IGNITION COILS BMW 528i 2000 E39 Workshop Manual

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020-21
Maintenance
Spark plugs, replacing
E39 engines use a coil-over-spark plug configuration, with
one ignition coil above each spark plug. Sparks plugs should
be removed only after the engine has cooled.
Remove engine
cover(s) over ignition coils:
Remove acoustic cover over fuel injectors
I intake
manifold.
6-cylinder engine: Remove oil filler cap.
Remove plastic trim covers (arrows).
Remove cover hold-down bolts. Remove coil
cover(s)
6-cylinder engine: Temporarily reinstall oil filler cap to
keep out contaminants.
Remove ignition coil grounding harnesses (arrows). 6-cylin-
der coils shown,
V-8 engine is similar.
< Remove ignition coils:
Pull up on spring clips to disconnect ignition coil harness
connectors.
Remove coil mounting bolts. Pull coils up and off spark
plugs.
- Remove spark plugs.

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100-6
( Engine-General
The main grounds for the fuel and ignition circuits of the DME
system are illustrated below; see 610 Electrical Component
Locations for additional ground and component locations.
4 Ground for engine management system in right rear of en-
gine compartment on E-box bulkhead (arrow).
6-cylinder models: Grounds
for ignition coils (arrows)
4 V-8 models: Grounds for ignition coils, at cylinders 3
(arrow) and 7.
4 Fuel pump ground (arrow) below right tail light in luggage
compartment.
NOTE-
Ground location for sedan shown, wagon models may
differ.

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11 3-6
Cylinder Head Removal and Installation
- Disable ignition system by removing DME main relay. See
610 Component Locations for relay location.
WARNING-
. The ignition system produces high voltages that can be fa-
tal. Avoid contact with exposed terminals and use
exfreme
caution when working on a car with the ignition switched on
or the engine running.
Do not touch or disconnect ignition
components while
the engine is running or being cranked by the starter.
Failure to remove the DME main relay or attempting to
disa-
bie the fuel andignition systems by other methods may result
in damaoe to the enoine control module
(ECM).
- - Remove plastic cylinder head cover(s)
,,I . ,. .*,.,,&- - Remove coil grounding straps.
I CAUTION-
I nition system components. I
- Remove coils.
- Remove spark plugs from all cylinders.
NOTE-
Check the spark plugs for oil deposits that may indicate poor
cylinder sealing, then set them aside in order. Used spark
plugs should be reinstalled in the same cylinder from which
they were removed.
4 Install compression gauge in first cylinder spark plug hole,
tight enough to form a good seal.
- With parking brake set, transmission in PARK or NEUTRAL,
and accelerator pedal pressed to floor, crank engine with
starter. Record highest value indicated by gauge.
NOTE-
* The compression gauge reading should increase with
each compression stroke and reach near its maximum
reading in about
4-6 strokes.
All cylinders should reach maximum compression in the
same number of
strolces. If a cylinder needs significantly
more strokes to reach
maximum compression, there is a
problem.

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. .- . --
Lr -- - - - -- Cylinder Head Removal and Installation I -
- Release pressure at compression gauge valve, then remove
gauge from spark plug hole. Repeat test for each cylinder
and compare results with values given in Table a.
Table a. Compression testing specifications
Minimum compression
6-cylinder
10-1 1 bar (142-156 psi)
V-8 12-14 bar (174-203 psi)
Maximum difference between
cylinders (all engines)
0.5 bar (7 psi)
- Compression readings may be interpreted as follows:
Low compression indicates a poorly sealed combustion
chamber.
0 Relatively even pressures that are below specification nor-
mally indicate worn piston rings
andlor cylinder walls.
Erratic values tend to indicate valve leakage.
Dramatic differences between cylinders are often a sign of
a failed head
gasket, burned valve, or broken piston ring.
- If readings are within specifications, reinstall spark plugs and
ignition coils.
NOTE-
Used spark plugs should be reinstalled in the same cylinder
from which they were removed.
Tightening torque Spark plug to cylinder head 25 Nm
(18 ft-lb)
lanition coils to cylinder head 10 Nm (7.5 ft-lb)
- Remainder of installation is reverse of removal. Be sure to re-
install all wires disconnected during test, especially ground
wires at coils and cylinder head cover (where applicable).
Wet compression test
To further help analyze the source of poorcompression,awet
compression test is the next step.
- Repeat compression test, this time squirt a teaspoon of oil
into each cylinder. The oil will temporarily help seal between
piston rings and cylinder wall, practically eliminating leakage
past rings for a short time.
- If this test yields a higher reading than "dry" compression
test, there is probably leakage between piston rings and
cylinder walls, due either to wear or to broken piston rings.
- Little or no change in compression reading indicates other
leakage, probably from valves.

