117 BMW 528i 1997 E39 Workshop Manual

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YOU are now in Volume I
I
Foreword ................... .. ........................................................................\
.......... v
Index
........................ .. ................................................................ rear of manual
General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder
Maintenance OiO 020 Maintenance
Engine
100 Engine-General 110 Engine Removal and Installation
113 Cylinder Head Removal and
Installation
116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain
119 Lubrication System
200 Transmission-General
2 Transmission 210 clutch 230 ManualTransmission
I20 Ignition System
121 Battery, Starter, Alternator
130 Fuel Injection
160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System
180 Exhaust System
240 Automatic Transmission
250 Gearshift Linkage 260 Driveshaft
Suspension, 300 Suspension, Steering and 330 Rear Suspension
Brakes-General 331 Final Drive
Steering and No Front Suspension 340 Brakes
320 Steering and Wheel Alignment
400 Body-General
410 Fenders, Engine Hood 411 Doors
412 Trunk Lid, Tailgate
510 Exterior Trim, Bumpers 512 Door Windows
Equipment 513 Interior Trim
7
Equipment and 720 seat Belts
Accessories 721 Airbag System (SRS)
OBD On-Board Diagnostics
. ............ ..
515 Central Lociting and
Anti-Theft
520 Seats 540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rear of manual
Electrical
6 system
600 Electrical System-General 620 Instruments
610 Electrical Comoonent Locations 630 Liohts
611 wipers and washers 612 Switches eati in^ and Air Conditioning
Radio
. ........... ........ .........................
Electrical Wiring Diagrams

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Engine-General
This section covers system descriptions and general informa-
tion on engines and engine management systems. Also cov-
ered is basic engine troubleshooting.
For specific repair procedures, refer to the appropriate repair
group:
110 Engine Removal and Installation
0 113 Cylinder Head Removal and Installation
116 Cylinder Head and Valvetrain
0 117 Camshaft Timing Chain
119 Lubrication System
120 Ignition System
130 Fuel Injection
0 170 Radiator and Cooling System
E39 models are fitted with a variant of either an inline 6-cylin-
der or a
V-8 engine. See Table a.
Table a. Engine specifications

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11 3-2
Cylinder Head Removal and Installation
This group covers cylinder head removal and installation as
well as cylinder
headlvalve diagnostic procedures.
In the procedures in this repair group, engines are referred to
by engine code. If necessary, see
100 Engine-General for
engine code and application information.
The information given in this repair group assumes that the
engine is installed in the engine bay. On the
6-cylinder en-
gines, the VANOS control unit must be removed in orderto re-
move the cylinder head from the engine block. On
M52TU
and M54 engines, camshafts must be removed from the cylin-
der head before the head is removed.
The cylinder head removal and installation procedures for the
M62 V-8 are also included, butthe proceduresforthe M62TU
V-8 with VANOS are not provided.
For cylinder head and valvetrain reconditioning information,
see
116 Cylinder Head and Valvetrain.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
If a head gasket problem is suspected, a compression test or
leak-down test will usually detect the fault See Diagnostic
Testing later
in this group.
Special tools
Special BMW service tools are required to properly remove
and install the cylinder head on engines covered by this man-
ual. The special tools are used to time the valvetrain to the
crankshaft, and to remove the VANOS control unit, the cam-
shafts and the
Tom (El2) head bolts. Read the entire proce-
dure through before beginning the job.

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- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
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 1209
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
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.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl

