Transmission BMW 528i 2000 E39 Workshop Manual

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YOU are now in Volume I
I
Foreword ................... .. ........................................................................\
.......... v
Index
........................ .. ................................................................ rear of manual
General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder
Maintenance OiO 020 Maintenance
Engine
100 Engine-General 110 Engine Removal and Installation
113 Cylinder Head Removal and
Installation
116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain
119 Lubrication System
200 Transmission-General
2 Transmission 210 clutch 230 ManualTransmission
I20 Ignition System
121 Battery, Starter, Alternator
130 Fuel Injection
160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System
180 Exhaust System
240 Automatic Transmission
250 Gearshift Linkage 260 Driveshaft
Suspension, 300 Suspension, Steering and 330 Rear Suspension
Brakes-General 331 Final Drive
Steering and No Front Suspension 340 Brakes
320 Steering and Wheel Alignment
400 Body-General
410 Fenders, Engine Hood 411 Doors
412 Trunk Lid, Tailgate
510 Exterior Trim, Bumpers 512 Door Windows
Equipment 513 Interior Trim
7
Equipment and 720 seat Belts
Accessories 721 Airbag System (SRS)
OBD On-Board Diagnostics
. ............ ..
515 Central Lociting and
Anti-Theft
520 Seats 540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rear of manual
Electrical
6 system
600 Electrical System-General 620 Instruments
610 Electrical Comoonent Locations 630 Liohts
611 wipers and washers 612 Switches eati in^ and Air Conditioning
Radio
. ........... ........ .........................
Electrical Wiring Diagrams

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01 0-2
General
This section is intended to help the do-it-yourselfer get start-
ed. Tips on workshop practices, basic tools, and a quick refer-
ence guide to emergencies can be found here.
WARNING-
Do not use this manual unless you are familiar with basic
automotive repair procedures and safe workshop
practices.
0 This manual illustrates the worl quired for most service work; it is not a substitute for full
and up-to-date information from the vehicle manufac-
turer or for proper training as an automotive technician.
Note that it is not possible to anticipate all of the ways
or conditions under which vehicles may be serviced or
to provide cautions as to all of the possible hazards that
may result.
MOW TO USE THIS MANUAL
WARNING -
Your common sense and goodjudgement are crucial to safe
and successful service
work. Read procedures through be-
fore starting them. Think about whether the condition of your
cac your level of mechanical skill, or pour level of reading
comprehension might result in or contribute in some way to
an occurrence that might cause you injury, damage your car;
or result in an unsafe repair. If you have doubts for these or
other reasons about your ability to perform safe repair work
on your car; have the work done at an authorized
BMW deal-
er or other qualified shop.
The manual is divided into ten sections:
0 GENERAL, MAINTENANCE
0 I ENGINE
2 TRANSMISSION
3 SUSPENSION, STEERING AND BRAKES
4 BODY
5 BODY EQUIPMENT
6 ELECTRICAL SYSTEM
7 EQUIPMENT AND ACCESSORIES
- ELE ELECTRICAL WIRING DIAGRAMS
OBD ON-BOARD DIAGNOSTICS

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(General
WARNING-
Do not rely on the transmission or the parking brake to
keep the car from rolling. They are not
a substitute forpos-
itively bloclcing the opposite wheel.
Never
work undera car that is supported only by a jaclc.
Use jack stands designed to support the car. See
Tools.
Working under car
- Disconnect negative (-) cable from battery so that car cannot
be started. Let others know what you will be doing.
CAUTION-- Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Raise car slowly as described above.
- Use at least two jack stands to support car. Use jack stands
designed for the purpose of supporting a car. See Tools.
WARNING-
* A jaclc is a temporary lifting device and should not be used
alone to support the car while you are under it.
Do not use wood, concrete
blocks, or bricks to support
a
ca,: Wood may split Blocks and bricks, while strong,
are not designed for that kind of load, and may break or
- Place jaclc stands on firm, solid surface. If necessary, use a
flat board or similar solid object to provide a firm footing.
- Lower car slowly until its weight is fully supported by jack
stands. Watch to
make sure that the jack stands do not tip or
lean as the car settles on them.
- Observe all jacking precautions again when raising car to re-
move jack stands.

