exhaust system BMW 528i 1999 E39 Service Manual

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170-1 1
Radiator and Cooling system/
4 Remove drain plug (arrow) at bottom of radiator.
Coolant is poisonous. It is especially lethal to pets. Clean up
spills immediately and rinse the area with
wate,: If coolant is
- Place a 3-gallon pail beneath the engine block. Remove en-
gine block coolant drain plug and drain coolant.
< M52 TU 1 M54 engine: Bloclc drain plug is located on exhaust
side of engine block at cylinder
2 (arrow).
M52 engine:
Bloclc drain plug is located on exhaust side of
engine
bloclc between cylinders 3 and 4.
- Reinstall radiator and engine block drain plugs using new
sealing washers.
- Before refilling radiator:
Switch ignition to
ON. (Do not start engine).
Set temperature controls to full warm.
Set blower control to low.
- Using a coolant mixture of 50% antifreeze and 50% distilled
water, fill expansion tank slowly. Continue until coolant
emerges from bleed screw. Cooling system capacity is listed
in Table c. Cooling system capacity (6-cylinder models).
NOTE-
Be sure radiator bleed screw is loose when filling cooling
system.
Tap water may cause corrosion of radiator, engine and
coolant hoses.
Coolant can be reusedprovided it is clean and less than
two years old. Do not reuse coolant when replacing dam-
aged engine parts.
- Bleed cooling system. See Cooling system, bleeding
Table c. Cooling system capacity (6-cylinder models)
Engine Capacity
M52, M52TU, M54
10.5 liters (1 1.1 US qls)

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170-1 3
Radiator and Cooling ~vsteml
< V-8 engine bloclc drain plugs (one shown at arrow) are locat-
ed on each side of engine block (exhaust manifold removed
for photo).
- Place 5-gallon pail underneath engine block coolant drain
plugs.
- Remove engine bloclc coolant drain plugs and drain coolant.
- Reinstall radiator and engine block drain plugs using new
sealing washers.
- Before refilling radiator:
Switch ignition to
ON. (Do not start engine)
Set temperature controls to full warm.
- Set blower control to low.
- Using a coolant mixture of 50% antifreeze and 50% distilled
water, fill expansion tank slowly. Continue until coolant
emerges from bleed screw. Cooling system capacity is listed
in Tabled. Cooling system capacity
(V-8 models).
NOTE- Be sure radiator bleed screw is loose when filling cooling
system.
Tap water may cause corrosion of radiator, engine and
coolant hoses.
Coolant can often be reused provided it is clean and less
than two years old. Do not reuse coolant when replacing
damaged engine parts.
- Bleed cooling system. See Cooling system, bleeding
Tabled. Cooling system
capacity (V-8 models)
M62, M62 TU 12.0 liters (12.7 US qts)
Tightening torques
Block drain plug
25 Nm (18 ft-lb)
Radiator drain plug
2 - 3 Nm (18 - 27 in-lb)

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180 Exhaust System
General Exhaust System
. . . . . . . . . . . . . . . . .
Exhaust system, removing and installing
Muffler, replacing..
. . . . . . . . . . . . . . . . .
Exhaust Manifolds . . . . . . . . . . . . . . .
Exhaust manifolds, removing
and installing (M52 engine)
. . . . . . . . . .
Exhaust manifolds, removing and
installing (M52
TU and M54 engines) . . .
Exhaust manifolds, removing
and installing (M62 engine)
. . . . . . . . . .
Oxygen Sensors. . . . . . . . . . . . . . . . . . . . 180-9
Oxygen sensors (precatalyst),
replacing
(M52 TU and M54) . . . . . . . . . . . . 180-9
Oxygen sensors (post-catalyst),
replacing (M52
TU and M54) . . . . . . . . . . . . 180-9
Oxygen sensor, replacing
(M52 and M62 engine) . . . . . . . . . . . . . . . 180-10
Exhaust System Diagrams . . . . . . . . . 180-1 1
M52 engine (528i 1997-1 998) . . . . . . . . . . 180-1 1
M52
TU and M54 engines
(528i 1999-2000 and 5251 2001-2003) . . . 180-1 2
M54 engine
(530i 2001-2003) . . . . . . . . . . 180-1 3
M62 engine
(540i 1997-1 998) . . . . . . . . . . 180-1 4
M62
TU engine (540i 1999-2003 . . . . . . . 180-1 5

