Fuel tank BMW 528i 1998 E39 Repair Manual

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160-25
Fuel Tank and Fuel pump1
The 312-way valve is also activated briefly if an engine misfire
is detected. This provides full fuel flow through the fuel rail to
determine if the misfire was caused by a lean fuel condition.
The valve is monitored by the ECM forfaults.
- Using BMW or compatible scan tool, read out fault memory.
See
OBD On-Board Diagnostics.
- Turn off ignition.
- Raise car and support safely.
CA UTIOW
Male sure the car is stable and well suppodedat all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floor jack is not adequate support.
- Worlting under car beneath driver's seat, remove protective
panel from fuel filter and 312-way valve.
- Clamp off fuel lines at 312-way valve.
4 To remove 312-way valve (V-8 model shown):
Disconnect electrical harness connector
(A) from valve.
Remove vacuum hose
(B) from fuel pressure regulator.
* Remove hose clamps (arrows) and disconnect fuel lines.
Remove
M6 mounting nuts and lower 312-way valve.
WARNING-
Fuel will be spilled. Use shop rags to capture fuelas fuellines
are disconnected. Do not
smoke or work near heaters or oth-
er fire hazards.
- Installation is reverse of removal. Use new hose clamps
NOTE-
Install protective cover and seals correctly to keep moisture
and road dirt out of underbody fuel system components.
Tightening torques Hose clamps
8 - 13 mm dia.
2 Nm (18 in-lb)
Hose clamps
10 - 16 mm dia.
2 Nm (18 in-lb)
Hose clamps
18 mm dia. 3 Nm (27 in-lb)
Hose clamps 42
- 48 mm dia. 4 Nm 136 in-ib)

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300-1 4
I Susoension. Steerina and Brakes - General
DSC system I
Dynamic Stability Control (DSC)
Dynamic Stability Control (DSC) utilizes many principles and
components of the ASC traction control system. DSC is ac-
tive throughoutthe driving range, unlike ASC which is only ac-
tive during acceleration and braking. DSC helps stabilize the
vehicle in cornering and avoidance maneuvers by adjusting
engine controls such as throttle, ignition, fuel injection and the
application of
brake pressure individually to the wheels.
Inputs
fi- 0
2 4-* .. o
[11-' IJ
411m4
3?-
G
4 The DSC control module uses various inputs to determine
vehicle instability during braking, cornering, or reduced trac-
tion situations. Based upon these inputs the ABSIDSC con-
trol module sends outputs to the engine control module and
the ABSIDSC hydraulic unit to activate torque reduction pro-
tocols and braking intervention.
-
ABSIDSC control module
OUI~YIS
4
The DSC system can be toggled on and off by a switch
mounted on the center console. Turning off the DSC system
does not disable ABS or ASC functions.
+
Measure ride height (A) from center of fender arch to bottom
of wheel rim.
Car in normal loaded position on the ground. See Normal
loaded position.
Engine
control
module
Specified tires and wheels, correct tire pressure, even tire
wear
-'* 9-
.%A
Correct wheel bearing play
T'== ..t, 9 B
-.m
Model with air suspension (EHC): Disconnect electrical har-
ness connector to air supply pump to prevent automatic
height regulation.
When finished, reset ride height using BMW diagnostic
scan tools DIS or
MoDiC.
NOTE-
Airsupply pump is located beneath a cover under the spare
tire in the floor of the cargo compartment.
- If ride height is outside specification listed, install new
springs. Suspension spring removal and installation is cov-
ered in
310 Front Suspension and 330 Rear Suspension.
Normal loaded position
Each front seat 68 kg (150 Ib)
Center of rear seat 68 kg (150 lb)
Trunk 21 kg (46 lb)
Fuel tank full

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Steering and Wheel Alignment
- Tighten nut while counterholding adjusting bolt,
- Tighten nut only after car has been lowered to ground and
suspension has settled.
Preparing for alignment
- The following conditions are necessary prior to wheel align-
ment:
Correct wheels and tires are installed, in good condition,
and are at the correct inflation pressures.
All steering and suspension parts and bushings are un-
damaged and show no signs of abnormal wear. Wheel
bearings are in good condition.
Ride height is in accordance with specifications. See
300
Suspension, Steering and Brakes-General.
Car is in normal loaded position. See below.
* Cars with air suspension: Remove air suspension power
fuse.
Normal loaded position
Each front seat
68 Kg (I50 lb)
Center of rear seat
Trunlc
Fuel tank
68 Kg (150 lb)
21 Kg (46 lb)
Full
Alignment specifications tables
In the alignment specification tables that follow, reference is
made to the various types of suspension used in
E39 cars.
The type of suspension can be identified by loolting at the la-
bel on the front strut tube.
Identifying symbol
None
Solid circle
Solid triangle
M5
Circle
Triangle Version
Standard suspension
Sports
suspension
Sports suspension
M sport package
Standard suspension
Sports suspension Model
Sedan
6-cylinder sedan
V-8 sedan
V-8 sedan
Touring (Sport Wagon)
Touring (Sport Wagon)

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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.

