Front lights BMW 528i 2000 E39 Workshop Manual

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Radiator and Cooling System
Remove rubber trim strip between top of shroud and radiator.
Using 32 mm wrench
(BMW special tool 11 5 040) on fan
clutch nut (arrow), turn wrench in a clockwise direction
(working from front of car) while counterholding pulley with
BMW special tool
11 5 030. Spin fan off coolant pump.
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
Unclip AUC (air quality) sensor from shroud,
M54 engine: Disconnect auxiliary coolant pump from base of
fan shroud.
Lift fan and shroud together out of engine compartment.
To replace fan clutch, remove fan mounting bolts and sepa-
rate viscous clutch from fan.
Installation is reverse of removal.
Tightening
torques
Clutch nut to pump
Without
BMW tool 11 5 040 40 Nm (29 ft-lb)
With BMW tool 11 5 040 30 Nm
(22 ft-lb)
Fan to viscous clutch 10 Nm (89 in-lb)
Electric cooling fan, removing and
installing
The electric cooling fan is mounted behind the front bumper,
in front of the
A/C condenser.
- Remove front bumper. See 510 Exterior Trim, Bumpers.
- Remove left and right headlights. See 630 Lights,
- Where applicable, detach horizontal air ducts behind front
bumper and fold to side.
- Disconnect fan electrical connector on right side of radiator
shroud and lay aside.
- Detach wire loom from air duct in front of cooling fan
- Pry out expansion rivets holding air duct. Slide air duct down-
ward to remove.

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--.
- - Manual Transmission
- V-8 engine: Remove heat shield from left front axle support.
< V-8 engine: Remove engine speed reference sensor from
transmission.
- Where applicable, remove brackets for transmission under-
body protection (adjacent to transmission).
4 Support transmission with transmission jack.
- Where applicable, remove reinforcing cross brace from
below driveshaft at transmission.
- Disconnect harness connector from back-up light switch
on transmission.
- Free harnesses for oxygen sensors and back-up lights
from crossmember and transmission.
Remove transmission crossmember: Remove transmission mount bolts
(A).
Remove transmission crossmember bolts (B)
Where applicable, remove bolts (C).
NOTE-
5-speed transmission shown in illustration. Crossmember
assembly for 6-speed transmission is similar.
Disconnect driveshaft from transmission and hang to one
side. See
260 Driveshaft.
I CAUTION- I
Do not damage constant velocity joint orprotective boot at
rear differential.
- 6-cylinder engine: Remove stabilizer bar links and swivel sta-
bilizer bar
u~wards.

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Body shell
Exterior and aerodynamics
Crash behavlor -frontal impact
-side impact
Body
-rear impact Structural body components -rigidity
-rollover -strength -vibrations -acoustics
Bumpers compartment lid -bendable Seets,.steerlng system .dents -vibrations bars -vibration patterns
Fenders -aerodvnamic
With its traditional styling features, such as the ltidney grille.
circular headlights behind a glass cover (for reasons of
streamlining), and the
"kiclt" in the rear most roof pillar (C-pil-
lar), the E39 can be immediately recognized as a BMW.
The BMW 5 Series chassis is a unibody design constructed of
high strength steel. Attaching parts, such as the front fenders,
rear quarter panels, doors,
trunk lid and hood are also con-
structed of
steel.
Computer aided design (CAD) techniques have been used in
refining the
E39 body to reduce vehicle weight while retaining
strength and increasing torsional rigidity. For good handling
purposes, the more rigid the structure the more precisely the
suspension can operate.
Wind resistance
Windows bonded flush to the body and the guided flow of
cooling air into the engine compartment provide the
carwith a
good coefficient of drag (Cd).
E39 cars have been designed
for balanced aerodynamics but not necessarily an extremely
low Cd. See table below.
Windshield wipers are designed for effectiveness at speeds
up to and beyond 200
ltph (124 mph).
Coefficient of aerodynamic drag (Cd)
6-cylinder sedan 0.30
V-8 sedan 0.31
6-cylinder Sport Wagon 0.31
V-8 Sport Wagon 0.33
Fenders
The exterior panels are corrosion-resistant zinc coated (gal-
vanized) steel. The front fenders are bolted on. For front fend-
er replacement information, see
410 Fenders, Engine
Hood.