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180-2
Exhaust System
The exhaust system is designed to be maintenance free, al-
though regular inspection is warranted due to the harsh oper-
ating conditions. Under normal conditions, the catalytic
converter does not require replacement unless it is damaged.
New fasteners, clamps, rubber mounts and gaskets should
be used when replacing exhaust components.
A liberal appli-
cation of penetrating oil to the exhaust system nuts and bolts
in advance may make removal easier.
WARNING -
The exhaust system and catalytic converter operate at
very high temperatures. Allow components to cool before
servicing. Wear protective clothing to prevent burns.
Do not use flammable chemicals near a hot
cataiyiic
converter.
Corroded exhaust system components crumble easily
and often have exposed sharp edges. To avoid injury,
wear eye protection and heavy gloves when working
Exhaust system, removing and installing
The removal and installation procedures given here are gen-
eral procedures for all models. The removal of the exhaust
system as a complete unit is recommended. Once the com-
plete system is removed from the car, individual pipes and
mufflers can be more easily replaced.
WARNING-
Exhaust gases are colorless, odorless, and very toxic. Run
the engine only in a well-ventilated area. Immediately repair
any
leaks in the exhaust system or structural damage to the
car body that
might allow exhaust gases to enter the passen-
ger compartment.
CAUTION-
Use care not to drag or bang oxygen sensors. Oxygen sen-
sors can be easily ruined.

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... .
Exhaust System
- With exhaust system fully cold, raise and support car for ac-
cess to exhaust system.
WARNING -
Do not worlc under a lifted car unless it is solidly supported on
jack stands designed for that purpose. Never work under a
car that is supported solely by a
jack.
- Disconnect oxygen sensor connector(s).
4 Loosen and remove bolts holding front exhaust pipes to ex-
haust manifolds (arrows). Right side of
V8 model shown.
- Support exhaust system
- Where applicable, disconnect exhaust support bracket as-
sembly from transmission.
< Remove hangers by prying off bracket (arrows).
- Lower exhaust system as a single unit to ground.
NOTE-
If the catalytic converterlfront exhaust pipe assembly is to be
replaced, transfer the oxygen sensors to the new
pipe(s).
Tightening torque
Oxygen sensor
55 Nm (41 ft-lb)
- installation is reverse of removal.
* Make sure there is at least 20 mm (314 in.) clearance be-
tween exhaust system and car body at every point.
Loosely install
ail exhaust system mounting hardware and
hangers before tightening fasteners to their final torque.
Coat manifold studs with copper paste before installing
nuts.
NOTE-
Where applicable, tighten front pipe with semi-flexible com-
pensator last when installing front pipe to
manifolds.
Tightening torques
Exhaust manifolds
to cylinder head 22 Nm (1 7 It-lb)
Front exhaust pipe to manifolds 30 Nm (22 ft-lb)
To prevent exhaust system rattles and vibration, the system
should be slightly preloaded by pushing the rear clamping
brackets forward about 7 mm (114 in).

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/Exhaust System Muffler, replacing
BMW offers individual mufflers as replacement parts for the
original one-piece assembly. Replacement of a rear muffler
may be possible with the system installed on the car. Re-
placement of the front or middle muffler should only be done
with the exhaust removed from the car.
< Mark length of new muffler pipe(s) on old system.
- Use exhaust pipe cutter to cut pipe(s). Deburr cut pipe
end@).
4 Use clamping sleeves to join new pipe(s) to old.
Make sure pipe ends are centered inside sleeve.
Point clamping sleeve bolt threads
(arrows) down.
- Reinstall exhaust system.

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Exhaust system1
Exhaust manifold removal procedures are organized accord-
ing to engine code. If necessary, see
100 Engine-General
for engine code and application information.
Exhaust manifolds, removing and installing
(M52 engine)
4 Exhaust manifolds for the M52 engine.
Always use new retaining nuts and gaskets when removing
and installing the exhaust manifolds.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work under a lined car unless it is solidly supported on
jack stands designed for that purpose. Never work under a
car that is supported solely by a jack.
- Disconnect secondary air check valve and pipe from exhaust
manifold.
- Unbolt front exhaust pipe@) from exhaust rnanifold(s)
- Remove exhaust support bracket from transmission.
- Loosen and remove nuts from exhaust manifolds and remove
manifolds. Discard nuts and gaskets.
NOTE-
On cars with oxygen sensors mounted in the exhaust mani-
folds, use care when removing manifolds.
To be safe, remove
the sensors from the manifolds before removing manifolds.
- Installation is reverse of removal
Coat exhaust manifold mounting studs with copper paste
before installing new nuts.
Install manifold gaskets with arched side facing manifolds.
Tightening torque
Exhaust manifolds
to cylinder head 20 Nm (15 ft-lb)