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- -
On-Board Diagnostics
Professional diagnostic scan tools available atthe time of this
printing include the BMW factory tools
(DISplus, GTI,
MoDiC) and a small number of aftermarket BMW-specific
tools. See
020 Maintenance.
In addition to the professional line of scan tools, inexpensive
generic OBD
II scan tool software programs and handheld
units are readily available. Though limited, they are
nonetheless powerful diagnostic tools. These tools read live
data streams and freeze frame data as well as a host of other
valuable diagnostic data.
Diagnostic monitors
Diagnostic monitors run tests and checks on specific
emission control systems, components, and functions.
A complete drive cycle is requiredforthe tests to bevalid. See
Drive cycle in this repair group. The diagnostic monitor
signals the
ECM of the loss or impairment of the signal or
component and determines if a signal or sensor is faulty
based on
3 conditions:
* Signal or component shorted to ground
Signal or component shorted to
B+
Signal or component missing (open circuit)
The OBD
II system monitors all emission control systems that
are installed. Emission control systems vary by vehicle model
and year. For example, a vehicle may not be equipped with
secondary air injection, so no secondary air readiness code
would be present.
OBD
II software monitors the following:
Oxygen sensors
Catalysts
Engine misfire
- Fuel tank evaporative control system
Secondary air injection Fuel system
Oxygen sensor monitoring. When driving conditions allow,
response rate and switching time of each oxygen sensor is
monitored. The oxygen sensor heater function is also
monitored. The OBD
II system differentiates between
precataylst and post-catalyst oxygen sensors and reads each
one individually. In order
forthe oxygen sensor to be
effectively monitored, the system must be in closed loop
operation.

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On-Board Diagnostics
Readiness codes indicate whether the OED Ii system is
actually ready to monitor the various emission control
systems on the vehicle. The vehicle must complete a drive
cycle to set readiness codes. The code is binary:
0 for ready
1 for not ready
f
4 The parameters which are monitored for readiness are:
llM readiness codes
1. Catalyst efficiency
2. Catalyst heating
3. Fuel tank evaporative control
4. Secondary air injection
5.
NC refrigerant
6. Oxygen sensors
7. Oxygen sensor heaters
8. Exhaust gas recirculation
Readiness codes are set to 1 (not ready) in the following
cases:
~9~~.f~[<+t~t~p:,~;:#j~~{]~y~ ,,... , , 8701Dbd001
The battery or ECM is disconnected.
When
all zeros are displayed, the system has established
DTCs are erased after completion of repairs and a drive
cycle is not completed.
readiness. Readiness codes
can be displayed using BMW
and aftermarket scan tools.
An
OED II scan tool can be used to determine IIM readiness.
Diagnostic trouble codes (DTCs)
SAE standard J2012 mandates a 5-digit diagnostic trouble
code (DTC) standard. Each digit represents a specific value.
Emission related DTCs
start with the letter P for power train.
When the engine service
light (MIL) is illuminated it indicates
that a DTC has been stored.
DTCs are stored as soon as they occur, whether or not the
engine service light illuminates.
DTCs store and display a time stamp.
DTCs record the current fault status: Present, not currently
present, or intermittent.

