electronic BMW 525i 2001 E39 User Guide

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11 3-56
I Cvlinder Head Removal and Installation
- Installation of the remaining parts is reverse or removal, not-
ing the following:
- Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
If necessary, adjust accelerator cable.
a Reconnect battery.
CAUTION- To prevent damaging the engine electronic systems, installall
ground wire previously removed, including the ground wires
for the
ionition coils.
Tightening torque Coolant drain
pluq to cylinder bloclc 25 Nm (1 8 ft-lb)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb) -
Radiator drain screw to radiator 2.5
Nm (22 in-lb)
spark plug to cylinder head 25
Nm (1 8 ft-lb)
CYLINDER MEAD REMOVAL AND
INSTALLATION (M62 ENGINE)
This procedure covers cylinder head removal and installation
for the
M62 V-8 engine. Procedures forthe M62 TU VANOS
engine are not covered in this manual.
Intake manifold, left cylinder head, and right cylinder head re-
moval and installation are written as separate procedures.
The intake manifold must be removed before the cylinder
heads can be removed.
WARNING
-
Due to risk of personal injuv be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation requires multiple spe-
cial service tools. Read the entire procedure before beginning
the repair.
Intake manifold, removal and installation,
M62 engine
- Disconnect negative (-) battery cable.
CAUTION- Prior to disconnecting the
batterj read the baitery discon-
nection cautions
in 001 General Cautions and Warnings.

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I Cylinder Head and Valvetrain
- Remove adjustable primary timing chain tensioner tool and
reinstall primary chain tensioner cylinder to cylinder head.
Tightening torque
Primary chain tensioner cylinder
to 70 Nm (52 ft-lb)
cylinder head
- Remove flywheel locking tool from crankcase. Replace spe-
cial tool bore sealing plug.
- Remove camshaft locking tools from cylinder head
Install intake camshaft cover and cylinder head cover.
Check for correct seating of half-moon seals (A) in back of
cylinder head cover.
Use a small amount of Three Bond
8 1209 or equivalent
sealing compound at corners
(B) of half-moon cutouts.
Seat gasket and seal corners at VANOS unit with Three
Bond
@ 1209.
Tightening torque Cylinder head cover to cylinder head
(M6) 10 Nm (89 in-lb)
- Installation of the remaininq parts is reverse or removal, not- -
ing the following:
Change engine
011 and f~lter as descr~bed in 020 Mainte-
nance.
Reconnect battery.
To prevent damaging the engine electronic systems, install
all ground wire previously removed, including the ground
wires for the ignition coils.
Tightening torque
-
Radiator cooling fan to coolant pump 40 Nm
(30 ft-ib)
Spark plug to cylinder head
25 Nm (18 ft-ib)

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1 17-2
Camshaft Timing Chain
This repair group covers timing chain and VANOS repair
information for the following engines:
M52 (Single VANOS 6-cylinder engine)
M52
TU and M54 (Double VANOS engines)
M62 (Non VANOS
V-8 engine)
NOTE-
The M62 TU V-8 engine with VANOS Variable Camshaft
Timing repair information is not included.
NOTE-
See 100 Engine General for engine code and application
information.
Worn timing chains and sprocltets can lead to noisy operation
and erratic valve timing. Afaulty tensionercan also cause tim-
ing chain noises.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
113 Cylinder Head Removal and Installation
119 Lubrication System
121 Ignition System
170 Radiator and Cooling System
Special tools
Special BMW service tools are needed to perform the service
and repairs procedures covered in this repair group. Many of
these tools are expensive and only available through an au-
thorized BMW dealer. Be sure to read each procedure thor-
oughly before starting a job to determine which special tools
will be necessary.
In addition, Double VANOS system diagnosis can only be
carried out by using BMW specific electronic scan tools, such
as BMW
DISplus, MoDiC or equivalent.
4 Torque wrench wl flex extension
(Tool No. BMW 00
9 250)

