
Replace brake pads. Ciean rotors. Replace leaking caliper:
as required.
Replace worn bearings. See 310 Front Suspension
or33C
Rear Suspension.
Check component installation. Checldreplace anti-rattle
springs.
Checlt fluid level and inspect for signs of leakage.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Replace master cylinder.
Bleed system using factory or compatible diagnostic tool.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Use light pedal pressure to dry pads while driving.
Replace
bralte pads and rotors. Replace leaking calipers.
lnspect vacuum lines. Test vacuum booster and replace as
required. Test vacuum non-return valve for one-way flow.
Resurface or replace rotors.
Replace brake pads.
Clean rotors. Replace leaiting calipers.
Incorrect tire pressures or worn tires
Brake pads on one side of car heat-
glazed or fluid-soaked
Caliper or brake pads binding
Worn suspension components
Brake caliper or brake pads binding
Master cylinder or traction control
system faulty lnspect
tire condition. Checlt and correct tire pressures.
Replace brake pads. Clean rotors. Replace leaking
calipers.
Clean and recondition brakes.
Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Ciean or replace caliper.
Replace master cylinder. Diagnose traction control system
using faclory or compatible diagnostic tool.

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Brakes
Brakes, bleeding
The procedure below requires a BMW Service Tester (DIS-
pluslGTl/MoDiC).
- Determine type of traction control (ASC, DSC with precharge
pump, DSC without precharge pump). Be sure to use correct
specification brake fluid, according to application table below.
Brake fluid applications
ABS I ASC and ABS / DSC models DOT 4 brake fluid
with precharge pump (to 911998)
ABS I DSC models without precharge DOT 4 low viscosity
pump (911998 and later) brake
fluid
< Remove left side interior ventilation microfilter housing:
Remove upper cover and microfilter loclting clip
(A).
Release locking clamp (B), and rotate air tube in direction
of arrow to remove.
Disconnect wiring harness from hood switch
(C).
Release filter body mounting clamp (D) and remove lower
microfilter housing.
- Top off bralte fluid in reservoir and connect BMW Service
Tester to
20 pin Data Link Connector (DLC) under hood or 16
pin
DLCIOBD I1 connector under dash.
- Call up service function Bleeding ABS / ASC or service func-
tion Bleeding ABS
/ DSC, depending on installed system.
- Fill pressure bleeding device with the correct brake fluid and
connect to brake fluid reservoir and apply pressurize.
Do not exceed a pressure of
2 bar (29 psi) when pressure
bleeding the
brake system. Excessive pressure will damage
4 Starting at right rear wheel, connect bleed hose and fluid re-
ceptacle to bleeder screw (arrow).
CA UTlON-
Bleeder hose must always remain submersed in clean brake
fluid whenever the bleeder valve is open.

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Brakes
- Pump brake pedal a few times to reduce vacuum in brake
booster. This makes removal of
check valve easier.
- Remove or loosen hose clamp(s) at check valve.
- Disconnect hoses. Remove valve to test or replace.
NOTE-
If valve is pressed into grommet in vacuum booster, pry it out
carefully.
- Reinstall valve using new hose clamps
NOTE-
Install the valve so that the molded arrow is pointing toward
the intake manifold.
Brake booster, removing and installing
CAUTIO&
All E39 vehicles sold in the USA are equipped with Antiloclc
Braking System (ABS) and either Automatic Stability Control
(ASC) or Dynamic Stability Control (DSC). In order for the
bralchg and stability controls to work properk if brake fluid
lines are disconnected and reconnected,
male sure that the
brake system is bled by an authorized BMW dealer or other
qualified repair facility using the BMW Service Tester: See
Brake Bleeding earlier in this group.
- Disconnect negative (-) cable from battery.
I CAUTION- I
Prior to disconnecting the battery read the battery discon-
nection cautions given in
001 General Cautions and
I Warnings. I
- Remove bralte master cylinder as described earlier.
- Disconnect engine vacuum hose from bralte booster.

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OED-2
On-Board Diagnostics
Specialized OED II scan tool equipment is needed to access
the fault memory and
OED I1 data.
The extra hardware needed to operate the OED
I1 system
consists mainly of the following:
* Additional oxygen sensors downstream of the catalytic
converters.
Fuel tank pressure sensor and device to pressurize
fuel
storage system.
Several engine and performance monitoring devices
Standardized 16-pin
OED II connector under the
dashboard.
Upgraded components for the federally required reliability
mandate.
Malfunction indicator light (MIL)
OED II software illuminates the malfunction indicator light
(MIL) when emission levels exceed 1.5 times Federal
standards.
4 For E34 cars covered by this manual, three different MIL
symbols were used, depending on year and model.
MIL illuminates under the following conditions:
Engine management system fault detected for
two
consecutive OED iI drive cycles. See Drive cycle in this
repair group.
- Catalyst damaging fault detected.
Component malfunction causes emissions to exceed 1.5
times OED
II standards.
Manufacturer-defined specifications exceeded. Implausible input signal.
Misfire
faults.
Leak in evaporative system,
Oxygen sensors observe no purge
flow from purge valve 1
evaporative system.
ECM fails to enter closed-loop operation within specified
time.
ECM or automatic transmission control
module (TCM) in
"limp home" mode.
ignition key ON before cranking (bulb
check function).
OED
II fault memory (including the MIL) can only be reset
using a special scan tool. Removing the connector from the
ECM or disconnecting the battery does not erase the fault
memory.