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On-Board ~ia~nosticsl
Engine diagnostic trouble codes: M62 engine (continued)
P-code
I I -
I I - -.
PI445 1186 / Diagnostic Module Tank Leakage (DM-TL) Pump Control Circuit Signal Low
PI357
PI382
PI386
PI413
PI414
PI441
PI442
PI443
PI444
P1356 1 53 I Misfire during Start Cylinder 8
BMW-FC
I P1523
I
I - -
1165 I 'A' Camshaft Position Actuator Signal Low (Banlc 1)
Explanation
P1381 1215 I Control Module Self-Test, Knock Control Onset (Bank 1)
53
21 6
21 4
84
84
1
1
1
186
PI 446
PI 447
PI 448
PI449
PI 450
PI451
PI452
PI476
Misfire Cylinder 8 with Fuel Cut-Off
Control Module Self-Test, Knock Control Test Pulse (Bank 1)
Control Module Self-Test, Knock Control Circuit Baseline Test (Bank 1)
Secondary Air Injection Pump Relay Control Circuit Signal Low
Secondary Air Injection Pump
Relay Control Circuit Signal High
Leakage Diagnostic Pump Control Open Circuit
Leakage Diagnostic Pump Control Circuit Signal Low
Leakage Diagnostic Pump Control Circuit Signal High
Diagnostic Module Tank Leakage (DM-TL) Pump Control Open Circuit
186
189
189
189
2
2
2
184
P1524
P1525
P1526
PI527
PI528
PI633
PI 634
PI 635
I I
PI 638 / 131 I Throttle Valve Position Control Throttle Stuck Temporarily
. -
Diagnostic Module Tank Leakage (DM-TL) Pump Control Circuit Signal High
Diagnostic Module
Tank Leakage (DM-TL) Pump Current Too High during Switching Solenoid Test
Diagnostic Module Tank Leakage (DM-TL) Pump Current Too Low
Diagnostic Module
Tank Leakage (DM-TL) Pump Current Too High
Diagnostic Module Tank Leakage (DM-TL) Switching Solenoid Control Open Circuit
Diagnostic Module
Tank Leakage (DM-TL) Switching Solenoid Control Circuit Signal Low
Diagnostic Module
Tank Leakage (DM-TL) Switching Solenoid Control Circuit Signal High
Leakaqe Diaqnostic Pump Clamped Tube
I I
165
165
166
166
166
136
133
134
'A' Camshaft Position Actuator Control Circuit Signal High (Banlc 1)
'A' Camshaft Position Actuator Control Open Circuit (Bank 1)
'A' Camshaft Position Actuator Control Open Circuit (Bank 2)
'A' Camshaft Position Actuator Control Circuit Signal Low (Bank 2)
'A' Camshaft Position Actuator Control Circuit Signal High (Bank 2)
Throttle Valve Adaptation Limp-Home Position Unknown
Throttle Valve Adaptation Spring Test Failed
Throttle Valve Adaptation Lower Mechanical Stop not Adapted
Throttle Valve Control Circuit
PI 636
PI639
P1643
P2088
P2089
PI 637 / 130 I Throttle Valve Position Control, Control Deviation
132
131
135
165
165 Throttle
Valve Position Control Thronle Stuck Permanently
Throttle Valve Actuator Start Test Amplifier Balancing Plausibility
'A' Camshaft Position Actuator Control Circuit Low (Banlc 1)
'A' Camshaft Position Actuator Control Circuit High (Bank 1)

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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

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2 INDEX
Battery, starter, alternator
alternator (generator)
121-10
6-cylinder engine, removingi
installing 121-15
M62 engine 121-16
M62 TU engine (water cooled)
121-18
battery
121-5 charging 121-9
safety terminal 121-3
testing 121-5 charging system, troubleshooting
121-12
starter
121-1 9
6-cylinder engine, removingi instaliinq 121-20 . V-8 engine, rernovinglinsialiing
121-21
solenoid, removinglinstalling
121-23 troubleshooting 121-19
see also Maintenance
Bearing, wheel
see Front suspension
see also Rear suspension
Belts see Maintenance, drive belts
Blade, wiper
see Wipers and Washers
Blower motor see
A/C
BMW emblem
see Exterior trim
BMW special tools 010-18 see also special tools section at
beginning
of each repair group
Body dimensions 400-2
interior features
400-9 salety and security 400-7
Body side molding
see Exterior trim
Bonnet see Engine hood
Boot see Trunk
Brake fluid
020-24, 340-8
Brake fluid pressure sensor
340-30
Brakes
ABS, ASC or DSC system
300-12
component replacement 340-26
ASCIDSC switch
see Switches
bleeding
bralces 340-8
brake booster 340-1 9 bralce Dads. caiioers and rotors ,., 340-1 1
descriotion 300-10
e~ectrdnic brake & stability 300-11
light switch
see Switches
master cylinder
340-16 pariking brake 340-22
troubleshooting 340-5
Bulbs see Lights
Bumper
lront 510-6 height, adjusting 510-12
rear 510-9
Bus system
600-4
Camber
320-33
Camshaft
removingiinslaiiing
M52 engine 116-12
M52 TU
/ M54 engine 116-1 9 M62 engine 11 6-39
wear
116-6
Camshaft position sensors
see ignition system
Camshaft timing chain
adjusting M52 engine
117-22
M52 TU I M54 engine 117-43
M62 engine 117-79 removinglinstalling
M52 engine 117-26
M52TU 1 M54 engine 113-46.116-
28
M62 engine 117-66
Capacities, fluid
020.10
Car rnemorvlicev memorv . . 600-10
see also Centrai
lociking
Carbon canister, activated
see Fuel
tank
Caster
320-33
Catalytic converter and oxygen sensor 020-19
see also Exhaust system: exhaust
manilolds
Cautions
001-3
CD changer
650-4
Center bearing, driveshaft
see Driveshait
Center brake light
sedan
630-13
Center console
513-3
Centrai body electronics (ZKE 111)
600-6
Central locking
car memoryiey memory 515.12 general module iunctions 515-2
remote entry (FZV) 515-8
remote lkey initialization 515-10 single lociddouble ioclk 515-6
switch 515-4
Chain
see Camshaft liming chain
Characteristic map (electrically heated) thermostat
see Electrically heated thermostat
Charging system
see Battery, starter, alternator
Cluster see instruments
Clutch fluid see Maintenance
hydraulics
210-4
mechanical 210-9
switch
see Switches, pedal ciuster
variations
210.10
Codes, fault OED-1
Coil
see Ignition system
Coil spring
see Front suspension
see also Rear
suspe nsion

