Remove intake manifold BMW 528i 2000 E39 Owner's Guide

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Fuel Injection
- If idle speed valve is not buzzing, or if idle decreases when
AIC is turned on, stop engine and disconnect harness con-
nector from idle speed valve.
connector
CAUTION-
Be sure ignition is OFFbefore disconnecting or reconnecting
DME system components.
Checlc resistance of valve across valve terminals.
Idle speed control valve resistance
Terminals
1 and 2 20 i-2Q
Terminals 2 and 3 20 C2Q
Terminals 1 and 3 40 C4Q
The idle speed control valve is mounted under the intake
manifold. Accessing the valve is best accomplished by first
removing the air filter housing and the throttle housing.
< Disconnect intake air boot from throttle housing. Unbolt throt-
tle body and lay aside. Do not disconnect throttle cable or
electrical harness connectors to throttle body.
NOTE-
For additional worlcing room, unfasten and lift out the com.
plete air filter housing.
- Working under intake manifold, disconnect electrical harness
connector from idle speed control valve.
Unbolt dipstick tube
bracket (A) from intalte manifold.
- Remove two bolts (B) retaining idle speed control valve to un-
derside of intalte manifold. Remove valve from intalte mani-
fold. Remove hose clamp and disconnect hose.
- Installation is reverse of removal. Use new gaskets when in-
stalling.

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I Fuel Injection
Release injector locking clips at each injector and pry injector
wiring duct up off injectors.
Clamp off fuel supply line and fuel return line at end of fuel
rail. Disconnect fuel supply fuel return lines from fuel rail.
WARNING -
Clamp off the fuel lines and then wrap a clean shop towel
around the lines before removing them. Residual
fuelpres-
sure is present in the lines.
Fuel is discharged. Do not disconnect any wires that
could cause electrical
sparks. Do not smoke or work
near heaters or other fire hazards. Keep an approved
I fire extinguisher handy. I
- Remove fuel rail mounting fasteners
- Pull up on fuel rail and remove individual injectors by remov-
ing injector retaining clip and pulling injector from rail.
- Installation is reverse of removal. Fit new O-rings when in-
stalling injectors. For ease of installation, lightly lubricate in-
jector O-ring with
SAE9O gear lube.
Tightening torque Fuel rail to
intake manifold 10 Nm (89 in-lb)
Evaporative emissions, overview
On E39 MS 41 .I cars, the evaporative emissions system is
combined with the tank ventilation system. The evaporative
system is monitored by the ECM for correct purge operation
and leak detection.
The carbon (purge) canister is purged using engine vacuum
via the
purgevalve.The purgevalve (located nextto the mass
airflow sensor) is ECM controlled and regulates the purge
flow into the intake manifold. The valve is powered open and
closed by an internal spring.
If the evaporative emission valve circuit is faulty, a fault code
is set and the MIL is illuminated when OBD
II fault criteria are
exceeded. If the valve is mechanically faulty, poor driveability
may result and a mixture adaptation fault is stored in the
ECM.
The leak diagnosis pump (LDP) is activated by the ECM and
pressurizes the fuel tank and evaporative system as apart of
theOED I1 leakdetection monitor. If the LDP orthe LDP circuit
is defective, afault code is set and the MIL is illuminated when
OBD
I1 fault criteria are exceeded. The LDP is mounted the
left rear wheel well behind the fender liner.

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130-1 8
1 Fuel injection Secondary air injection
1. Secondary air pump (in right
front wheel housing)
2. Secondary air vacuum vent
valve solenoid (on intake mani-
fold)
3. Secondary air check valve
4. Intake manifold
5. Exhaust manifolds
6. Diverter valve (at exhaust mani-
fold)
Engine control module (ECM),
removing and installing
The ECM uses stored functions and processing programs to
process the input signals from the sensors. These input sig-
nals are used to calculate the control (output) signals to the
actuators
(e.g., ignition coils, injectors).
NOTE-
Consult an authorized BMW dealer before replacing the
ECM.
- Disconnect negative (-) battery cable. Wait approximately
one minute.
Prior to disconnecting the
battely, read the battery discon-
nection cautions in
001 General Warnings and Cautions.
Access engine control module (ECM):
Release interior ventilation filter cover latch
(A) and re-
move cover.
Release plastic locking tab
(B).
Rotate air duct inward (arrow) to unloclc from bulk head
and remove duct.
Release spring lock
(C) to remove lower filter housing.
Slide filter housing away from inner fender to remove.
- Remove electrical box (E-box) cover fasteners and remove
cover.
- If testing ECM or connected components, use breakout box
to allow tests to be made with connector attached to the
ECM. This prevents damage to small terminals in connector.

