Electric BMW 528i 2000 E39 Repair Manual

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1 17-68
Camshaft Timing Chain
4 Remove left and right side ignition coils and spark plugs:
- Remove positive (+) terminal cable from left cylinder head
cover.
- Unbolt lefl and right side cable ducts from fuel rail,
4 Disconnect fuel injector electrical connectors:
Pry corner of wire lock clip to release connector from injec-
tor
(arrow).
Repeat for all injectors.
Lift off wiring ducts.
4 Remove Fasteners (arrow) from lefl and right cylinder head
cover fasteners and remove covers.

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Camshaft Timing chain1
< Remove Automatic Stability Control (ASC) throttle body:
Disconnect electrical harness from throttle position sensor.
Disconnect ASC actuator cable (arrow).
Remove
3 mounting fasteners and remove throttle body.
4 Disconnect fuel tank vent valve line and cap off line (arrow).
- Drain engine coolant and remove hoses from thermostat
housing. See
170 Radiator and Cooling System.
- Remove water pump and thermostat housing. See 170 Ra-
diator and Cooling System.
- Remove left side upper timing chain cover retaining bolts and
remove cover.
4 Counter hold right intake camshaft
CAUTION-
Counter hold camshaft with a 27mm open-end wrench while
loosening sprocket bolts. Grind wrench if necessary to pre-
vent damage to head.

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[camshaft Timina Chain
< Remove cylinder head cover sealing gaskets from lefl cylin-
der head cover. Install
BMW special tool 11 1 412 into gasket
groove of cylinder head cover.
Install lefl cylinder head cover. Fit cylinder head cover re-
taining nuts to cylinder head cover studs at cylinders
5 and
6 (first two cylinders on left side cylinder bank).
Tighten nuts uniformly in
'I2 turn steps
Tightening torque
Timing case cover to head
15 Nm (1 1 ft-lb)
- Remove special tool 11 1 41 2 and install new gaskets to cyl-
inder head cover:
Clean gasket groove and install new gasket.
Apply Three Bond
12098sealant tojoint between cylinder
head and timing cover and at half-moon shaped cut-outs.
Tighten cylinder head cover nuts.
Tightening torque Cylinder head cover to head
I5 Nm (1 1 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Where applicable remove protective film from gaskets.
Use new gaskets when mounting intake manifold. Tighten
nuts finger tight first, then torque to specification in stages
worlting diagonally from center out.
Ground straps for ignition coil harnesses are at cylinders
no.
3 and no. 7. See 120 Ignition System.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
Change engine oil and filter as described in
020 Mainte-
nance.
CAUTIOI\C
To prevent damaging engine electrical systems, be sure to in-
stall ail ground wires previously removed.

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Camshaft Timing chain/
Camshaft timing, checking and adjusting
(M62 engine)
WARNING -
Allow engine to cool before beginning this procedure. 1
- Working inside luggage compartment, disconnect negative
battery cable.
CAUTIOI\C
Prior to disconnecting battery cable, read the battery discon-
nection cautions given
in 001 General Cautions and
Warninss.
4 Removing plastic top covers:
Press down on locking pins (arrows) to release locks. Lift
intake manifold cover straight up to remove.
Pry out caps from side covers.
Remove fasteners from beneath
caDs. Lift off covers.
4 Remove air filter housing and ducts:
Disconnect mass air flow sensor and intake air tempera-
ture sensor electrical harnesses
(A and B).
Remove air filter housing mounting fastener (arrow).
Release hose clamp at intake air duct on base of air filter
housing.
Loosen intake hose clamp
(C) and release hose from
mass air flow sensor.
Remove hose at idle air stabilizer.
Release hose clamp at throttle body and remove hose.
Remove upper air filter housing with mass air flow sensor.
- Unbolt left and right side cable ducts from fuel rail.

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Camshaft Timing Chain LL. .- - - - I
4 Remove left and right side ignition coils and spark plugs:
- Disconnect electrical harness connectors at ignition coils
(A).
Remove left and right side ignition coil mounting fasteners
and coils.
NOTE-
Make note of location of ground strap (arrow).
Remove sparlc plugs.
- Remove positive (+) terminal cable from left cylinder head
cover.
- Unbolt cable ducts from fuel rail at left and right sides.
Disconnect fuel injector electrical connectors from injectors:
Pry corner of wire
loclc clip (arrow) to release connector.
Repeat for remaining injectors.
* Lift off wiring ducts.