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400-8
Body-General
Airbags
Front airbags, s~de a~rbags, pyrotechnic seat belt tensioners
and the Battery Safety Terminal (BST) are integrated into the
Supplemental Restraint System (SRS) and its variants.
NOTE-
The BMW SRS system is called Multiple Restra~nt System
(MRS). Over the years,
E39 cars were equipped with MRS,
MRS
11, MRS 111. Each version offers varied features and im-
provements over the previous system.
< As many as 8 airbags may be installed in E39 cars, depend-
ing on model and MRS version.
The front
airbags operate without sodium azide propellant,
widely considered an irritant when an
airbag is deployed.
Starting with
1999 models. "smart"front passenger and driver
airbags were installed. These are of the dual-threshold, dual
stage design, including a
sensorto help prevent the unneces-
sary deployment of the passenger side
airbag if the seat is un-
occupied.
MRS control Depend~ng on options chosen, one airbag may be installed in module each door of the sedan and Sport Wagon models, protecting
passengers against
s~de impacts.
Head Protection System (ITS)
airbags strelch diagonally
across the tops of the front doors.
Airbag deployment automatically triggers fuel shutoff, turns
on the hazard and interior lights, and unlocks the doors.
- -
WARNING -
Airbags are inflated by an explosive device. Handled im-
properly or without adequate safeguards,
airbag units can
be very dangerous. Special precautions must be observed
prior to any worlc at or near any of the airbags. See
721 Air-
bag System (SRS).
Always disconnect the battery and cover the negative
(-) battery terminal with an insulator before starting di-
agnostic, troubleshooting or service work on cars fitted
with SRS, and before doing any welding on the
car.

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400-9
Body-General
Battery safety terminal
(BST)
4 Starting with 1999 models (9198 production and later), a py-
rotechnic (explosive charge) device automatically discon-
nects the battery positive terminal during impacts. Key
features,
like power windows and door locks, remain opera-
tional.
Security
Electronic immobilization (EWS)
Ignition key transponder signal All
E39 vehicles incorporate an electronic immobilization sys-
tem known as EWS. This svstem uses a wireless comrnuni-
cation link between a transponder chip in the ignition key and
the ring antenna surrounding the ignition switch. The EWS
control module blocks the starting of the vehicle unless the
correct coded ignition key is used.
NOTE-
Electronic immobilization is sometimes referred to as the
driveaway protection system.
Antitheft alarm (DWA)
This is adealer-installed option for which the E39 vehicles are
factory-wired. When armed, the system monitors door
loci(
contacts and trunk and engine hood locks and sounds a siren
if it detects tampering.
E39 interiors have a unique character, with a combination
of
sporty features and innovativedesign. All body versions were
made in a wide choice of interior and exterior colors. New col-
ors with matching leather or leatherette upholstery were intro-
duced for each model year.
Driving
comfort is enhanced by power steering, tilt steering
wheel, height-adjustable front seats, and electrically adjust-
able and heated rear-view mirrors. Inside the car there are
reading lights at four seating positions.

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I Airbag System (SRS)
Two-stage airbag (MRS Ill)
Beginning with 2000 model year (911 999 production) the front
airbags were changed to a two-stage style airbag. This en-
sures that the force of
airbag inflation is not greater than nec-
essary to provide
protection. The airbags are designed to
Drovide "soit" de~lovment if the acceleration sensor detects a
iow-speed impact, and "hard deployment in higher speed im-
pacts.
NOTE-
A two-stage passenger airbag was used on cars built be-
tween
9/1998 and 3/1999. This pre-smart technology airbag
used two ignition stages. Stage one is designed to ignite first
during an impact. Stage two ignites after a timed period, as
programmed in the MRS
I1 control module.
Airbag indicator light
The MRS control module detects and stores system status
The
airbag indicator light in the instrument cluster displays
the status of the
airbag system when the ignition key is in "ac-
cessory" or
ON positions.
System normal: lndicator light comes on briefly, then goes
out.
- System malfunction: lndicator light fails to come on.
System malfunction: lndicator light comes on briefly, goes
out and lights up again.
The
airbag indicator light also comes on if the seat belt pyro-
technic tensioners have been triggered.

