Air hose BMW 528i 1999 E39 User Guide

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I Engine Removal and Installation
WARNING -
Use extreme caution when draining and disposing of engine
coolant. Coolant is poisonous andlethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingest-
---
Working at rear of intake manifold:
Disconnect brake booster vacuum line (A).
Disconnect fuel tank vent line
(6).
Disconnect hoses (C and D) at coolant manifold
- Remove transmission harness support (E).
- Remove oil filter housing assembly from fender:
- Remove oil filter housing mounting fasteners.
Use stiff wire to secure oil filter housing to engine.
NOTE-
Do not disconnect oil lines from filter housing.
4 Disconnect supply and return fuel lines (where applicable) at
or near fuel rail. Plug open fuel lines.
NOTE-
BMW uses three styles of fuel line connections; a slngle use
clamp, a locking fitting that uses special tool
16 7 050 to re-
lease, and a
quiclc release sleeve (arrows) that disconnects
the line when depressed.
WARNING-
Fuel In fuel line is under pressure (approx. 3 - 5 bar or45 -
75 psi) and may be expelled. Do not smoke or worlc near
heaters or other fire hazards. Keep a fire extinguisher
handy. Before disconnecting fuel hoses, wrap a cloth
around fuel hoses to absorb any lealcing fuel. Catch and
dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before worlcing on the tank or lines.
< Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor (A) and
intalte air temper-
ature sensor
(6) electrical harness connectors.
. Remove air filter housing mounting fastener (arrow).
Loosen intake hose clamp (C).
M62 engine: Remove hose at idle air stabilizer.
Remove air filter housing with mass air flow sensor.
Remove intalte hose from throttle body.

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--
-- Engine Removal and installation' -
Remove polyribbed A/C compressor belt:
Mark direction of belt travel if belts are to be reused.
Loosen bolts
(A).
Turn adjusting lug (B) clocltwise to release belt tension.
Working beneath car, remove power steering pump and air
conditioner compressor. Suspend from body using stiff wire.
Remove exhaust manifolds. See
180 Exhaust System.
< lnstall engine lifting device (BMW 11 0 000 or equivalent) to
front and rear engine supports and raise engine until it's
weight is supported. Detach engine mounts.
a Watch carefully for hoses and electrical wires that might
snag.
- installation is reverse of removal:
Replace all gaskets, O-rings and seals.
V-8 engine mounts have two sets of mounting holes. E39
cars use front most mounting holes.
* On cars with automatic transmission, use new O-rings at
ATF cooler lines.
Use new alignment sleeves when installing transmission.
Be sure engine drive belts properly engage pulley grooves.
When installing belt, preload tensioner to stop (toward
belt), then tighten tensioner clamping nut.
lnstall front exhaust pipes using new gasltets and copper
paste and new mounting hardware. See
180 Exhaust
System.
Change engine oil and filter. Check all other fluid levels as
described in
020 Maintenance.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
CAUTION-
Do not interchange knoclc sensor harness connectors. Seri-
ous engine damage may result

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11 3-9
Cylinder Head Removal and Installation
< Remove left and right interior ventilation ducts (left shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic locking tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclockwise to unlock from bulkhead and
remove (arrow).
Disconnect electrical connector from hood switch
(C).
Release spring lock (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel: Remove rubber sealing
gasket (arrow).
0 Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift out panel.
< Remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from
~ntake
duct (6) and disconnect Idle speed control valve electr~cal
harness connector.
Disconnect
electr~cal harness connector (C) from mass alr
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.
4 Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jumper post (A).
Loosen and remove battery lead mounting nut.
Remove battery lead and push down through intake mani-
fold.
Remove trim caps (arrows) from fuel injector cover.
Remove cover hold down fasteners and lift off cover.

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113-10
Cylinder Head Removal and Installation
4 Working above engine, disconnect the following:
Vent line from cylinder head cover
(A).
. Oxygen sensor connectors (B).
Electrical harness connector from VANOS solenoid
valve
(C).
Electrical harness connectors at throttle valve position
switch
(D), ASC valve position switch (E), fuel injector har-
ness
(F) and vent valve (G).
CAUTION-
Be sure to mark oxygen sensor harness connectors so that
they can be reassembled correctly Do not interchange con-
nectors.
4 Where applicable, remove schraeder valve cap (arrow) from
air connection on fuel rail. Using a tire chuck, blow fuel back
through feed line using a brief burst of compressed air (max-
imum of
3 bar or 43.5 psi).
WARNING-
. Fuel in fuel line is underpressure (approx. 3 - 5 bar or 45 -
75 psi) and may be expelled. Do not smoke or work near
heaters or other fire hazards. Keep a fire extinguisher
handy Before disconnecting fuel hoses, wrap a cloth
around fuel hoses to absorb any leaking fuel. Catch and
dispose of escaped fuel. Plug open fuel lines.
- Always unscrew the fuel rank cap ro release pressure
;n the tank before working on the tank or lines.
Disconnect fuel lines by sliding locking collar in (arrows) and
pulling lines apart.
NOTE-
BMW uses three styles of fuel line connections; a one-time
use
clamp; a locking fitting that uses BMWspecial tool 16 1
050 to release; and a quick release sleeve (above) that dis-
connects the line when depressed.

