Electric BMW 528i 2000 E39 Workshop Manual

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I Fuel Tank and Fuel Pump
- Expose right side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover insu-
lation.
Peel back insulation at
perforations to expose fuel tank ac-
cess cover.
Remove right side cover to expose electrical harness con-
nector.
WARNING -
Fuel may be spilled. Do not smolce or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
Remove
tank sending unit:
Release electrical harness by sliding lock back, then lifting
off connector.
a Disconnect hose (arrow).
Unscrew threaded collar from fuel
pumpifuel level sender.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may re-
sult if the special tool is not used.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CAUTION-
Do not bend fuel level sender arm.
To remove fuel pump, press locking tabs (arrows) towards
pump body.
Lifl out pump, using care not to damage hoses.

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Fuel Tank and Fuel Pump
- To reinstall:
Use new sealing ring at tank collar.
* Align tab of sending unit with matching recess in opening
of tank.
Be sure that fuel line connections point in same direction
as they came out.
Reconnect harness connector and hose.
Fill tank and check for leaks by running engine.
Install access cover and its mounting fasteners.
CAUTIOI\C
After finishing repairs but before starting engine, be sure
there is at least
5 liters (1.5 gallons) of fuel in the tank. The
NOTE-
It is common practice to replace the fuel filter when the fuel
pump
unit is replaced. See 020 Maintenance.
Tightening torque
Tank collar locking ring to tank 35 Nm (26 lb-ft)
Fuel level sender (left side),
removing and installing
The procedure for removing and replacing the left side fuel
level sender is
simllar to that used for the r~ght side. There is
no fuel pump on the left side.
- Remove rear seat lower cushion by lifting off catches at front.
- Expose left side access cover:
- Peel forward lip of carpet.
Release rubber grommet from center of access cover
insulation.
Peel back insulation at
perforations to expose fuel tank
access cover.
Remove cover to expose electrical harness connector.
WARNING-
Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.

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/ ~uel Tank and Fuel Pump
4 Remove tank sending unit:
Disconnect electrical harness connector.
Disconnect hose (arrow).
- Unscrew threaded collar from fuel level sender.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may
result if the special tool is not used.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CA UTIOW-
Do not bend fuel level sender arm.
4 Once level sensor unit has been lifted partially out of tank,
disconnect tank siphon hose by pressing tabs (arrows).
- Installation is reverse of removal
Attach tank siphon hose to sender unit firmly.
Use new sealing ring at tank collar.
. Be sure that fuel sender float points in same direction as
during removal.
- Reconnect harness connector.
Fill tank and
check for leaks by running engine.
CAUTION-
After finishing repairs but before starting engine, be sure
there is at least
5 liters (1.5gallons) of fuel in tan/(. The fuel
pump will be damaged if run without fuel.
Tightening
torque
Tank collar loclting rlng to tanlt 35 Nm (26 lb-ft) -

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Fuel Tank and Fuel pump/
- Remove suction hose from tank filler neck carefully to avoid
damaging filler neck baffle plate.
CAUTION-
After finishing repairs but before starling engine, be sure
there is at least
5 liters (1.5 gallons) of fuel in tanlc. The fuel
pump will be damaged if run without fuel.
Fuel tank, removing and installing
- Remove fuel tank filler cap and drain tank as described
earlier.
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove rear seat bottom cushion. Peel forward lip of carpet
from beneath seat cushion and carefully peel back insulation
to expose fuel tank access cover on left and right sides. Re-
move covers.
Disconnect right side supply hose and
electr~cal harness
connector (arrows).
D~sconnect left side return hose and electrical harness
connector.
Working inside car, disconnect parking
bralte cable ends
from parking brake lever. See
340 Brakes.
Lift car and support safely.
Make sure the car is stable and
we/ supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A floorjaclc is not adequate support.
- Remove complete exhaust system and heat shield. See 180
Exhaust System.
- Remove drive shaft. See 260 Driveshaft

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160-22
Fuel Tank and Fuel Pump
4 Working underneath car, pinch off supply and return fuel hos-
es (arrows), then disconnect hoses from rigid metal lines.
- Remove right rear wheel and wheel housing splash shield.
4 Worlting at right rear wheel housing, loosen hose clamp
(arrow) and disconnect filler pipe from tank.
- Support tank from below. Remove tank strap mounting bolts.
Lower and remove tank, disconnecting right side vent and
other
hoses/electrical connectors as necessary.
Always use new seals, gaskets, O-rings, and hose clamps.
lnspect hoses and replace any that are chafed,
dr~ed out or
cracked.
lnspect heat shield and replace if corroded.
Inspect rubber buffers and
hers on fuel tank, support
straps and on underside of body. Replace rubber parts that
are hardened or damaged.
- After finishing repairs but before starting engine, fill fuel tank
with at least
5 liters (1.5 gallons) of fuel.
CAUTlOI+
The fuelpump will be damaged if run without fuel.
* If the filler neck has been removed from the body, be
sure to reattach the
neck grounding screw (where ap-
plicable). Check electrical resistance between the
ground tab and wheel
hub. The resistance should be
no
hiaher than 0.6f2
Tightening torques
Fuel tank to body 23 Nm (17 ft-lb)
Hose clamp
8 -13 mm dia. 2 Nm (18 in-lb)
Hose clamp 13
- 16 mm dia. 3 Nm (27 in-lb)
Hose clamp 42
- 48 mm dia. 4 Nm (36 in-lb)

