ad blue BMW 528i 2000 E39 Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
--
Benllcy Publishers, a division ol Robcrt Bcnlley, In=. 1734 M~SB~CIIUP~IIS Avenue Cumbitdge. MA02138 USA Information lhat makes 800-423-4885 / 61 7.547.4170 the diiierence"
BentleyPublishe~
Technical contact inlormation I
We :.€ c3me ,o.lr leeooaca. Pieasc. ;Jam 1 cllriecl 00s an0 zoo ions lo our BhFLt/ recnns? o rcdss'un lor~m a1 http://~~~.BentleyPublishere.com
Errata information
We will evaluate submissions and post appropriate editorial
changes online as text errata or tech discussion. Appropriate
errata will be incorporated with the
boolc text in future printings.
Read errata information for this book before beginning work on
your vehicle. See the following web address tor additional
information:
http://unw.BentleyPublishers.com/errata/
WARNING-important safety notice
Do not use this manual unless vou are familiar with basic automotive reoair orocedures and safe
workshoo oracfices. This manual illustrates
the workshop procedures requked formoslservice work. It is not a subsiituti for full and up-to-date information from thevehiclemanufaciurer
or for proper training as an automotive technician. Note that it is not possible for us 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.
The vehicle manufacturer will continue to issue service information updates and parls retrofits
after the editorial closing of this manual. Some
of lhese updates and retrofits will apply lo procedures and specifications in this manual. We regret that we cannot supply updates to
purchasers of this manual.
We have endeavored to ensure the accuracy
of the information in this manual. Please note, however, that considering the vast quantity and
the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information contained in this
manual.
FOR
THESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAICES ANY WARRANTIES, EXPRESS OR IMPLIED, THATTHE INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS. AND WE EXPRESSLY DISCLAIM THE IMPLIED WARRANTIES OF MERCHANTABILTTY AN0 OF FITNESS FOR A PARTICULAR PURPOSE, EVEN IFTHE PUBLISHER OR AUTHOR HAVE BEEN ADVISED OFA PARTICULAR PURPOSE, AND EVEN IF A PARTICULAR
1 PURPOSE IS INDICATED IN THE MANUAL. THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LlABlLrrY FOR DIRECT. INDIRECT. INCIDENTAL OR 1 I CONSEQUENTIAL DAMAGES THAT RESULT FROM ANY USE OFTHE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION INTHIS BOOK. IN NO EVENT 1
I Your common sense and oood iudoment are crucial to safe and successful service work. Read orocedures throuoh before startino them. I . -- - -~ ~ ---~. - ~ ~~ Think about whether the condition of your car, &r level of mechanical skill, or your level of reading compreh&sion might resill in or
contribute in some way to an occurrence which might cause you injuly, damage your car, or result in an unsafe repair. If you have doubts
for these or other reasons about your ability to pelform safe repair work on your car, have the work done at an authorized BMW dealer or
other qualified shop.
Part numbers listed in this manual are for identification purposes only, not for ordering. Always check wilh your authorized BMW dealer to
verify part numbers and availability before beginning service work lhat may require new
park.
Before anempting any work on your BMW, read the 001 General Warnings and Cautions, and any WARNING or CAUTION that
accompanies a procedure in the service manual. Review the WARNINGS and CAUTIONS each time you prepare to work on your BMW.
I Spec a too s req.1 red to perlorm cena n service operations arc oenl fed n the manLa an0 arc recomrnenoeo lor JSC Jse ol loo s olner than those recommended In lh s serv ce manual may be oelnmcnlal lo lrlc car's sale open1 on as rvec as lne salely 01 lne person servcng I the car. I
Copies of this manual may be purchased from most automotive accessories and parts dealers specializing in BMW automobiles, from
selected booksellers, or directly from the publisher.
This manual was published by Robert Bentley,
Inc., Publishers. BMW has not reviewed and does not vouch for the accuracy of the
technical specifications and procedures described in this manuai.
Libratv of Conaress Cataloaino-in-Publication Data " " -
BMW 5 Series (E39) : service manual : 523. 528i, 530i. 540i, sedan, sport wagon, 1997,
1998, 1999,2000,2001,2002
~Acludes index.
ISBN 0-8376-0317-X (obi<) ,, , 1. BMW 5 series automobiles--Maintenance and repair--Handbooks manuals, etc. 1.
Robert Bentley, Inc.
TL215.8258623 2003 629.28'722--dc23 2003052231
Bentley Stock No. 8502
Editorial closing 08/03
090807 10987654
The paper used in this publication is acid
free and meets the requirements of the National Standard for Information Sciences-
Permanence of Paper for Printed Library Materials. @
OCopyright 2007 Robert Bentley. Inc. Bentiey Publishers is a trademark of Robert Bentley, Inc.
All rights reserved. All information contained in this manual is based on the information available to the publisher at the time of editorial
closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
ofhenvise, without the
prior written consent of the publisher. This includes text, figures, and tables. All rights reserved under Berne and Pan-American Copyright
conventions.
Cover photos of car exteriors by Jonathan Richard for
Bentley Publishers @ Robert Bentley, Inc. Cover design and use of blue band on
spine and back cover are trademarks
of Bentley Publishers. All rights reserved.
Manufactured in the United States of America