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180-6
Exhaust System
Exhaust manifolds, removing and installing
(M52 TU and M54 engines)
I Exhaust manifolds with converters I 4 The exhaust manifolds incorporate the catalytic converters.
Two precatalyst and two post-catalyst oxygen sensors are
mounted in the exhaust manifold assembly.
Under normal conditions, the catalytic converters do not re-
quire replacement unless damaged. Always use new retain-
ing nuts and gaskets when removing and installing the
exhaust manifolds.
I\
1 4 Using engine support equipment (BMW special tools 00 0
200. 00 0 201. 00 0 202.00 0 204.00 0 208 or equivalent).
connect to
lifting eye on front of engine. Rhise engine approx.
/I 1
5 mm (IH in).
With exhaust system cold, raise and support car for access
to exhaust system.
WARNING-
Do not worlc undera liftedcar unless it is solidly supported on
jack stands designed for that purpose. Never worlc under
a
car that is supported solely by a jaclc.
in order to avoid damaging oxygen sensors:
- Detach oxygen sensor harness connectors,
Remove oxygen sensors from exhaust manifolds as de-
scribed later in this group.
Unbolt and remove secondary air
checkvalve and pipe from
right front of cylinder headlexhaust manifold.
Working underneath car, unbolt front exhaust pipes from ex.
haust manifolds.
With engine supported from above, remove right engine
mount
bracket and right engine mount (arrow).
Loosen and remove nuts from exhaust manifolds and remove
manifolds. Discard nuts and gaskets.
CA UTIOG
Take care tliat the front and rear oxygen sensor connectors
are not mixed up.
-

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1 Exhaust ~vsteml
NOTE-
The front exhaust manifold must be removed before the rear
manifold.
- Installation is reverse of removal.
Coat exhaust mounting studs with CRC or equivalent cop-
per paste.
Use new gasltets and self-locking nuts.
Tightening torques Exhaust manifold to cylinder head 20 Nm
(15 ft-lb)
Front exhaust pipe to manifold 30 Nm
(22 ft-lb)
Oxygen sensor to manifold 50
Nrn (37 ft-lb)
Exhaust manifolds, removing and installing
(M62 engine)
Always use new retaining nuts and gasltets when removing
and installing the exhaust manifolds.
NOTE-
Access to manifolds is extremely limited. If removing exhaust
manifolds as part of additional engine worlc (such as cylinder
head removal), it may be easier to first remove engine.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work undera lifted car unless it is solidly supported on
jaclt stands designed for the purpose. Never worlc undera car
that is supportedsolely
by a jack.
- Remove exhaust system. See Exhaust system, removing
and installing.
- Removing right side exhaust manifolds (cylinder bank 1-4):
Remove heat baffle plate.
Disconnect plug connection to oxygen sensor.
securing exhaust manifolds to head.
Remove manifolds towards bottom.
- Installation is the reverse of removal.
Coat exhaust mounting studs with CRC or equivalent
copper paste.
Use new gasltets and self-loclting nuts.

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-- -
Exhaust System
Oxygen sensors (precatalyst), replacing
(M52 TU and M54)
The precatalyst oxygen sensors are installed at the top of the
exhaust manifolds.
WARNING-
Allow components to cool before servicing.
- Using BMW scan tool DlSplus (Diagnostic Information Sys-
tem) or equivalent, read out and clear ECM fault codes.
Working at right side of engine above exhaust manifolds,
remove front or rear oxygen sensor harness connector
(arrows) from bracket, then separate plug.
NOTE-
In photo, secondary air pump has been removed for clarity.
Remove oxygen sensor using special oxygen sensor
removal socket.
Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing a sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
- -.
Oxygen sensor to manifold 50 Nm (37 ft-lb)
Oxygen sensors (post-catalyst), replacing
(M52 TU and M54)
The post-catalyst oxygen sensors are installed at the rear of
the catalytic converters.
WARNING-
Allow components to cool before servicing
- Using BMW scan tool DlSplus or equivalent, read out and
clear ECM fault codes.
- Remove large cover from above fuel raillintake manifold.