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WARNING
Your common sense, good
judgement, and general alertness are
crucial lo sale and
successlul service
work. Belore attempling any work on
your BMW, be sure to read 001
General Warnings and Cautions
and lhe copyright page
a1 llle Iron1 01
the manual. Review lliese warnings
and cautions each time you prepare
lo work on your
BMW Please also
read any warnings and
caulions lhal
accompany the procedures In !he
manual.
Component locations
see Electrical system
Compression test
113-5
Compressor see
AlC
Condenser see
AlC
Constant velocity (CV) joint
see Maintenance
see also
Driveshall
see also Drive axles
Consumer cutoff
600-10
Control arm see Front suspension
see also Rear suspension,
suspension arms
Coolant (antifreeze) see Maintenance
see also Cooling system
Coolant pump
see Cooling system Cooling system
coolant bleeding
170-14 6-cylinder engine, draininglfilling
170-10
V-8 engine, draininglfilling 170-12
coolant pump 170-3
6-cyiinder engine, replacing 170-1 9
V-8 engine, replacing 170-20 cooling fan 170-4
viscous ciutch fan, removingi
installing 170-14
electric fan, removlngiinstailing 170-1 5
expansion tank, removinglinstalling
170-22
electrically heated (ciiaracterislic
map) therrnostat 170-4
radiator, removinglinstaliing 170-22
service
see Maintenance
therrnostat 170-16
transmission fluid heat exchanger
170-5 troubleshooting 170-7
combuslion leal( test 170-10
pressure test
170-9
Crankshaft oil seals
iront
117-6
rear 11 9-6
Crankshaft speed sensor
see Ignition syslem
Crash sensor
see
Airbag system (SRS), side-impact
airbag crasii sensor
Cruise control clutch switch 612-9
CV joint
see Maintenance
see also Driveshalt
see also Drive axles
CV joint boot
see Maintenance
see also Drive axles
Cylinder head removinglinslaliing
M52 engine 113-8
M52 TU / M54 engine 113-22
M62 engine 113-56
Cylinder head and valvetrain
hydraulic lifters, checking and
replacing
116-7 leak test 116-5 valves 11 6-56
see
alsocylinder head Dashboard
513-7
Deck
lid
seeTrunk lid
Diagnostic monitors
OED-4
Diagnostic trouble codes
(DTCs)
080-7
Digital multimetel
010-17
Differential see Final drive
DLC (data
link connector) 020-4, OED-4
DME (digital motor electronics)
see
130 under appropriate fuel
injection system
see also ignition system
DM-TL (detection module-tank leak)
see
Fuel lank, leak deteclion unit
Drive
belts
see Maintenance
Dome light
seeLighls, interior lights
Door
door
check, replacing 411-4
hinge adjustment 41 1-5
loci(
see Door lock see also Central locking
removinglinslaliing 41
1-2
panel, removinglinstaliing 41 1-7 window
see Door window
Door
check
see Door
Door
handle
see Door lock
Door glass
see Door window
Door
lock
handles and loci(s 515-16
see also Central locking
Door
molding
510-13
Door panel see Door