Downloaded from www.Manualslib.com manuals search engine
- -
/Battery, Starter, Alternator -- - -. - --I
< Check for battery voltage at alternator terminal 30 (B+) (ar-
row):
Pull back rubber insulating cover at terminal 30 at rear of
alternator.
Connect voltmeter between terminal 30 and ground and
check for battery voltage.
If voltage is not present, check
wiring for faults.
NOTE-
On V-8 engines, access to the rear of the alternator is limited.
Check for battery voltage between the jump start post on the
left cylinder head and ground.
r Disconnect harness connector from alternator. Turn ianition
on and check for battery voltage between terminal
lgand
ground. If voltage is not present, check wiring and fuses for
faults.
Reconnect connector to alternator.
Locate the blue wire coming from terminal
61E of the alter-
nator connector. Carefully connect the positive
(+) test lead
to the wire using a piercing test lead end.
Turn ignition key on and check for voltage. Voltage should be
less than 1.5 VDC and charge indicator lamp should light.
- Making sure all test equipment and tools are clear, start en-
gine. Voltage should increase to
8.0 VDC or higher. The
charge indicator light should go out.
If voltage does not increase and system is not charging,
the fault is in alternator.
- If voltage does not increase, but system is charging, inter- - roaate svstem for faults usina an appropriate BMW scan - .. . tool and'reset fault memory.
- If a load tester is not available, a quick alternator output test
can be done by running engine at about 2000 rpm and turn-
- -
ing on electrical loads (fans, lights, rear window defroster, -
- and wipers). With all accessories on, battery voltage should
be above 12.6
V.

Downloaded from www.Manualslib.com manuals search engine
.-- -
/ Fuel Tank and Fuel Pump - .. -. -- 1
Fuel pump fuse and relay
Troubleshooting of any fuel pump fault should begin with
checking the fuel pump fuse and the fuel pump relay. The
DME main relay should also be checked. The fuel pump relay
is located behind right side luggage compartment interior
panel.
I Fuel pump relay
BLU =blue ERN = blo$,m GRN =groan GRY = grsy ORG =orange PNI< =pink RED =red VIO =violel WHT = wlilte
rk-; I I 1 ECM
I I I 31 8 ,._--___.I
NOTE-
Special tools are required for some of the tests described
here.
4 Fuel pump circu~t is fuse-protected.
0 6-cylinder models with Siemens DME MS41 .I, MS42, V-8
models with Bosch DME M5.2, M5.2.1 englne manage-
ment: Fuse
F54,15A (luggage compartment fuse panel)
6-cylinder models with Siemens DME MS43 engine man-
agement: Fuse
F22,25A (glove compartment fuse panel)
V-8 models with Bosch DME M7.2: Fuse F54,25A (lug-
gage compartment fuse panel)
- Fuse 31 in glove compartment fuse panel supplies power to
coil side of fuel pump relay. Engine control module (ECM)
supplies switched ground to relay. During starting, fuel pump
runs as long as ignition switch is in START position and con-
tinues to run once engine starts. If electrical system fault in-
terrupts power to fuel pump, engine will not run.
. .
Operating fuel pump for tests
- To operate fuel pump for testing purposes without having to
run engine, bypass fuel pump relay to power pump directly.
< To run fuel pump, open luggage compartment and release
right side trim panel.