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Fuel Injection
Engine coolant temperature
(ECT) sensor,
testing and replacing
4 The ECT sensor is located below cylinder 6 intake port at the
rear of the engine (1).
The ECT sensor is a dual temperature sensor. One circuit
provides coolant temperature information to the ECM while
the other circuit provides coolant temperature information to
the instrument cluster.
The ECM determines the correct ignition timing and airlfuel
mixture required
forthe engine temperature by monitoring an
appliedvoltage
(5vdc) to the sensor.Thevoltage drop across
the sensor varies as the coolant temperature (sensor resis-
tance) changes.
NOTE-
The ECT sensor is an NTC (negative temperature coeffi-
cient) type sensor. In other words, as the temperature rises,
resistance through the sensor decreases.
If the ETC sensor input is faulty or non-plausible, the MIL is il-
luminated when the MIL is illuminated when
OED II fault crite-
ria are exceeded. The ECM assumes a substitute value
(80" C 11 76'F) to maintain engine operation. The ignition tim-
ing is set to a
conservativelsafe basic setting.
- Remove intake manifold to access ECT sensor on the M52
TU and the M54 engines. See 113 Cylinder Head Removal
and Installation.
- Check ECT sensor resistance using a multimeter at sensor
terminals.
WARNING -
Due to rislc of personal injury, be sure the engine is cold be-
fore removing ECT sensor connector.
ECT sensor resistance @ 20°C (68°F)
CAUTIOI\C
Be sure ignition is OFFbefore disconnecting or reconnecting
DME svstem components.
2.2 - 2.7 k
4 Disconnect ECT sensor harness connector (arrow). Un-
screw ECT sensor from cylinder head.

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Fuel Injection
- Installation is reverse of removal:
Use new copper sealing washers when installing sensor.
Replace any lost coolant.
Tightening torque
Temperature sensor to cylinder head
13 Nm (10 ft-lb)
Intake air temperature (IAT) sensor,
testing and replacing
4 The intake airtemperature (IAT) sensor, located at the top of
I the intake manifold, adapts (fine tunes) the fuel mixture and i
T engine timing based on varying intake air temperatures.
i If the intaite air temperature signal is implausible, a fault code
! is set and the MIL is illuminated when OBD I1 fault criteria are
I exceeded. The ECM then operates the engine using the ECT
i sensor sional inout as a back uo.
type sensor. In other words,
a> the temperature rises, resis-
tance through the sensor decreases.
lid I The IATsensor can be tested using a multimeter:
/IAT sensor resistance at 20'C (68°F) 2.2 - 2.7 kd
Remove engine cover by prying off plastic trim caps (arrows)
and removing nuts below caps.

