brake 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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001 General Warnings and Cautions
PLEASE READ THESE WARNINGS AND CAUTIONS
BEFORE PROCEEDING
WITH MAINTENANCE AND REPAIR WORK.
WARNINGS-
See also CAUTIONS
- Some repairs may be beyond your capability. If you lack the skills, - Catch draining fuel, oil, or brake fluid in suitable containers. Do
tools and equipment, or a suitable workplace for any procedure
not use
foodor beverage containers that might mislead someone
described in this manual, we suggest you leave such repairs to
into
drinking from them. Store flammable fluids away from fire
an authorized BMW dealer service department or other qualified
hazards. Wipe up spills at once, but do not store the oily rags,
shop. which can ignite and burn spontaneously.
. Do not reuse any fasteners that are worn or deformed. Many fas- Always observe good worRshop practices. Wear qoqqles when
teners are designed to be used only once and become
unreliable you operate machine tools or work with battery acid:kloves or
and mav fail when used a second time. This includes, but is not other
~rotective clothino should be worn whenever the iob re-
limited io, nuts, bolts, washers, self-locking nuts or bolts, clrclips yires' working with harmful substances.
and cotter pins. Always replace these fasteners with new parts.
Greases, lubricants and other automotive chemicals contain toxic
. Never work under a lifted car unless it is solidly supported on
substances, many of which are absorbed directly through the
stands
desiqned for the purpose. Do not supeort a car on cinder
skin. Read the manufacturer's instructions and warninos careful-
blochs, hollow tiles orotherbrops that may drurnbie undercontin-
uous toad. Never work under a car that is supported solely by a
iack. Never work under the car
while the enqine is runninq. - -
If you aregoing to work underacaron the ground, makesure that
the ground is level. Block the wheels to
keep the car from rolling.
Disconnect the battery negative
(-) terminal to prevent others
from starting the car while you are under it.
- Never run the engine unless the work area is well ventilated. Car-
bon monoxide kills.
Rings, bracelets and other jewelry should be removed so that
they cannot cause electrical shorts, get caught in running ma-
chinery, or be crushed by heavy parts.
- Tie long hair behind your head. Do not wear a necktie, a scarf.
loose clothing, or a necklace when you work near machine tools
or running engines. if your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
DO not attempt to
work on your car if you do not feel well. You in-
crease the
danger of injuryto yourseliand others if you are tired,
uDset or have taken medication or anv other substance that mav
keep you from being fully alert.
Illuminate your work area adequately but safely. Use a portable
iy. Use hand and eye protection. Avoid direct skin conGct.
Disconnect the battery negative (-) terminal whenever you work
on the fuel system
orthe electrical system. Do not smokeorwork
near heaters or other fire hazards. Keep an approved fire extin-
guisher handy.
. Friction materials (such as brake pads or shoes or clutch discs)
contain asbestos fibers or other friction materials. Do not create
dust by grinding, sanding, or by cleaning with compressed air.
Avoid breathing dust. Breathing any
friclion material dust can
lead to serious diseases and may result in death.
Batteries
giveoff explosive hydrogen gas during charging. Keep
sparks, lighted matches and open flame away from the top of the
battery. If hydrogen gas escaping from the cap vents is ignited, it
will ignite gas trapped in the cells and cause the battery to ex-
plode.
Connect and disconnect battery cables, jumper cables or a bat-
tery charger only wilh the ignition switched off. Do not disconnect
the battery while the engine is running.
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.
. . safety lighiforworking lnsideor under the car. Make sure the bulb - Do not allow battery charging vollage to exceed 16.5 volts. If the
is enclosed bv a wire caoe. The hot filament of an accidentallv
batten! beoins ~roducina oas or boilino violentiv, reduce the
broken bulb can ignite spilled
fuel, vapors or oil. , - - - charglng rate. ~oostlng a sutfaled battery at a igh charging rate
can cause an
explosion.
-
Continued on next page

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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
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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General
ADVICE FOR THE BEGINNER
The tips that follow are general advice to help the do-it-your-
self BMW owner
periorm repairs and maintenance taslts
more easily and more professionally.
Planning ahead
Know what the whole job requires before starting. Read the
procedure thoroughly, from beginning to end, in
orderto know
just what to expect and what parts will have to be replaced.
Workshop practices
Keeping things organized, neat, and clean is essential to do-
ing a good job. When working under the hood, iender covers
will protectthe finish from scratches and otherdamage. Make
sure the car finish is clean so that dirt under the cover does
not scratch the iinish.
Any repair job will be less troublesome if the parts are clean
For cleaning old parts, there are many solvents and parts
cleaners commercially available.
For cleaning parts prior to assembly, commercially available
aerosol cans of parts cleaner or brake cleaner are handy to
use, and the cleaner will evaporate completely.
WARNING-
Most solvents used for cleaning parts are highly flammable
as well as toxic, especially in aerosol form. Use with extreme
care. Do not smoke. Do not use these products indoors or
near any source of heat, sparks or flame.
Non reusable fasteners
Many fasteners used on the cars covered by this manual
must be replaced with new ones once they are removed.
These include but are not limited to: bolts, nuts (self-locking,
nylock, etc.), roll pins, clips and washers. Genuine BMW
parts should be the only replacement parts used for this pur-
pose.
Some bolts are designed to stretch during assembly and are
permanently altered, rendering them unreliable once re-
moved. These are known as torque-to-yield fasteners. Al-
ways replace fasteners where instructed to do so. Failure to
replace these fasteners could cause personal injury
orvehi-
cle damage. See an authorized BMW dealer for applications
and ordering information.

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01 0-1 4
General
Specialty tool suppliers
Peake Research, Automotive Products Division
P.O. Box 28776
San Jose, CA 95159
408-369-0406
[email protected]
http://www.peakeresearch.com
Basic tool requirements
The basic hand tools described below can be used to accom-
plish most of the simple maintenance and repair tasks.
Screwdrivers
4 The common flat-blade type, Phillips type, and TorxO type
screwdrivers will handle almost all screws used on
BMWs.
Two or three different sizes of each type will be required,
since a screwdriver of the wrong size will damage the screw
head.
Wrenches
4 Wrenches come in different styles, including open-end. 12
point box-end,
6 point box-end and flare nut. The basic open-
end wrench is the most widely used, but grips on only two
sides. The box-end wrench has better grip on all six sides of
a nut or bolt.
A 12 point box-end can loosen a nut or bolt where there is less
room for movement, while
a 6 point box-end provides better
grip. For hex fasteners on fluid lines, like brake lines and fuel
lines, a flare-nut wrench offers the advantages of a box-end
wrench with a slot that allows it to fit over the line.
The combination wrench is the most universal. It has one
open-end and one box-end. 10 mm and 13 mm wrenches are
the most common sizes needed.
A more complete set of
wrenches would include
6 mm through 19 mm sizes.

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Spare parts kit
Carrying a basic set of spare parts can prevent a rninorbreak-
down from turning into a major repair annoyance. The list be-
low is a good place to start.
Spare parts kit
- basic
Polyribbed drive
belt(s)
BMW engine oil: one or two quarts
BMW engine coolant:
1 gallon of premixed 50150 BMW
anti-freeze and water
Fuse assortment:
7.5A. IOA, 1 5A, 20A, 30A. 50A
Radiator hoses: upper and lower
Spare parts
kit - additional contents
Exterior lighting bulbs: headlight, bralte light, turn signal,
and taillight
* Wiper blades or blade inserts
Brake fluid: new, unopened bottle, DOT
4 specification
Main relay for DME system

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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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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 *