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01 0-1 2
1 General
Information you need to know
Model
When ordering parts it is important that you know the correct
model designation for your car. Models covered in this E39
manual are the
525i,5281,530i, 540i in Sedan and Station
Wagon body styles.
Model year
This is not necessarily the same as date of manufacture or
date of sale.
A 1999 model may have been manufactured in
late 1998, and perhaps not sold until early 2000. It is still a
1999 model. Model years covered by this manual are 1997 to
2002.
Date of manufacture
This information is necessary when ordering replacement
parts or determining if any of the warranty recalls are applica-
ble to your car. The label on the driver's door below the door
latch will specify the month and year that the car was built.
Vehicle
Identification Number (VIN)
This is a combination of letters and numbers that identify the
particular car. The VIN appears on the state registration doc-
ument, and on the car itself. One location is on the right front
strut tower in the engine compartment (arrow), another in the
lower left corner of the windshield.
Engine code
5 Series car covered in this manual are powered by
6 and 8 - cylinderengines. For information on engine codes and en- -. -
gine applications, see 100 Engine-General. -
Transmission code
The transmission type with its identifying code may be
impor- :
tant when buying clutch parts, seals, gaskets, and other .- transmission-related parts. For information on transmission
codes and applications, see 200 Transmission-General.

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01 0-20
General
more information on the Check Engine Light and the on-
board diagnostic system.
Towing
The cars covered by this manual should be towed with a tow
truck using wheel lift or flat bed equipment. Do not tow the car
on all four wheels except
forvery short distances to move it to
a safe place.
CA U JION-
Do not tow with sling-type equipment The front spoilers and
b~m~er covers may sustain damage.
4 To access threaded towing eye socltet, pry open trim on front
or rear bumper.
NOJE-
A towing eye is provided in the luggage compartment tool lcit.
The towing eye can be screwed into the front or rear bumper.
4 Install towing eye into threaded hole.
- Standard transmission: Do not tow with rear wheels on
ground unless absolutely necessary.
- Automatic transmission: Have rear wheels placed on dollies,
or use flat bed truck. Use towing eye for winching vehicle on
flat bed.
CAUTION-
Automatic transmission fluid (ATF) does not circulate when
I the car is towed. Severe transmission damage may result.
NOTE-
Be sure transrnission fluid has been topped off before
starting tow.
Always tow car with transrnission lever in
N (neutral).
. ATF draining and filling is covered in 240 Automatic
Transmission.
Be sure to read the filling and draining pro.
cedure, as special service equipment is required to
checlc
the fluid level.

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020 Maintenance
General ........................... .02 0.2
Special tools ........................ .02 0.2
Service Interval Indicator (Sll) ........... .02 0.3
Service Interval Indicator (Sll), resetting ... .02 0.3
Inspection I, Inspection 11 ............... .02 0.5
Maintenance Tables ................ .02 0.6
Fluid and Lubricant Specifications .. .02 0.9
Fluids and lubricants ................. .02 0.10
Engine Oil Service ................ .02 0.1 I
Engine oil. checking level ............. .02 0.12
Engine oil and filter. changing .......... .02 0-13
Engine Compartment Maintenance . .02 0.14
Accelerator and linkage ............... .02 0.14
Air filter. replacing ................... .02 0.1 4
Cooling system service ............... .02 0.15
Engine drive belt service .............. .02 0.16
Idlespeed .......................... 020-19
Catalytic converter and oxygen sensors .. .02 0.19
Power steering fluid, checking level ..... .02 0.20
Spark plugs ........................ .02 0.20
Spark plugs, replacing ................ .02 0.21
Interior ventilation microfilter, replacing ... .02 0.22
Other Mechanical Maintenance ..... .02 0.22
Battery, checking. cleaning. and replacing .02 0-22
Brake fluid. replacing ................. .02 0-24
Brake pad 1 rotor wear. checking ........ .02 0.24
Brake system, inspecting ............. .02 0.25
Parking brake. checking ............... 020-25
Clutch fluid. checking ................. 020-26
Differential oil level. checking ........... 020-26
Drive axle joint (CV joint) boots. inspecting 020-27
Exhaust system. inspecting ............ 020-27
Fuel filter. replacing .................. 020-27
Fuel tank and fuel lines. inspecting ...... 020-28
Suspension. front. inspecting ........... 020-29
Suspension. rear. inspecting ........... 020-29
Tires. checking inflation pressure ........ 020-29
Tires. rotating ....................... 020-29
Transmission service. automatic ........ 020-29
Transmission service. manual .......... 020-30
Transmission fluid. checking and filling
(manual transmission)
................ 020-30
Wheels. aligning ..................... 020-30
Body and Interior Maintenance ..... 020-31
Body and hinges. lubricating ........... 020-31
Exterior washing ..................... 020-31
Interior care ........................ 020-31
Leather upholstery and trim ............ 020-31
Polishing ........................... 020-32
Seat belts .......................... 020-32
Special cleaning ..................... 020-32
Washing chassis ..................... 020-32
Waxing ............................ 020-32
Windshield wiper blade maintenance ..... 020-33

