air condition BMW 528i 2000 E39 Workshop Manual

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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

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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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I General Warnings and Cautions
WARNINGS (continued)
. The air conditioning system is filled with chemical refrigerant,
which is hazardous. The AIC system should be serviced only by
trained technicians using approved refrigerant recoverylrecycling
equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
. Do not expose any part of the AIC system to high temperatures
such as open flame. Excessive heat will increase system pres-
sure and may cause the system to burst.
Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away
from the tire repair area. Inflate and deflate the
tire at least four
times before breaking the bead from the rim.
Completely remove the tire from the rim before attempting any re-
pair.
Cars covered by this manual are equipped with a supplemental
restraint system (SRS), that automatically deploys
airbags and
pyrotechnic seat belt tensioners
In the event oi a frontal or side
impact. These are explosive devices. Handled improperly or with-
out adequate safeguards, they can be accidently activated and
cause serious injury.
- The ignition system produces high voltages that can be fatal.
Avoid contact with exposed terminals and use extreme care when
working on a car with the engine running or the ignition switched
on.
. Place jack stands only at locations specified by the manufacturer.
The vehicle
illtino iack su~olied with the vehicle is intended fortire -. , . changes only. A heavy duty floor jack should be used lo lift vehicle
before installing
jacl( stands. See 010 General.
- Battery acid (electrolyte) can cause severe burns. Flush contact
area
with water, seek medical attention.
Aerosol cleaners and solvents may contain hazardous or deadly
vapors and are highly flammable. Use only in a well ventilated ar-
ea. Do not use on hot surfaces (engines, brakes, etc.).
Do not remove
coolant reservoir or radiator cap with the engine
hot. Danger of burns and engine damage.
CAUTIONS-
See also WARNINGS
- if you lack the slqills, tools and equipment, or a suitable worl(shop
for any procedure described in this manual, leave such repairs to
an authorized BMW dealer or other qualified shop.
BMW is constantly improving its cars and sometimes these
changes, both in parts and specifications, are made applicable to
earlier models. Therefore, part numbers listed in this manual are
for reference only. Always check with your authorized BMW deal-
er parts department for the latest information.
Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read ail the instructions thorough-
ly, and do not attempt shortcuts. Use tools appropriate to the
work and use only replacement parts meeting BMW specifica-
tions.
Use pneumatic and electric tools only to loosen threaded parts
and fasteners. Never use these tools to tighten fasteners, espe-
cially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque specification listed.
Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the
oil. Do not
pour
oil onto the ground, down a drain, or into a stream, pond or
lake. Dispose of waste in accordance with Federal, State and
Local laws.
The control module for the anti-lock brake system
(ABS) cannot
withstand temperatures from a paint-drying booth or a heat
lamp
in excess of 203" F (95°C) and should not be subjected to tem-
peratures in excess of 185°F
(8S°C) for more than two hours.
- Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative
(-) terminal (ground strap) and
the ABS control module connector.
- Always make sure ignition is off before disconnecting battery.
Label battery cables before disconnecting. On some models, bat-
tery cables are not color coded.
Disconnecting the battery may erase fault code@) stored in control
module memory. Using special BMW diagnoslic equipment, check
lor
iauit codes prior to disconnecting the battery cables. If the mal-
I.mct on ndicator Ignt (MIL) s I. ..minaled. see OBD On-Board
Diaanostics
Tl11s iant is iuenlfted as lne Check Ena~ne oht
(1997-2000 models jor~ervlce Engine Soon light (2061 andlater
models). If any other system iaults have been detected (indicated
by an illuminated warning light), see an authorized BMW dealer.
If a normal
or rapid charger is used to charge battery, the battery
must be disconnected and removed from the vehicle in order to
avoid damaging the vehicle.
- Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the
battery a second time.
* Connect and disconnect a battery charger only with the battery
charger switched off.
- Sealed or "maintenance free" batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the bat-
tery's ampere-hour (Ah)
rating.
. Do not allow battery charging voltage to exceed 16.5 volts. If the
battery begins producing gas or boiling violently, reduce the
charging rate.
Boosting a sulfated battery at a high charging rate
can cause an explosion.