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Fuel Tank and Fuel Pump 1
Activated carbon canister I fuel tank leak
detection unit
(LDP or DMTL), removing . . -
and installing
- Raise rear end of car and support safely.
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 floor jack is not adequate support.
- Remove left rear wheel and inner fender panel
Remove carbon canisterlfuel tank leak detection unit
(V-8 model shown):
Disconnect electrical harness connector
(A) from fuel tank
leak detection unit.
Pinch and remove quick-disconnect fittings at intake line to
air filter housing
(5) and hose to expansion tank (C).
* Remove mounting clamp and lower canister with fuel tank
leak detection unit.
Installation is reverse of removal.
Tightening
torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp
13 - 16 rnm dia 3 Nm (27 in-lb)
Running losses (312-way) valve,
removing and installing
The running losses (312-way) valve is located under the car
beneath the driver's seat, just ahead of the fuel filter. A protec-
tive covershieldsfuel system components from road hazards
and dirt.
The engine control module
(ECM) controls the operation of
the 312-way valve (pulse-width modulated). On engine start
up, the valve solenoid is energized for 20 seconds in order to
supply full fuel volume to the fuel rail.
After20 seconds, the
solenoid is deactivated and sprung closed (the bypass is
opened). This reduces the amount of fuel circulating through
the fuel rail and diverts the excess to return to the fuel tank
through the fuel pressure regulator.
The fuel injectors are supplied with pressurized fuel, but ex-
cess fuel is diverted to the fuel tank without first passing
through the fuel rail. This prevents the excess fuel from ab-
sorbing heat in the engine compartment, thus lowering the
temperature and amount of vaporization in the fuel tank.

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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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176 Radiator and Cooling System
General ........................... .I7 0.2
Special tools
........................ .I7 0.2
Cooling system overview
(M52 TU shown. others similar) ......... .I7 0.3
Coolant pump
....................... .I7 0.3
Thermostat
......................... .I7 0.3
Mechanical thermostat (M52 engine)
..... .I7 0.4
Electrically heated thermostat
.......... .I7 0.4
Radiator and expansion tank
........... .I7 0.4
Mechanical cooling fan with viscous clutch
.I7 0.4
Electric (auxiliary) cooling fan ........... .I7 0.4
Transmission fluid heat exchanger
....... .I7 0.5
Warnings and cautions
................ .I7 0.7
Troubleshooting ................... .I7 0.7
Cooling system inspection
............. .I7 0.8
Cooling system pressure test
........... .I7 0.9
Combustion chamber leak test
......... .I7 0.10
Thermostat
........................ .I7 0.1 0
Cooling System Service ........... 170-10
Coolant. draining and filling
(6-cylinder models)
.................. 170-1 0
Coolant. draining and filling (V-8 models)
. 170-12
Cooling system. bleeding
............. 170-14
Mechanical (viscous clutch) cooling fan.
removing and installing
............... 170-14
Electric cooling fan.
removing and installing
............... 170-15
Thermostat. removing and installing
(M52engine) ....................... 170-16
Thermostat. removing and installing
(M52 TU or M54 engine) .............. 170-17
Thermostat. removing and installing (V-8 models)
....................... 170-1 8
Coolant pump. replacing (6-cylinder models)
.................. 170-1 9
Coolant pump. replacing (V-8 models) ... 170-20
Radiator. removing and installing
....... 170-22
Expansion tank. removing and
installing . . 170-24

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-. - - - Radiator and Cooling sYstelll/ --
Cooling system overview
(M52 TU shown, others similar)
Coolant pump
A centrifugal coolant pump is mounted to the front of the en-
gine. The belt-driven pump circulates coolant through the
system whenever the engine is running.
Thermostat
Two types of thermostats are used in the cars covered by this
manual. 6-cylinder models built up to
911 998 (M52 engine)
use a conventional mechanical thermostat. All
V-8 models
and 6-cylinder models from
911998 use an electrically heated
thermostat.

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I Radiator and Cooling System
Mechanical thermostat
(M52 engine)
4 The mechanical thermostat relies on coolant temperature to
operate. While coolant is cold, it remains closed, and circu-
lating coolant bypasses the radiator for rapid engine warm
up. At higher coolant temperature, the thermostat progres-
sively opens to allow coolant flow through the radiator, thus
controlling engine temperature. Port
A restricts coolant flow
from radiator, and port
B restricts coolant flow to radiator.
Electrically heated thermostat
4 The electrically heated thermostat is DME map-controlled.
The engine control module (ECM) activates the thermostat to
maintain engine coolant temperature within a narrow range.
In case of failure of the electronics, the mechanical function of
the thermostat acts as a fail-safe.
Radiator and expansion tank
The radiator is a crossflow design. An expansion tank pro-
vides for coolant expansion at higher temperatures and easy
monitoring of the coolant level.
On cars with automatic transmission, ATF is circulated
through an additional heat exchanger (ATF cooler).
Mechanical cooling fan with viscous clutch
The mechanical cooling fan is belt-driven via a viscous fluid
coupling (clutch) attached to the front of the coolant pump.
The fan clutch controls the speed of the fan based on the tem-
perature of the air flowing through the radiator core.
Electric (auxiliary) cooling fan
The electric cooling fan is mounted on the bumper side of the
radiator.
In models manufactured up to
911 998 (M52 or 1997 M62 en-
gine), the electric cooling fan is controlled by a dual tempera-
ture fan switch mounted in the side of the radiator.