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020-2
Maintenance
The information given in this repair group includes the routine
checlts and maintenance steps that are both required by
BMW under the terms of the vehicle warranty protection and
recommended by BMW to ensure long and reliable vehicle
operation.
NOTE-
Aside from keeping your car in the best possible condition,
proper maintenance plays a role in maintaining full protection
under
BMW's new car warranty coverage. If in doubt about
the terms and conditions of your car's warranty, an autho-
rized BMW dealer should be able to explain them to you.
Special tools
Some special tools are required for performing engine main-
tenance tasks. Be sure to have the necessary equipment on
hand before starting any job.
4 Hand pump for manual transmission lifetime oil
71 (Tool No. BMW 002 080)
4 Cooling fan counterhold wrench
(Tool No. BMW 11 5 030)
I I 4 Coolina fan wrench
I
4 Service position hood props
(Tool No. BMW 51 2 160)

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Table b. Inspection I Service (continued)
Checlt transmission and differential for
external lealts.
Check CV joint boots for damage or leaks.
Visually
check fuel tank, fuel lines, and
connections for
leaks.
New parts
Tools Required required
Check condition, position, and mounting
ol
exhaust system. Visually check and adjusl
if necessary.
Check power steering system for lealts.
Check power steering
fluid level and adjust
if necessary.
Check steering racidbox and tie rods for
tightness. Checit condition of front axle
joints, steering
linkage, and steering shaft
joints.
Check overall thickness of front and rear
bralte pads using
BMW special tool. If
replacement is necessary:
Examine brake disc surface.
Clean brake pad contact points in calipers
Grease wheel centering hubs.
Checlt thickness of parking brake linings
only when replacing rear brake shoes.
Checit operation of pariting brake and
adjust as necessary.
Checlt front control arm bushings for
damage or wear.
Check brake system connections and
lines
for leaks, damage, and incorrect
positioning Warm
engine
(~ealer service Irepair , required recommended lnformat~on
Check parking braite actuator. Adjust if
necessary
Check ail tire pressure (including spare)
and correct if necessary.
Checlt condition of tires (outer tread
surface), tread wear pattern: in case of
uneven wear, perform wheel alignment.
inspect entire body according to terms of
rust oerforation limited warrantv. (Must be
*:
4:
2 ~ perfdrmed at least every two years). I
Read out on-board diagnostic (OBD 11) fault
codes.
Checkengine coolant
system1 heater hose
connections for
leaks.
Checit coolant level and antifreeze
protection level. Add coolant as necessary.
* 100113010BD
I
170

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--- -
Maintenance
Table b. Inspection I Service (continued)
I I I I
Warm engine Dealer service
required recommended
Check windshield
washer fluid level and
antifreeze protection.
Add washer fluid as necessary.
Replace ventilation
microfilter. (Note:
reduce replacement intervals in dusty
operation conditions)
Reset Service interval Indicator
(Sil).
Additional
repair
information
Tools Required
*
eck aim of washer jets and adjust if
necessary.
covers, obvious damage or attachment o
s or accessories.
Road test
Check braking performance, steering,
heating and air conditioner operation.
Check manual transmission and clutch
operation or automatic transmission
operation. New
parts
required
*
Bodylelectrical
121
630
630
Checic battery state of charge
Check operation of:
headlights,
parking iights, back-up lights.
license plate lights, interior lights,
glove box
illumination, engine compartment light,
trunk light, turn signals, emergency
flashers, stop iights.
Check operation of horn and headlight
dimmer switch
:i:

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020-1 0
Maintenance Fluids and lubricants
Table d. Engine oil with filter change
V-8
models
BMW part no.
07 510 017 868
5W-30 synthetic oil
BMW part no.
07 51 0 017 866
Specification
1997
- 1998
15W-40 mineral oil
Fluid
6-cylinder models
Table e. Manual transmission oil
Approximate
capacity
6.5
liters (6.9 US qt)
Specification
Fluid
I I
Approximate
capacity
Getrag S5D 250G 1 .I liters (1.2 US
quarts) BMW
part no.
83 22 408 942
I
quarts)
Getrao
S6S 420G 11.9
liters (2.0 US
Table f. Automatic transmission fluid
(ATF)
Lifetime fluid (drain and refill)
(Additional fluid required when installing dry torque converter)
ZF S5D
3202
(MTF-LT-1)
u
Approximate I , , . Transmission Icapacity Spec~flcatlon
1.3 liters (1.4 US . .
quarts)
A5S 31 02
Trell~~2634) Total 9.7 liter volume: (10.2 US qt)
A5S
4402
Oil change volume:
4.0 liter (4.2 US qt)
I
A5S 360R /~otal volume:
Total
volume:
7.8 liter (8.2 US qt)
Oil change volume:
3.3 liter (3.5 US
qt)
(Exxon LT 71141) -.
BMW 83229407 807