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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 Tightening fasteners
When tightening the bolts ornuts on acomponent, it is always
good practice to tighten the bolts gradually and evenly to
avoid misalignment or over-stressing any one portion of the
component. For components sealed with gaskets, this meth-
od helps to ensure that the
gasket will seal properly.
WARNING
-
Table a: General bolt tightening torques in Nm (max.
permissible) is
a general reference only The values listedin
the table are not intended to be usedas a substitute for tor-
ques specifically called out in the text or in manufacturer's in-
formation.
4 Where there are several fasteners, tighten them in a se-
NOTE-
* Metric bolt classes or grades are rnarlced on the bolt head.
* Do not confuse wrench size with bolt diameter. Fora listing
of the common wrenches used on various bolt
diameters,
see Basic tool requirements.
2 BOO~FNG
quence alternating between opposite sides of the compo-
nent. Repeat the sequence until all the bolts are evenly
tightened to the proper specification.
For some repairs a specific tightening sequence is
neces-
sary, or particular order of assembly is required. Such special
conditions are noted in the text, and the necessary sequence
is described or illustrated. Where no specific torque is listed,
Table
a: General bolt tightening torques in Nm (max. per-
missible) can be used as a general guide for tightening fas-
teners.

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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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Maintenance
The intervals for most tasks listed in the maintenance tables
below are determined by the Sll.
NOTE-
BMW is constantly upgrading recommended maintenance
procedures and requirements.
The information contained
here is as accurate as possible at the time of publication. if
there is any doubt about what procedures apply to a specific
model or year, or what intervals should be followed, remem-
ber that an authorized
BMW dealer has the latest information
on factory-recommended maintenance.
Except where noted, the maintenance items listed apply to all
models and model years covered by this manual. The num-
ber in the "additional repair information" column refers to the
repair group in this manual where additional information can
be found.
Table a.
Oil Service
I I I I I Additional
( New parts (Tools Required requrred
Under car maintenance
1 I I I I
I I - I I
Engine compartment maintenance
Check overall thickness of front and rear
bralte pads.
If replacement is necessary:
Examine
braite disc surface.
Clean brake pad contact points in calipers.
Grease wheel centering hubs.
Checlc thickness of parking braite linings
only when replacing rear brake pads.
Checlc operation of parking brake and
adjust as necessary.
spare
Table b.
Inspection I Service
I 1 I I [Additional
020
020
020
New parts Warm engrne Dealer service Irepair , /Tools Required (required (required . (recommended lnformatlon
Change oil and oil filter
Reset Service Interval indicator [Sli)
Replace interior ventilation microfilter
*
A
*
*
*
I I I I I
Undercar maintenance
Checlc engine drive belt condition 020
ri: * Change oil and oil filter. 020 *

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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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--- -
Maintenance
Table c. Inspection II Service
Additional
New parts Warm engine Dealer service repair
Tools required required required recommended information
Engine compartment maintenance
Replace air filter element. (Note: reduce
replacement intervals in dusty operating
conditions).
Replace brake
fluid every 2 years (time
interval begins from vehicle production
date).
Cooling system service
Spark plug service
Brake
system maintenance
:j:
*
Replace coolant every 3 years (time
interval begins from vehicle production
date).
Replace oxygen sensor every 160,000
itm
(1 00,000 miles).
020
FLUID AND LUBRICANT
SPECIFICATIONS
:I:
Oxygen sensor service
*
x:
Spark plugs:
M52
1 M62 engine:
Replace every 60,000 itm (48.000 miles).
M52
TU I M54 1 M62 TU engine:
Replace every 160,000
ltm (100.000
miles).
< Engine oil viscosity (SAE grade) vs. operating temperature
range for the BMW engines covered in this manual.
Fluid and lubricant capacities and specifications are listed be-
low. See
Fluids and lubricants.
:I:
*
*
*
WARNING -
The use of fluids that do not meet BMW" specifications may
impair performance and
reliabilitl: and may void warranty
coverage.
340
170
180
* 020