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. .- -
L
- --
- - -. - -- Lubrication ~~stern
- Remove pressure gauge and reinstall pressure switch with
new sealing washer.
Tightening torque
Oil pressure switch to oil filter housing 27 Nm (20 ft-lb)
If testing shows low oil pressure, one or more of the following
conditions may be indicated:
Worn or faulty oil pump or faulty pump pressure relief valve
Worn or damaged engine bearings
Severe engine wear
Any of these conditions indicate the need for major repairs.
Oil pressure warning system, testing
4 When the ignition is turned on, the oil pressure warning light
comes on. When the engine is started and the oil pressure
rises slightly, the oil pressure switch (arrow) contact opens
and the warning light goes out. Make sure the oil level is cor-
rect before making tests.
- Turn ignition switch on.
- Warning light on instrument panel must light up
- Remove connector from oil pressure switch.
Warning light on instrument panel must go out.
NOTE-
If the light does not go out, the wiring to the switch is most
likely grounded somewhere between the switch terminaland
the warning light See
ELE Electrical Wiring Diagrams for
electrical schematics.
- If warning light does not light when ignition is on, remove con-
nector from oil pressure switch and use a jumper wire to
ground connector terminal to a clean metal surface. The oil
pressure warning light should come on.
NOTE-
If there are two wires to the oil pressure switch, ground the
brown/green wire that carries the signal to the warning light.
- If the warning light comes on, check the switch as described
in the next step. If the warning light does not come on, the
wiring to the instrument cluster or to the light itself is faulty.

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Lubrication system/
4 Install engine lifting tool at front of engine and raise engine
approximately
5 mm (114 in).
< Remove pinch bolt (arrow) at steering column universal joint
near steering rack. See
320 Steering and Alignment.
- Remove power steering pump, leaving hydraulic lines con-
nected to pump. Suspend pump using strong wire. See
320
Steering and Wheel Alignment.
NOTE-
For better access to power steering assembly, unbolt fluid
reservoir and suspend with wire.
Loosen upper nuts (arrow) in right and lefl engine mounts,
< Remove right and left lower engine mount nuts (arrow)
- On cars with automatic transmission, remove ATF cooler line
brackets from engine oil pan.
- Disconnect electrical harness connector at oil level sensor on
oil pan.

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.
[Lubrication System
< Disconnect electrical harness connector (arrow) at oil level
sensor.
< Remove lower oil pan mounting bolts (arrows)
CAUTIOI\C
If the lowerpan does not separate easily from upperpan, a
few taps with a rubber mallet should break it free. Do
notpry
the oil pan loose.
- When installing oil pan:
Thoroughly clean all old
gasltet material from mating sur-
faces and use a new gasket.
4 Install threaded guide studs at locations marked by arrows
to guide new oil pan
gasltet and oil pan into position and to
prevent damage to sealing lip.
- Install new oil pan mounting bolts (threads coated with
sealer).
Remove guide studs and install remainder of oil pan bolts.
- Remainder of reassembly is reverse of disassembly
- After adding engine oil, start and run engine. Raise engine
speed to 2,500 rpm until oil pressure warning light goes out
(about 5 seconds).
Tightening torques Lower oil pan to upper
oil pan
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (10.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Oil drain plug to oil pan (M12) 25 Nm (18 ft-lb)

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... . . Lubrication sy=
Upper oil pan, removing and installing (V-8)
The engine oil pan removal procedure requires that the en-
gine be supported from the top and the front suspension
sub-
frame be lowered.
- Disconnect negative (-) battery cable
4 Lift hood into assembly position.
- While supporting hood, disconnect support struts.
Open hood
fully and lock in piace by installing bolts
(arrow) in left and right hinges to lock hood in place
4 Remove engine top cover:
- Early version: Pry off caps (arrows) and remove fasteners.
Late version: Depress fasteners (arrows) and lift cover.
4 Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor
(A) and intake air temper-
ature sensor
(B) electrical harness connectors.
Remove air filter housing mounting fastener (arrow)
Loosen
intake hose clamps (C and D).
Remove air filter housing with mass air flow sensor.
Remove intake hose from throttle body.

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1 19-1 7
Lubrication System
Disconnect electrical harness connect01
sensor.
. (arrow)
4 Remove lower oil pan bolts (arrows) and pan, oil
level
CAUTION-
If the lowerpan does not separate easily from upperpan, a
few taps with a rubber mallet should break it free. Do not pry
the oil pan loose.
Remove
NC drive belt tensioner.
Remove adjustment bolt
(B).
Remove retaining bolt (A) and remove tensioner from oil
pan.
- Remove power steering pump from engine block, leaving hy-
draulic lines connected. Suspend from chassis using stiff
wire. See
320 Steering and Wheel Alignment.