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Fuel Injection
4 Remove electrical harness connector (arrow) from IAT sen-
sor.
CAUTION-
Be sure the ignition switch is in the off position before repiac-
ins the intake temperature sensor.
- Depress loclting clip on side of temperature sensor and pull
straight out of intake manifold.
- Installation is reverse of removal
- Use a new sealing O-ring at base of sensor and lubricate with
assembly lubricant for
ease of installation
MS 42.0 throttle valve assembly, replacing
< The motor driven throttle valve for the MS 42.0 system is re-
- ferred to as MDK (motor driven throttle valve). The MDK unit
is electronically operated to regulate intake air flow by the
ECM.
The
MS 42.0 system uses a throttle cable from the accelera-
tor pedal to the MDK unit. The throttle cable is connected di-
rectly to the integral pedal position sensor
(PWG) in the MDK
unit. This sensor communicates pedal position to the ECM,
which in turn electronically regulates throttle plate position.
The MDK pulley is linked to the throttle shaft by springs to al-
low ASC intervention to override the driver's pedal position.
NO TE -
The MDIC unit is non-adjustable and must be replaced as
a complete unit if found to be faulty.
if replacing the
MDK unit, the adaptation values stored in
the ECM must be clearedand the new unit initialized using
BMW special service tools.
CAUTION-
If the adaptation process is not completed correct& the en-
gine wiii
not start.
- Disconnect battery negative (-) cable in luggage compart-
ment.
CAUTION-
Prior to disconnecting the battern read the battely discon-
nection cautions in
001 General Warnings and Cautions.

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Fuel lniection I
4 Remove complete air filter housing:
Disconnect electrical harness connector on mass air flow
sensor
(A).
Disconnect vacuum line at intake boot (B).
Loosen Intake air duct clamp (C).
Remove filter housing mounting screws
Disconnect air duct and
lift complete air filter housing and
MAF sensor out of engine compartment, pulling it forward
away from throttle housing.
- Pull throttle cable upwards out of rubber retainer and unhoolc
ball end of cable from throttle actuator.
4 Remove nuts and bolts (arrows) retaining wiring harness to
throttle housing.
- Working at throttle housing, turn harness plug counterclock-
wise and remove plug.
4 Working at side of intake manifold, disconnect electrical har-
ness connectors:
Idle control valve (A)
lntalce manifold resonance valve (B)
- Disconnect electrical harness connectors at oil pressure
sender and oil temperature sender at base of oil filter hous-
ing.
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/Fuel Injection
4 Remove dipstick guide tube:
Disconnect wiring harness brackets from tube (A).
Unclip fuel lines from dipstick tube
(El).
Remove lower guide tube mounting bolt (C). Pull out dip-
stick guide tube.
< If necessary, disconnect electrical harness connector at fuel
tank venting valve (A). Disconnect hose at quick disconnect
fitting (arrow).
Working at throttle housing, turn harness plug counterclock-
wise and disconnect. Remove throttle assembly mounting
fasteners (arrows) and pull assembly off manifold.
Installation is reverse of removal
Replace sealing ring between throttle assembly and intake
manifold.
0 Reattach throttle assembly harness connector with care.
Arrow on fully tightened connector must line up with corre-
sponding arrow on throttle assembly housing.
* Connect BMW test equipment or equivalent and carry out
throttle plate adaptation following the on-screen directions.
Reattach throttle cable and check cable adjustment as de-
scribed under Throttle cable, adjusting
(MS 42.0).

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130-36
[~uel Injection
4 Remove nuts and bolts (arrows) retaining wiring harness to
throttle housing.
- Working at throttle housing, turn harness plug countercloclc
wise and remove.
4 Working at side of intake manifold, disconnect electrical bar-
ness connectors:
Idle control valve (A)
Intake manifold resonance valve (B)
- Disconnect electrical harness connectors at oil pressure
sender and oil temperature sender at base of oil filter hous-
ing.
4 Remove dipstick guide tube:
Disconnect wiring harness brackets from tube
(A)
Unclip fuel lines from tube (B).
Remove lower guide tube mounting bolt (C).
Pull out dipstick guide tube.

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-.
Fuel Injection 1
4 If necessary, disconnect electrical harness connector at fuel
tank venting valve (A). Disconnect hose at quick disconnect
fitting
(arrow).
< Worlting at throttle housing, turn harness plug counterclock-
wise and disconnect. Remove throttle assembly mounting
fasteners
(arrows) and pull assembly off manifold.
- Installation is reverse of removal.
0 Replace sealing ring between throttle assembly and intake
manifold.
Reattach throttle assembly harness connector with care.
0 Arrow on fully tightened connector must line up with corre-
sponding arrow on throttle assembly housing.
- Use BMW scan tool to reset ECM adaptation values.