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INDEX 'tl
WARNING
Your common sense, good
judgemenl, and general alertness are
crucial to sale and successiul service
worlr. Belore attempting any work on
your
BMM be sure lo read 001
General Warnings and Cautions
and the
copyriglll page at the front 01
the manual. Review these warnings
and
caulions each lime you prepare
lo work on your BMW. Please also
read any warnings and cautions that
accompany
tile procedures in the
manual.
312-way valve (running losses)
see Fuel tank
Abbreviations, commonly used 600-14
ABS (antilock brake system)
see
Bral(es
A/C air distribution motors
see stepper motors (below)
blower final stage (resistor pack),
replacing
640-16
blower, removinglinslalling
640-1 5
compressor, replacing
640-24 condenser, replacing 64045
control panellmodule, removing1
installing
640-1 1
evaporakr, removinglinstalling 640-29
evaporator temperature sensor
640-12 expansion valve, removinglinstailing
640-27
IHKA/ IHKR system description 640-5
receiveridrier, replacing 640-26
stepper motors 640-1 3 ventilation microiilter, replacing
020-22. 640-17
see also Heating
Accelerator
iinlcage
see Maintenance
Activated carbon canister
see Fuel tank
ADS (auxiliary throttle valve)
130-57
Air compressor
330-44
Air conditioning
see
AIC
Air distribution (flap) motors
seeNC, stepper motors
Air filter see Maintenance
Air spring
300-6, 330-12
Airbag system (SRS)
2-stage
airbag 721-4
control module, replacing 721-7 driver airbag, removinglinstalling
721-8
iiead protection airbag 721-12 components 721-1 1
indicator
lighl721-4
passenger airbag, removinglinstalling
721-9 side-impact airbags crash sensor,
replacing
721-7
Airflow sensor see 130 under appropriate
fuel
injection system
Air pump
see 130 under appropriate fuel
injection system, secondary air
injection system
Air suspension
see Electronic height control
(EHC)
Alarm
see Anti-theft alarm
Alignment see
Wheei alignment
Aluminum suspension components
300-2
Antenna 650-6
Alternator see Battery, starter, alte rnator
Amplifier
650-4
Anti-theft alarm (DWA)
515-24 emergency disarming 515-31
Antifreeze (engine coolant)
see Maintenance
see also Cooling system
Antilock brake system (ABS) see Brakes
ASC see Brakes
ATF (automatic transmission fluid)
see Automatic transmission
see also Cooling systern
Automatic headlight adjustmenl
(LWR) see Lights
Automatic seat belt tensioner
720-4
Automatic shiftloclc
see
Gearshift
Automatic transmission
applications
200-3, 240-4
ATF 020-10, 200-4
capacity 240-8 checking 240-6
drainingifilling 240-7
heat exchanger 170-5
fluid pan and strainer 240-9 gearshift
see Gearshift
ID tag
200-3 range switch 610-6
removaliinstallation 240-10
steptronic see Gearshift
Auxiliary cooling fan
see
Coollng system, electric Ian
Auxiliary throttle valve (ADS)
130-57
Axle joint
see Drive axle
Back-up light switch
automatic transmission see Automatic transmission. range switch
- .~.~~~
manual transmission 230-8 -
- I

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2 INDEX
Battery, starter, alternator
alternator (generator)
121-10
6-cylinder engine, removingi
installing 121-15
M62 engine 121-16
M62 TU engine (water cooled)
121-18
battery
121-5 charging 121-9
safety terminal 121-3
testing 121-5 charging system, troubleshooting
121-12
starter
121-1 9
6-cylinder engine, removingi instaliinq 121-20 . V-8 engine, rernovinglinsialiing
121-21
solenoid, removinglinstalling
121-23 troubleshooting 121-19
see also Maintenance
Bearing, wheel
see Front suspension
see also Rear suspension
Belts see Maintenance, drive belts
Blade, wiper
see Wipers and Washers
Blower motor see
A/C
BMW emblem
see Exterior trim
BMW special tools 010-18 see also special tools section at
beginning
of each repair group
Body dimensions 400-2
interior features
400-9 salety and security 400-7
Body side molding
see Exterior trim
Bonnet see Engine hood
Boot see Trunk
Brake fluid
020-24, 340-8
Brake fluid pressure sensor
340-30
Brakes
ABS, ASC or DSC system
300-12
component replacement 340-26
ASCIDSC switch
see Switches
bleeding
bralces 340-8
brake booster 340-1 9 bralce Dads. caiioers and rotors ,., 340-1 1
descriotion 300-10
e~ectrdnic brake & stability 300-11
light switch
see Switches
master cylinder
340-16 pariking brake 340-22
troubleshooting 340-5
Bulbs see Lights
Bumper
lront 510-6 height, adjusting 510-12
rear 510-9
Bus system
600-4
Camber
320-33
Camshaft
removingiinslaiiing
M52 engine 116-12
M52 TU
/ M54 engine 116-1 9 M62 engine 11 6-39
wear
116-6
Camshaft position sensors
see ignition system
Camshaft timing chain
adjusting M52 engine
117-22
M52 TU I M54 engine 117-43
M62 engine 117-79 removinglinstalling
M52 engine 117-26
M52TU 1 M54 engine 113-46.116-
28
M62 engine 117-66
Capacities, fluid
020.10
Car rnemorvlicev memorv . . 600-10
see also Centrai
lociking
Carbon canister, activated
see Fuel
tank
Caster
320-33
Catalytic converter and oxygen sensor 020-19
see also Exhaust system: exhaust
manilolds
Cautions
001-3
CD changer
650-4
Center bearing, driveshaft
see Driveshait
Center brake light
sedan
630-13
Center console
513-3
Centrai body electronics (ZKE 111)
600-6
Central locking
car memoryiey memory 515.12 general module iunctions 515-2
remote entry (FZV) 515-8
remote lkey initialization 515-10 single lociddouble ioclk 515-6
switch 515-4
Chain
see Camshaft liming chain
Characteristic map (electrically heated) thermostat
see Electrically heated thermostat
Charging system
see Battery, starter, alternator
Cluster see instruments
Clutch fluid see Maintenance
hydraulics
210-4
mechanical 210-9
switch
see Switches, pedal ciuster
variations
210.10
Codes, fault OED-1
Coil
see Ignition system
Coil spring
see Front suspension
see also Rear
suspe nsion

