ESP BMW 525i 2001 E39 User Guide

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I Cvlinder Head Removal and Installation
4 Install secondary chain tensioner on cylinder head (arrows).
Keep tensioner compressed using BMW special tool 11 3
291 or suitable pin.
< Install exhaust camshaft splined sleeve. Confirm that gap in
sleeve splines aligns with corresponding gap in
camshaft
splines (arrows).
Slide splined shaft onto exhaust camshaft. Be sure that locat-
ing tooth of shaft fits into spline gaps of camshaft and splined
sleeve
(arrows).
- Push splined shaft in further to rotate splined sleeve until the
three threaded holes in primary chain sprocket are centered
in the small slots of the splined sleeve.
4 Place intake and exhaust sprockets in BMW special tool 11 6
180. Position spline gap on intake sprocket (arrow) as shown
and place secondary chain on sprockets.

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-7 Cylinder Head Removal and lnstallat~on -- -- - -
Remove chain and sprockets from tool and slide sprockets
on camshafts. Confirm that gap in intake sprocket splines
lines up with corresponding gap in camshaft splines (arrow).
CAUTIOI\C
Do not alter position of sprockets with respect to chain when
removing
from special tool 11 6 180.
< Align locating tooth of splined shaft with gaps on camshaft
and sprocket. Slide splined shaft onto intake camshaft until
approx.
1 mm (0.04 in) of splines (arrows) are visible.
4 Install intake camshafl spring plate so that FRONT mark is
visible. Install mounting nuts (arrows) finger tight.
Insert sprocket mounting bolts (arrows) on exhaust side
camshaft assembly.
Initially tighten to approx.
5 Nm (44 in-lb) and then back off
by half a turn.

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11 6-6
Cylinder Head and Valvetrain
4 Before machining the head to correct for warpage, measure
the total height
(A) (thickness of the cylinder head). Minimum
height specifications are given in Table a. Cylinder head
height.
NOTE-
6 cylinder and V-8 engines share cylinder head height spec-
ifications.
Table a. Cylinder head height
New Minimum height
(A)
140.0 rnrn (5.512 in.) 139.7 rnrn (5.500 in.)
Valves, leak test
To test the valves for leakage, the cylinder head must be dis-
assembled with camshafts and camshaft carriers removed.
With valve assemblies and spark plugs installed, place the
cylinder head on a workbench with the combustion chamber
facing upward. Fill each combustion chamber with a thin non-
flammable liquid. After fifteen minutes, check the level of the
fluid. If the fluid level in any cylinder drops, that cylinder is not
sealing properly.
Camshaft wear
Camshaft wear is usually caused by insufficient lubrication.
Visually inspect camshaft lobes and journals for wear. Cam-
. ~~ shaft wear specifications are given in Table b. Camshaft
wear specifications.
CA UTIOI\C
If the camshaft is being replaced due to cam lobe wear, it is
recommended that the corresponding lifters should also be
replaced to avoid damaging the new camshaft
Table b. Camshaft wear specifications
6 cylinder engines V-8 engines
Axlal play 0.150-0.330 rnrn 0 200-0 360 rnrn - .-
(0.0060-0 013 in.) (0.008 - 0.014 in ) - - Radlal play 0.020-0.054 rnrn 0.040-0.074 rnrn
(0.0008-0.0021 in.) (0.016 - 0.029 in.)

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11 6-32
Cylinder Head and Valvetrain
4 Install secondary chain tensioner (arrows). Keep tensioner
compressed using
BMW special tool 11 3 292 or suitable pin.
4 Fit exhaust camshaft splined sleeve. Confirm that gap in
sleeve splines aligns with corresponding gap in carnshaft
splines
(arrows).
Slide splined shaft onto exhaust camshaft so that locating
tooth of shaft fits into spline gaps of camshaft and splined
sleeve
(arrows).
- Push splined shafl in further to rotate splined sleeve until the
three threaded holes in primary chain sprocket are centered
in the small slots of the splined sleeve.

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Cylinder Head and valvetrain1
< Place intake and exhaust sprockets in BMW special tool
11 6 180. Position spline gap on intake sprocket (arrow) as
shown and place secondary chain on
sprocitets.
< Remove chain and sprockets from tool and slide sprockets
on camshafts. Confirm that gap in intalte sprocket splines
lines up with corresponding gap in camshaft splines (arrow).
CAUTIOI\C
Do not alter position of sprockets with respect to chain when
removinq from saecial tool 11 6 180.
4 While aligning locating tooth of shaft with spline gaps on
camshaft and sprocket, slide spiined
shaft onto intalte carn-
shaft until approx. 1 mm (0.04 in.) of splines (arrows) are
visible.
4 lnstall intake camshaft spring plate so that FRONT mark is
visible. install mounting nuts (arrows) finger tight.

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11 7-60
Camshaft Timing Chain
< Install and tighten down threaded locating studs (arrows) in
end of exhaust camshaft.
Tightening torque Exhaust camshaft locating
stud 20 Nrn (15 ft-lb)
4 Install secondary chain tensioner on cylinder head.
- Make sure tensioner is locked in compressed position as
described earlier.
Fit exhaust camshaft splined sleeve, aligning gap in sleeve
splines with corresponding gap on
camshaft splines
(arrows).