Downloaded from www.Manualslib.com manuals search engine
- Fuel Tank and Fuel pump]
Remove fuel pump
relay (arrow).
4 Connect relay socitet terminal 6 (redlviolet wire) to relay
socket terminal
2 (whitelblue wire) with a fused jumper wire.
After completing tests, remove jumper harness.
CA
UTIOG
Relay locations may vary Use care when identifying relays
and making electrical checks at
the fuse/relay panel. See
610 Electrical Component Locations for additional re-
lay information.
The fuel pump relay has a 1.5
md red/violet wire at
terminal
6 in the relay socket. Terminal2 has a 2.5md
white/blue wire. See ELE Electrical Wiring Diagrams
for additional wiring information.
NOTE-
* The fuel pump will run as soon as the jumper wire Is at-
tached.
The jumper wire should be 1.5
md (14 ga.) and include
an in-line fuse holder with a 15A fuse. To avoid
fuse/relay
panel damage from repeated connecting and disconnect-
ing, also include a toggle switch in the jumper harness.
- If pump does not run with jumper installed, fault could be in
fuel pump, fuses
F31 or F22 1 F54, or wiring to pump. Check
pump, fuses and its wiring as described below.
Fuel pump electrical circuit, testing
- The test given below assumes that the fuel pump relay circuit
is functioning correctly as described earlier. Access to the
pump is from below the rear seat bottom cushion.
- Remove rear seat lower cushion by lifting front edge off left
and right catches.

Downloaded from www.Manualslib.com manuals search engine
160-8
I Fuel Tank and Fuel Pump
4 Disconnect harness connector from tank sending unit by
sliding connection lock to release connector.
Connect voltmeter between fuel pump terminals on
connector.
NOTE-
Fuel pump power (+) is supplied through the white/blue wire
Ground
(-) is supplied by the brown wire.
With jumper wire connected in place of fuel pump relay as
described above, check for battery voltage at fuel pump
harness connector terminals.
If voltage and ground are present, fuel pump is probably
faulty. If there is no voltage, check wiring between fuel pump
and relay.

Downloaded from www.Manualslib.com manuals search engine
.- -
Fuel Tank and Fuel purnpl
Fuel pump power consumption, testing
To achieve accurate test results, the battery voltage at the
fuel pump connector should be
12.6 volts. Charge the battery
as necessary.
A higher than normal power consumption may indicate a
worn fuel pump, which may cause intermittent fuel starvation
due to pump overheating and seizure. The only remedy is
pump replacement.
A lower than normal power consumption
may indicate a blockage. Be sure to check that the return line
and the pump pickup are not obstructed before replacing the
pump.
- Expose right side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover insu-
lation.
Peel back insulation at perforations to expose fuel tank ac-
cess cover.
Remove right side cover to expose electrical harness con-
nector.
Disconnect harness connector from tank sending unit by slid-
ing lock back. Lift off connector.
Test fuel pump for current draw by attaching digital ammeter
between pump and harness (terminal
2, whitelblue wire) and
connect a jumper wire between pump and harness (terminal
1, brown wire) as shown.
CAUTION-
Do not allow the test leads to short to ground.
NOTE-
See 600 Electrical Systern-General for information on elec-
trical tests
using a digital multirneter.
Run pump as described in Operating fuel pump for tests.
- Compare ammeter reading with specification listed in ac-
companying table.
Fuel
pump current
Current consumption (average) 9.5 amps

Downloaded from www.Manualslib.com manuals search engine
Rear Suspension
Air spring, removing and installing
CAUTION-
If vehicle is driven with airspring depressurized, the airspring
will be permanently damaged and must be replaced.
An air spring is made from a flexible rubber material which
forms an airtight cavity. It is pressurized by an air supply
pump activated by an electronic control unit to provide a
vari- . . able spring rate depending on vehicle load
CAUTIOIG
Disable air supply pump by disconnecting electrical plug
before performing any repairs. Pump is located beneath a
cover under the spare tire in the floor of
the cargo compart-
ment.
When removing and installing air connections, extreme
cleanliness must be followed. Small dirt particles can
cause leakage in the system.
Remove luggage compartment floor mat.
- Working above air spring, loosen quick coupling screw con-
nection to allow
air pressure to escape.
- Once pressure has been reduced, retighten screw.
Tightening torque Quick coupling screw
to air pump 2 Nm (18 in-lb)
- Remove quick coupler. Plug openings to keep dirt out,
- Remove air spring mounting clips.
- Raise car and remove rear wheels.
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place
jaclc stands under
suspension parts.
- Working underneath rear suspension, lift wheel bearing car-
rier to relieve rear spring tension. Then unbolt air spring
mounting bolt from seat on wheel bearing carrier. Remove air
spring.
NOTE-
Left and right air springs are different. The left air spring is
marked with a red identification
marl. The right air spring is
marked with a blue identification mark.