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120-3
Ignition System
Warnings and cautions
The ignition system produces dangerous high voltage. In ad-
dition the sensitive electronic components can be damaged
if
proper precautions are not adhered to.
WARNING-
* Do not touch or disconnect any cables from the coils while
the engine is running or being
cranked by the starter.
The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when working on a car with the ignition
switched on or the engine running.
- Connect and disconnect tlie DME system wiring and
test equipment leads only when the ignition is
OFF:
Before operating the starter without starting the engine
(for example when
making a compression test) always
disable the ignition.
CA
U TIOW-
Do not attempt to disable the ignition by removing the coils
from the spark plugs.
Connect or disconnect ignition system wires, multiple
wire connectors, and ignition test equipment leads only
while the ignition is
off Switch multimeter functions or
measurement ranges only with the test probes discon-
nected.
* Do not disconnect the battery while the engine is run-
ning.
A high impedance digital multimeter should be used for
all voltage and resistance tests. An LED test light
should be used in place of an incandescent-type test
lamp.
In general, make test connections only as specified by
BMW as described in this manual, or as described by
the instrument manufacturer.
Engine management
BMW €39 engines use an advanced engine management
system known as Digital Motor Electronics (DME). DME in-
corporates on-board diagnostics, fuel injection, ignition and
other engine control functions. DME variants are listed in
Table a. Engine management systems.
Second generation On-Board Diagnostics
(OED II) is incor-
porated into the engine management systems used on the
cars covered by this manual. Use a BMW-specific electronic
scan tool, or a "Generic"
OED II scan tool to access Diagnos-
tic Trouble Codes (DTCs). DTCs can help pinpoint ignition
ine management problems.

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I lgnition System
Additional information about DTCs and engine management
system electronic system diagnosis is provided in
OBD On-
Board Diagnostics.
Table a. Engine management systems
Year
l~ngine I Engine type IDME svstem I - I - . . I
Ignition system
1997-1 998
1997
1998
1999-2002
4 All engines use a distributorless ignition system with individ-
ual ignition coils for each cylinder. There is no distributor cap
or ignition rotor.
4 Each coil is controlled and monitored by the Engine Control
Module (ECM) on a cylinder-by-cylinder basis.
1999-2000
1~52 TU 16-cylinder l~iemens MS
42.0
M62
M62
M62TU
Siemens MS 41 .I M52 6-cylinder
V-8
V-8 V-8 Bosch
M 5.2
Bosch M 5.2.1
Bosch ME 7.2

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Lnition switch
4 The positive (+) power supply to the ignition coils comes to
the ignition switch via an unloader relay. When the ignition
switch is turned on, the relay closes, to provide voltage to the
ignition coils. The coils are then actuated at the negative side
by the engine control module.
NOTE-
Schematic diagrams shown are for illustrative purposes only.
See ELE Electrical Wiring Diagrams for engine manage-
ment specific wiring information.
WARNING- Do not touch or disconnect any cables from the coils while
the engine is running or being cranked by the starter:
The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when
working on a car with the ignition
switched on or the engine running.
* Connect and disconnect the DME system wiring and
test equipment leads only when the ignition is
OFF
Before operating the starter without starting the engine
(for example when
making a compression test), always
disable the ignition.
4 Knock sensors (arrows) monitor the combustion chamber for
engine-damaging knock. Six-cylinder models (shown) use
two sensors with each sensor monitoring three cylinders.
V-
8 models use four sensors, each monitoring two cylinders. If
engine
knock is detected, the ignition point is retarded by the
ECM.
I Ignition advance Ignition timing is electronically mapped and not adjustable.
The ECM uses engine load, engine speed, coolant tempera-
ture, knock detection, and intake air temperature as the basic
inputs for timing control.
A three dimensional map similar to
the one shown is digitally stored in the ECM.
- The initial ignition point is determined by the crankshaft
speed sensor during cranking. Once the engine is running.
timing is continually adjusted based on operating conditions.

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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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121-11
Battery, Starter, ~lternatorl
Alternator 1997 - 98 5281 1997 540i
/-- -----,
I'
-----------
F15 / 7.5A/ :
&.. .... , 30 1 Xi0015
Battery
Hol in run 61 E (D+) Alternator
and stsrt
lBL
(Generator)
1 .--------,charge , . I , indicator I xGoli i
I <"9,7,a,T
Alternator, basic
On 1997-1 998 6-cylinderand 1997 V-8 models, the charging
system indicator light is supplied voltage
(+) to one side of the
light bulb, and the other side of the bulb is connected to the
voltage regulator.
With the engine off and the key in the run position, voltage
from the ignition switch flows through the regulator to ground,
completing the circuit and illuminating the charge indicator
bulb.
When the vehicle is started and the alternator begins to pro-
duce voltage, the output of the diode trio increases and the
light is turned off.
Alternator with multi-function control
(MFR)
Alternator with multi-function control
(MFR)
The multi-function controlled alternator is used on:
* 1999-2002 6-cylinder models
* 1998-2002 V-8 models
4 On cars with multi-function control alternator, the charge in-
dicator lamp is activated by means of an electronic switch in-
tegrated in the alternator controller. This switch receives its
voltage supply from terminal
15 on the 3-pin connector at the
rear of the alternator. The controller measures internally the
voltage difference between terminal 30 and terminal
15 and
signals the DME ECM to turn the charge indicator lamp on.
The controller features integrated fault detection. The battery
charge indicator lamp will come on in the event of:
* Failure of belt drive
No charge due to an
electrical/electronic fault
Interruption in excitation circuit
Over-voltage due to a defective controller output stage Fault or break in charge line
No charge due to alternator fault

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Battery, Starter, ~lternatorl
Charging system quick-check
Use a digital multimeter to measure voltage across the bat-
tery terminals with key off and then again with engine running.
Battery voltage should be about 12.6 volts with key off and be-
tween 13.5 and 14.5 volts with engine running.
NOTE-
The regulated voltage (engine running) should be between
13.2 and 14.5, depending on temperature andoperating con-
ditions.
If the voltage is higher than 14.8, the voltage regula-
tor or
mulitfunction controller is most likely faulty
Check for clean and tight battery cables. Check ground cable
running from negative
(-) battery terminal to chassis and
ground cable running from engine to chassis. Check alterna-
tor drive belt condition and tension.
Charging system, checking
CAUTIOI\C
* Do not disconnect the battery while the engine is running.
Damage to the alternator and/or engine electronic systems
may result.
Only use a digital multimeter when testing charging
system components.
--7
4 Turn ignition key on. Check that battery warning light comes
on.
NOTE-
If the warning light does not come on, repair bulb or wiring
faults before continuing to checlc the charging system.
/ Charge indicator
502820805
4 6-cylinder engines only, remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

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Fuel Injection
Warnings and cautions
For personal safety, as well as the protection of sensitive
electronic components, adhere to the warnings and cautions
on the following pages.
WARNING-
Gasoline is highly flammable and its vapors are explosive.
Do not smoke or work on a car near heaters or other fire
hazards when diagnosing and repairing fuel system prob-
lems. Have a fire extinguisher available in case of an emer-
gency
Renew fuel system hoses, clamps and O-rings any
time they are removed.
When working on an open fuel system, wear suitable
hand protection, as prolonged contact
with fuel can
cause illnesses and skin disorders.
* The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when
working on a car with the ignition
switched on or the engine running.
CAUTION-
- Disconnecting the battery may erase fault code($ storedin
memory Check for fault codes prior to disconnecting the
battery cables. Read the battery disconnection cautions in
001 General Warnings and Cautions.
a Connect and disconnect the DME system wiring and
1 test equipment leads only when the ignition is switched
off.
Wait at least 1 minute after turning off the ignition be-
fore removing the engine control module (ECM) con-
nector. If the connector is removed before this time,
residualpower in the system relay may damage the
control module.
Fuel system cleaners and other chemical additives oth-
er than those specifically recommended by BMW may
damage the catalytic converter, the oxygen sensor or
other fuel supply components.
* Do not connect any test equipment that delivers a 12-
volt power supply to terminal 15 (+) of the ignition coil.
The current flow may damage the ECM. In general,
connect test equipment only as specified by BMW or
the equipment maker.
Only use a digital
multirneter for electrical tests. Only
use an LED test light for
quiclc tests.