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WARNING
Your common sense, good
judgement, and general alertness are
crucial lo sale and
successlul service
work. Belore attempling any work on
your BMW, be sure to read 001
General Warnings and Cautions
and lhe copyright page
a1 llle Iron1 01
the manual. Review lliese warnings
and cautions each time you prepare
lo work on your
BMW Please also
read any warnings and
caulions lhal
accompany the procedures In !he
manual.
Component locations
see Electrical system
Compression test
113-5
Compressor see
AlC
Condenser see
AlC
Constant velocity (CV) joint
see Maintenance
see also
Driveshall
see also Drive axles
Consumer cutoff
600-10
Control arm see Front suspension
see also Rear suspension,
suspension arms
Coolant (antifreeze) see Maintenance
see also Cooling system
Coolant pump
see Cooling system Cooling system
coolant bleeding
170-14 6-cylinder engine, draininglfilling
170-10
V-8 engine, draininglfilling 170-12
coolant pump 170-3
6-cyiinder engine, replacing 170-1 9
V-8 engine, replacing 170-20 cooling fan 170-4
viscous ciutch fan, removingi
installing 170-14
electric fan, removlngiinstailing 170-1 5
expansion tank, removinglinstalling
170-22
electrically heated (ciiaracterislic
map) therrnostat 170-4
radiator, removinglinstaliing 170-22
service
see Maintenance
therrnostat 170-16
transmission fluid heat exchanger
170-5 troubleshooting 170-7
combuslion leal( test 170-10
pressure test
170-9
Crankshaft oil seals
iront
117-6
rear 11 9-6
Crankshaft speed sensor
see Ignition syslem
Crash sensor
see
Airbag system (SRS), side-impact
airbag crasii sensor
Cruise control clutch switch 612-9
CV joint
see Maintenance
see also Driveshalt
see also Drive axles
CV joint boot
see Maintenance
see also Drive axles
Cylinder head removinglinslaliing
M52 engine 113-8
M52 TU / M54 engine 113-22
M62 engine 113-56
Cylinder head and valvetrain
hydraulic lifters, checking and
replacing
116-7 leak test 116-5 valves 11 6-56
see
alsocylinder head Dashboard
513-7
Deck
lid
seeTrunk lid
Diagnostic monitors
OED-4
Diagnostic trouble codes
(DTCs)
080-7
Digital multimetel
010-17
Differential see Final drive
DLC (data
link connector) 020-4, OED-4
DME (digital motor electronics)
see
130 under appropriate fuel
injection system
see also ignition system
DM-TL (detection module-tank leak)
see
Fuel lank, leak deteclion unit
Drive
belts
see Maintenance
Dome light
seeLighls, interior lights
Door
door
check, replacing 411-4
hinge adjustment 41 1-5
loci(
see Door lock see also Central locking
removinglinslaliing 41
1-2
panel, removinglinstaliing 41 1-7 window
see Door window
Door
check
see Door
Door
handle
see Door lock
Door glass
see Door window
Door
lock
handles and loci(s 515-16
see also Central locking
Door
molding
510-13
Door panel see Door

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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan