bolt BMW 528i 1999 E39 User Guide

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Maintenance
< Remove NC compressor belt:
Loosen tensioner mounting fasteners (arrows)
Swing tensioner down to remove belt.
4 To reinstall compressor belt:
Route belt over pulleys.
* Pretension belt by turning adjuster clockwise (arrow) to
stop.
- Tighten tensioner mounting bolts (A).
Tightening torques
Fan clutch to coolant pump (left- hand thread)
with BMW tool
11 5 040
30 Nm (22 ft-lb)
without BMW tool 11 5 040
40 Nm (29 ft-lb)
Tensioner to engine block
8.8 grade
22 Nm (16 ft-lb)
10.9 grade (Ilquid-cooled alternator) 30 Nm (22 ft-lb)
Idle speed
Engine idle speed can change due to a number of factors, in-
cluding normal wear. The idle speed is electronically adaptive
and not adjustable. See
130 Fuel Injection for more informa-
tion.
Catalytic converter and oxygen sensors
OBD II enhanced emission standards require the engine
control module (ECM) to monitor the oxygen content in the
exhaust with oxygen sensors placed before and after the cat-
alytic converter. This allows for tighter control of tail pipe
emissions and also allows the ECM to diagnose converter
problems. If the ECM detects that catalytic converter or oxy-
gen sensor efficiency has degraded past a certain
prepro-
grammed limit, it will turn on the malfunction indicator light
(MIL), and store a diagnostic trouble code (DTC) in the ECM.
See OBD On-Board Diagnostics for more information on
OBD
ll systems.
Replacement of oxygen sensors at the specified intervals
he engine and emission control system will

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020-21
Maintenance
Spark plugs, replacing
E39 engines use a coil-over-spark plug configuration, with
one ignition coil above each spark plug. Sparks plugs should
be removed only after the engine has cooled.
Remove engine
cover(s) over ignition coils:
Remove acoustic cover over fuel injectors
I intake
manifold.
6-cylinder engine: Remove oil filler cap.
Remove plastic trim covers (arrows).
Remove cover hold-down bolts. Remove coil
cover(s)
6-cylinder engine: Temporarily reinstall oil filler cap to
keep out contaminants.
Remove ignition coil grounding harnesses (arrows). 6-cylin-
der coils shown,
V-8 engine is similar.
< Remove ignition coils:
Pull up on spring clips to disconnect ignition coil harness
connectors.
Remove coil mounting bolts. Pull coils up and off spark
plugs.
- Remove spark plugs.

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7 Maintenance
< Unbolt caliper from steering arm to properly inspect:
Brake pad thickness
(A)
Brake rotor
Condition of caliper seal
(B)
Condition of caliper slider bolts (C)
NOTE-
Brake caliper removal and installation procedures are given
in
340 Brakes.
Brake pad lining minimum thickness
Dimension
A 3.0 mm (0.12 in)
Brake system, inspecting
Routine maintenance of the brake system includes maintain-
ing the brake fluid in the reservoir,
checking bralte pads for
wear, checking parking brake function, and inspecting the
system for fluid lealts or other damage:
- Check that bralte hoses are correctly routed to avoid chafing
or
Itinking.
- lnspect unions and brake calipers for signs of fluid leaks.
- lnspect rigid lines for corrosion, dents, or other damage.
- Inspect flexible hoses for cracking
- Replace faulty hoses or lines as described in 340 Brakes.
WARNING-
Incorrect installation or overtightening hoses, lines, and
unions may cause chafing
orlealage. This can lead to partial
Parking brake, checking
The parking brake system is independent of the main braking
system and may require periodic adjustment depending on
use. Adjust the parking brake if the brake lever can be pulled
up more than
8 clicks. Check that the cable moves freely. A
description of the parking brake and
parlting bralte adjust-
ment can be found in
340 Brakes.

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Engine Removal and lnstallationl
< Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jump start post
(4.
Loosen and remove battery lead mounting nut.
Remove lead and push down through intake manifold
Remove trim covers
(arrows) from fuel injector cover.
Remove cover hold down bolts and lift off cover.
Working above engine, disconnect the following:
Vent line from cylinder head cover (A).
M52 engine: Oxygen sensor connectors (8).
Electrical harness connector from intalte camshaft VANOS
solenoid valve
(C).
M52 engine: Disconnect electrical harness connectors at
throttle valve position switch
(D), ASC valve position switch
(E), fuel injector harness (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 M52 TU, M54 engine: Disconnect fuel injector electrical con-
nectors from injectors.
Use small screwdriverto pry one corner of wire lock clip on
fuel injector
1 connector.
Repeat for all injectors.
Lifl off connector loom and lay aside.