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-
Cylinder Head Removal and Installation c
q Remove secondary air inject~on check valve (arrow).
4 Remove cylinder head top cover:
Remove plastic trim caps (arrows).
Remove engine oil filler cap.
Remove cover hold down fasteners and lift off cover.
4 Remove ignition coils:
Disconnect ignition coil harness connectors.
. Remove coil mounting fasteners.
Remove coils.
Remove ground straps.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
- Remove sparlc plugs.
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original locations. Make
note of their arrangement during removal.

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Cylinder Head Removal and Installation
4 If applicable, remove secondary air injection pump:
Disconnect hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
Disconnect electrical harness from bottom of secondary
air injection pump.
Remove mounting bracket from strut tower.
4 Remove ignition coils:
* Disconnect ignition coil harness connectors.
Remove coil mounting fasteners.
Remove coils.
* Remove ground straps.
CA UTIOI\C
Note location of all ground wires. Failure to reinstall grounds
can result in permanent damage to engine control module or
ignition system components.
Set coil harness to side of engine compartment
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
ltets should be reinstalled in their original locations. Male
note of their arrangement during removal.
- Remove spark plugs
4 Remove oil baffle cover from above intake camshaft.

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- .-
.. Cylinder Head Removal and Installation I -
< Disconnect the following electrical harness connectors:
Knock sensors
(A).
Thermostat (6).
Throttle position sensor and idle valve (C).
Camshaft position sensor (D).
Ignition coils (E).
< Remove mounting nuts (arrows) from wiring harness ducts.
4 Release fuel injector connectors by releasing spring clip
(arrow) on each injector.
Lift up and remove electrical ducts and set to one side

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11 3-61
Cylinder Head Removal and installation I
Remove intake manifold fasteners (A).
Carefully lift intake manifold off engine while checking that all
hoses and harnesses have been disconnected.
Left cylinder head, removing, M62 engine
- Remove intake manifold as described earlier
- Remove left side exhaust manifold. See 180 Exhaust Sys-
tem.
- Drain engine coolant, then remove viscous clutch cooling
fan. See
170 Radiator and Cooling System.
WARNING -
Use extreme caution when draining and disposfng of eng~ne
coolant. Coolant is poisonous and lethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste.
Seek med~cal attention immediately if coolant is ingest-
ed.
4 Remove coolant manifold mounting fasteners and carefully
remove manifold.
NOTE-
Engine shown removed from engine bay
4 Remove ignition coil fasteners and coils (noting location of
ground strap).
- Remove spark plugs.

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11 3-73
Cylinder Head Removal and Installation /
1
- Remove viscous clutch cooling fan. See 170 Radiator and
i Cooling System. i i I 4 Remove ignition coil fasteners and coils (noting location of
~ ground strap).
1
Remove sparlc plugs.
i
Remove oil distribution tube fasteners and remove tubes
from both cylinder heads.
4 Using crankshaft center bolt, turn crankshaft cloclcwise until
number one cylinder (front cylinder right side) is in
TDC (ar-
rows).

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11 6-9
Cvlinder Head and valvetrain1
4 Remove ignition coils and spark plugs.
V-8 models: remove mounting nuts (arrows) from wiring har-
ness ducting.
< V-8 models: disconnect fuel injector electrical connectors
from injectors:
Pry one corner of wire
loclc clip (arrow) on first injector.
Repeat for all injectors.
Lift wire ducts off and set aside.
- V-8 models: disconnect battery jump start post terminal from
left cylinder head cover.
- 6-cylinder models: remove oil filler cap and unclip vent con-
nection from cylinder head cover.
- Remove cylinder head cover mounting fasteners and re-
move cylinder head cover(~).
NOTE-
The cylinder head cover mounting bolt insulators and gas-
Icets should be reinstalled in their original locations. Make
note of their arrangement
during removal.