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..
Cylinder Head Removal and Installation 1
< Remove intake throttle valve and ASC throttle assemblies:
Disconnect ASC throttle cable
(A).
- Remove ASC throttle housing mounting fasteners (B).
NOTE-
It is not necessary to disconnect coolant hoses (C) 01
bowden cables (D).
Remove intake throttle housing mounting hardware, pull
throttle housing off
intake manifold, and set aside.
- Working under intake manifold, disconnect the following:
Engine oil dipstick tube support.
Oil separator return line from dipstick tube.
Intake air temperature sensor electrical harness connector
(underside of intake manifold near throttle body).
* Fuel tank vent line and electrical harness at canister vent
valve.
Remove lower intake manifold supports (arrows).
- Disconnect coolant line retaining bracket at cylinder block.
4 Remove manifold mounting hardware (arrows).
- Remove intake manifold from cylinder head while carefully
checking for electrical connections or hoses.
NOTE-
Fuel rail is removed with intake manifold,
CAUTIOI\C
Stuff clean rags into open intake ports to prevent any parts
from falling into
Nie engine intake.
- Drain cooling system (engine block and radiator), then re-
move radiator cooling fan and fan shroud. See
170 Radiator
and Cooling System.
- Disconnect coolant hoses from thermostat housing.

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- --
Cylinder Head Removal and Installation 1 --
< Remove complete air filter housing assembly with mass air
flow sensor:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intake duct
(B) and disconnect idle speed control valve electrical har-
ness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
. Loosen air intalte duct clamp (F).
Carefully lifl air filter housing, mass air flow sensor, and in-
take duct hose out of engine bay.
4 Disconnect positive battery cable and remove intake rnani-
fold cover:
Remove protective cover from positive (+)jumper post.
Loosen and remove battery lead mounting nut (A).
Remove lead and push down through intake manifold.
* Remove trim covers (arrows) from fuel injector cover.
Remove cover hold down fasteners and lifl off cover.
4 Worlting above engine, disconnect the following:
Vent line from cylinder head cover. To remove, pinch clips
(arrows).
Electrical harness connector from VANOS solenoid valve
(A).
- Remove oxygen sensors and exhaust manifolds. See 180
Exhaust System.
CAUTION-
Remove oxygen sensors before removing exhaust mani-
fold to prevent damage.
Label oxygen sensor harness connectors so that they
can be reassembled correctly Do not interchange con-
nectors.
NOTE-
Front exhaust manifold must be removed before rear
manifold.

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. .- -
Cylinder Head Removal and Installation
- Working at side of intake manifold near left strut tower, dis-
connect intake manifold resonance valve electrical harness
connector.
4 Disconnect fuel injector electrical harness connectors from
injectors.
- Use small screwdriver to pry out wire lock clip on fuel injec-
tor
1 connector.
Repeat for remaining injectors.
Release harness conduit fasteners from injector rail.
- Disconnect intake air temperature sensor electrical har-
ness connection (between intake runners for cylinders
3
and 4).
Lift off connector assembly and lay aside.
4 Where applicable, remove schraeder valve cap (arrow) from
fuel
ra~l. Using a tire chuck, blow fuel back through feed line
using a brief burst of compressed air (maximum of
3 bar or
43.5 psi).
WARNING-
Fuel is underpressure (approx. 3 - 5 bar or 45 - 75psi) and
may be expelled. Do not smoke or
work near heaters or
other fire hazards. Keep a fire extinguisher handy Before
d~sconnecting fuel hoses, wrap a cloth around fuel hoses
to absorb any leaking fuel. Catch and
dfspose of escaped
fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
I in the tank before working on the tank or lines.
Disconnect manifold vacuum line (arrow)
Raise car and support in a safe manner,
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A
floorjack is not adequate support.
Remove protective engine splash guard from below engine.

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Cylinder Head Removal and Installation
4 If applicable, remove secondary air injection pump:
Disconnect hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
Disconnect electrical harness from bottom of secondary
air injection pump.
Remove mounting bracket from strut tower.
4 Remove ignition coils:
* Disconnect ignition coil harness connectors.
Remove coil mounting fasteners.
Remove coils.
* Remove ground straps.
CA UTIOI\C
Note location of all ground wires. Failure to reinstall grounds
can result in permanent damage to engine control module or
ignition system components.
Set coil harness to side of engine compartment
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
ltets should be reinstalled in their original locations. Male
note of their arrangement during removal.
- Remove spark plugs
4 Remove oil baffle cover from above intake camshaft.

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Cylinder Head Removal and Installation /
4 Remove top engine cover by releasing quick release fasten-
ers (arrows) by pressing down.
NOTE-
Earlier models may have an engine cover with pry off caps
and fasteners
In place of quick release fasteners.
4 Remove left and right interior ventilation ducts (left side
shown):
- Release locking tabs (A) or locking strap (early models, not
shown).
Release spring lock (B).
* Rotate duct inward (arrow) to remove.
Disconnect electrical harness from hood light switch (C).
Release locking clip and remove ventilation housing cover
(D).
Lift out housing from inner fender.
- Removal of right side ventilation housing is similar.
4 Air filter housing assembly, removing:
Disconnect electrical harness connectors from mass air
flow sensor (A) and temperature sensor (B).
Loosen hose clamp (C).
Remove filter housing mounting fastener (arrow) and re-
move filter housing with mass air flow sensor.

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-. .
Cylinder Head and Valvetrain -- v . -- --- --
4 Remove air filter housing and ducts:
Loosen hose clamps as necessary and disconnect electri-
cal harnesses.
- Remove air filter housing mounting fastener (arrow).
Loosen hose clamp at throttle body.
Remove air filter housing with mass air flow sensor and
duct.
Disconnect the following electrical harness connectors.
Knoclc sensors (A).
Thermostat housing (B).
Throttle position sensor/throttle position switch and idle
valve
(C).
Camshaft position sensor (D).
* Ignition coils (E).
Remove mounting nuts (arrows)
ducting. from
wiring harness