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- Camshaft Timing chain]
< Slide splined shaft onto exhaust camshaft, aligning larger
tooth with corresponding gap of splined sleeve (arrows).
Slide splined shaft in further until
3 small or elongated slots
in splined sleeve are centered to
3 threaded holes in
sprocket.
4 Place intake and exhaust sprocltets in BMW special tool 11 6
180. Position spline gap on intalte sprocket (arrow) as shown
and place secondary chain on sprocltets.
< Carefully remove chain and sprockets from tool and slide
onto camshafts. Align gap in
intalte sprocket splines with cor-
responding gap in camshaft splines (arrow).
CAUTION-
Do not alterposltion ofsprocl(ets with respect to chain when
removing from
specfa1 tool 1 1 6 180.
4 Slide splined shaft onto intake camshaft until approx. 1 mm
(0.04 in.) of splines can still be seen.

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< Ignition voltage peaks in response to sudden acceleration
load:
1. Normal ignition pattern. Beginning of dying out pattern
is not much higher than ignition voltage peak.
2. Beginning of dying out pattern considerably higher than
ignition voltage peak. Fault in injection system:
Lean fuel mixture
Defective fuel injector
Low compression in cylinder
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Ignition firing order
Normal secondary voltage patterns
(4-cylinder pattern shown).
4 Each ignition coil is mounted above the corresponding spark
plug.
- Number one cylinder is located at the front on 6-cylinder
models.
Number one cylinder is located at the right (passenger side)
front on
V-8 models. Cylinder firing order is shown.
Firing order
M52 - M52 TU - M54 6-cylinder 1-5-3-6-2-4
M62 - M62 TU V-8 1-5-4-8-6-3-7-2

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130-1 3
Fuel Injection I
< Unplug harness connector (arrow) from sensor.
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
NOTE-
Do not confuse the throttle position sensor on the main Nirot-
tle body with the throttle position switch on the secondary
throttle body, where applicable.
- Remove two mounting screws holding sensor to throttle
housing.
- Installation is reverse of removal. Clear adaptation settings
from ECM using BMW-compatible scan tool.
NOTE-
Poor idle quality may be noticeable for a period if the adapta-
tion settings are not cleared after installing new TPS.
ldle speed control valve,
checking and replacing
The idle speed control valve regulates idle speed by redirect-
inq airaround the throttlevalve.The idlespeed control valve is
mounted on the underside of the intake manifold adjacent to
the dipstick tube bracket. Accessing the valve is best accom-
plished by first removing the air filter housing and the throttle
body assembly.
The valve issupplied with
batteryvoltagefrom the ECM relay.
The idle speed control valve incorporates a two-coil rotary ac-
tuator. The ground sides of each coil are pulsed
sirnulta-
neously by the ECM. The duty cycle of each circuit is varied to
achieve the required idle speed.
Afaulty ldle speed control valve sets afault code and the MIL
is illuminated when
OED II fault criteria are exceeded.
Before checking the idle speed control valve, confirm that the
throttle position sensor is working correctly.
- With engine running, check that idle speed control valve is
buzzing.
- Turn on AIC system or shift transmission into drive. ldle
should remain steady or increase slightly.

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130-51
Fuel Injection
Oxygen sensors, checking
The oxygen sensor provides an input voltage signal [0.2 vdc
(lean) to 0.8 vdc (rich)] to the
ECM based on the oxygen con-
tent in the exhaust gas. To generate voltage, the sensor tem-
perature must exceed 575"
F (300" C). Therefore the sensor
is electrically heated.
NO JE -
The test given below is not a conclusive test of oxygen sen-
sor efficiency and does not test how the oxygen sensor re-
acts to changing conditions. Pin numbers and wire colors
can vary Always check the wiring diagrams to confirm wire
color and pin assignment.
0 The oxygen sensorconnectorplugs are locatednext to the
catalytic converters.
With connector attached to sensor, connect digital voltmeter
between
A and B wires in connector.
WARNING -
Exhaust manifolds andpipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
NOJE-
Connector style may vary depending on system application.
Consult wiring diagram for system-specific wiring. See
ELE
Electrical Wiring Diagrams.
Start engine.
A fluctuating voltage signal should show on the
meter.
If voltage is incorrect, turn engine off and check pre-
heater circuit as described below.
NOJE-
To check sensor response to lean and rich mixtures, create
an air leak.
Oxygen sensor
voltage at idle
- Connect digital voltmeterbetween sensor heaterwires (white
wires,
C and D). Start engine and check for battery voltage.
If voltage is not present, check oxygen sensor heater fuses.
0.2 to 0.8 vdc fluctuating
NOJE-
The oxygen sensor heater is powered via fusedpositive (+)
battery voltage and a switchedground from the ECM. See
ELE Electrical Wiring Diagrams for specific circuit informa-
tion.
- The ground side of the oxygen sensor heater circuit is pulsed
on and off by the
DME control module.