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Engine Removal and lnstallationl
M52 TU, M54 engine: Disconnect electrical harness connec-
tor at fuel tank venting valve
(A). Disconnect vent hose at fit-
ting (arrow).
- Working under intake manifold, disconnect the following:
Engine oil dipstick tube support.
Oil separator return line from
dipsticlc tube.
Intake air temperature sensorelectrical harness connector
(underside of intake manifold near throttle body).
M52 TU, M54 engine: Resonance valve electrical harness
connector.
M52 engine: Fuel tank vent line and harness.
< Working underneath car, remove lower intalte manifold sup-
port mounting bolts (arrows).
4 M52 TU. M54 engine: Remove fuel rail mounting bolts
(arrows):
Carefully pry fuel rail off manifold.
Separate fuel line support bracket at rear of intake
manifold.
NOTE-
* M52 TU engine shown. M54 engine is similar.
M52 engine: Fuel rail is removed with intalte manifold.

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110-12
Engine Removal and Installation
4 Remove hoses from thermostat housing by releasing locks
(arrows). If applicable, detach electrical harness connector
for thermostat housing.
NOTE-
Two different types of hose fasteners are used on the E39
car; lock clamp type as shown above or standard band
clamps.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator as described in
170 Ra-
diator and Cooling
System.
CAUTION-
32 mm radiator fan mounting nut has left hand threads.
4 Disconnect coolant hose (arrow) at rear left side of engine
above starter.
4 Disconnect coolant hose (arrow) at front left side of engine
mount.
- Unbolt power steering fluid reservoir and pull aside without
detaching hoses. Secure to fender with cord or stiff wire.

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Engine Removal and Installation
4 Working at E-box at right rear of engine compartment:
Disconnect engine electrical harness connectors
(arrows).
Lift off harness looms and lay over engine.
- Remove polyribbed drive belts. Mark direction of rotation if
belts will be reused. See 020 Maintenance.
- Remove exhaust system and transmission from car. See 180
Exhaust System, 230 Manual Transmission or 240 Auto-
matic Transmission.
NOJE-
Detach automatic transmission cooler lines from radiator, re-
move brackets holding lines to side of engine, andstore lines
in a clean environment.
- Remove power steering pump:
If necessary, remove steering pump pulley.
Remove front and rear pump mounting bolts.
Suspend pump from body using stiff wire.
4 Remove A/C compressor mounting bolts (arrows) and AIC
compressor from its mounting bracketwithoutdisconnecting,
distorting, or deforming any refrigerant lines. Suspend from
body using stiff wire.
4 If applicable, remove secondary air pump:
Remove hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
- Disconnect electrical harness from bottom of secondary
air pump.
Remove bracket from strut tower.

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11 0-20
Engine Removal and Installation
Working at right side of transmission bellhousing, disconnect
electrical harness connections (arrows) from starter. Re-
move starter retaining bolts and remove starter from trans-
mission mount.
M62 TU engine: Disconnect electrical harness connector
for right oxygen sensor from retaining clip and remove re-
taining clip from transmission.
- Working underneath engine compartment at left side:
Unclip positive battery cable from oil pan.
. Remove alternator cooling duct.
4 M62 engine: Remove fastener A and plug connector B from
alternator.
- M62 TU engine: Remove electrical harness connectors from
front of water cooled alternator.
- Remove exhaust system and transmission. See 180 Ex-
haust System and 230 Manual Transmission or 240 Auto-
matic Transmission.
- Working at front of engine:
Remove upper and lower hoses from radiator.
D~sconnect expansion tank hose from coolant pump.
- Remove belt-driven cooling fan:
Counterhold fan with special tool
11 5 050.
Turn fan mounting nut (32 mm) clockwise (left hand
threads) to loosen.
Rotate fan clockwise to remove.
Remove cooling fan shroud:
Disconnect electrical connectors from coolant level sensor
(B) and coolant temperature sensor (C).
. Remove expansion rivets (A) from each side of shroud
Remove coolant hose
(D).
Slide fan shroud with expansion tank up. Remove radiator
overflow tube from spout of expansion tank. Remove radi-
ator fan shroud with expansion tank.
Remove radiator. See
170 Radiator and Cooling System.

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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 3-2
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.