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. .- --
Cylinder Head Removal and Installation
Secure camshaft sprockets and impulse wheels:
Tighten mounting screws
(A) on exhaust camshaft impulse
wheel to approx.
5 Nm (44 in-lb).
Tighten mounting nuts
(8) on exhaust and intake sprocket
assemblies to approx.
5 Nm (44 in-lb).
Torque down mounting screws (A) and nuts (B) to final
specifications.
Tightening torques
sprocket assembly to camshaft
initial torque
5 Nm (44 in-lb)
Sprocket assembly
wheel to camshaft
M7 torx screws (A) 20 Nm (15 ft-lb)
M6 mounting nuts (5) 10 Nm (8 ft-lb)
- Remove crankshaft locking tool from transmission bell hous-
ing so that crankshaft is no longer secured in
TDC position.
- Remove camshaft locking tools from cylinder head.
4 Turn engine over twice in direction of rotation until cylinder 1
intake and exhaust camshaft lobes (arrows) face each other.
- Secure crankshaft in TDC position with BMW special tool 11
2 300.
4 Place BMW special tool set 11 3 240 over camshafts and
measure clearances.
CAUTION-
- If the exhaust side of the tool (A) is not flush with tlie head,
camshaft timing is incorrect Reset camshaft timing as de-
scribed in
117 Camshaft Timing Chain.
* Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft tim-
ing is set correctly, the intake side of special tool
11 3
240 (6) may be up to 1 mm (0.04 in.) above the surface
of the cylinder head. This is normal. Reassemble en-
gine.
Othe~lise, reset camshaft timing as described in
11 7 Camshaft Timing Chain.
- Remove BMW special tool 11 6 150 from front of cylinder
head.

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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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116-12
I Cylinder Head and Valvetrain
Camshaft and lifter removal and installation
(M52 engine)
Camshafts and lifters, removing (M52 engine)
WARNING
-
The process of evenly loosening the camshaft bearing cap
nuts is NOT an acceptable method of removing the cam-
shafts. Special tools should always be used to remove the
camshafts. Be sure to read the procedure
tlirough before
starting a job.
I Allow engine to cool before beginning this procedure. /
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the batfew read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove VANOS control unit from cylinder head. See 117
Camshaft Timing Chain.
I I 4 Remove loosened bolts (arrows) from front of exhaust
sprocket
nuts
(arrows) from intake camshaft

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Cylinder Head and valvetrain1
- Remainder of installation is reverse of removal, noting the
following:
See
117 Camshaft Timing Chain for VANOS control unit
installation.
Tightening torques
Camshaft bearing caps
to cylinder head (M7) 15 Nm (1 1 ft-lb)
Cylinder head cover to cylinder head (M6) 10 Nm (89 in-lb)
Sparic plugs (M12) 23 Nm (17 ft-lb)
Camshaft and lifter, removal and
installation
(M52 TU and M54 engine)
Camshafts and lifters, removing
(M52 TU and M54 engine)
WARNING-
Allow engine fo cool before beginning this procedure.
- Disconnect negative (-) cable from battery.
CAUTION--
Prior to disconnecting the battea read the battery discon-
nection cautions in
001 General Cautions and Warnings.
Remove VANOS control unit. See 117 Camshaii Timing
Chain.
Remove primary timing chain tensioner (arrow).
CAUTION-
Primary timing chain tensioner is under spring pressure. 1

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-
. - - -- Cylinder Head and valvetrain]
Turn engine over twice in direction of rotation until cylinder 1
intake and exhaust camshaft lobes (arrows) face each other.
- Lock crankshaft in TDC position with BMW special tool
11 2 300.
4 Place BMW special tool set 11 3 240 over camshafts and
measure clearances.
NOTE-
@ If the exhaust side of the tool (A) is not flush with the head,
camshaft timing is incorrect. Reset camshaft timing as de-
scribed in 11
7 Camshaft Timing Chain.
Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft timing
is set correctly, the intake side of special tool set
11 3 240
(B) may be up to 1 mm (0.04 in.) above the suiface of the
cylinder head. This is normal. Reassemble engine. Other-
wise, reset camshaft timing as describedin 1
l?Camshaft
Timing Chain.
- Remove BMW special tool 11 6 150 from front of cylinder
head.
4 Clean contact edges of cylinder head face and VANOS unit
and apply a thin coat of Three Bond
12090 or equivalent
sealing compound to surfaces.
CAUTION-
Male sure all gasket material is removed from face of cyl-
inder head. Clean sealing face and keep free of oil.
Check locating dowel
(A) and dowel sleeve (B) at top
of cylinder head for damage or incorrect installation.
- Using a new steel gasket, install VANOS unit to front of cyi-
inder head. See 117 Camshaft Timing Chain.
NOTE-
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in 117 Camshaft Tim-
ing Chain.
- Reinstall engine lifting eye.
- Reconnect electrical harness connectors to camshaft posi-
tion sensors and
VANOS solenoid valves.