control valve BMW 528i 2000 E39 Workshop Manual

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Engine identifying features
4 The M52 engine (MY97-98 528i) used a single on-off vari-
able intake valve timing system (called VANOS). The cylinder
block is cast iron and the cylinder head is aluminum. The en-
gine management system is Siemens MS 41
.I and features
NGK-type (0-5 volt) oxygen sensors.
NOTE-
VANOS is an acronym based on the German words Variable
Nocltenwellen Steuerung (variable camshaft timing).
4 The M52 TU engine (MY99-00 5281) and the M54 engines
(MY01-02 525il530i) are fitted with double VANOS. The en-
gine
blocits are constructed of aluminum alloy with cast iron
cylinder sleeves.
4 The double VANOS (variable camshaft control) system incor-
porates true variable control of both the
intake and exhaust
camshafts, as compared to the single VANOS system on the
M52 engine
(onloff control of the intaite camshaft only).
The M54 engines use a fully electronic throttle control (drive
by wire). There is no accelerator cable connecting the throttle
pedal to the throttle housing in these cars.

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100-4
I Engine-General
The M62 90" V8 engine uses four valves per cylinder, double
overhead camshafts and light alloy cylinder head and cylin-
der
bloclc engine construction.
On 1997 and 1998 540i models, Bosch engine management
systems are utilized. Table a lists engine management sys-
tem applications.
4 For the 1999 model year, the M62 TU VANOS engine was in-
troduced to the 540i models. This engine is primarily a carry-
over from the earlier M62 engine, but contains many unique
identifying components and technology:
Variable camshaft timing (VANOS) for the intake valves.
Bosch ME 7.2 engine management system with electronic
throttle control. There is no accelerator cable connecting
the throttle pedal to the throttle housing in these cars.
Compact water-cooled generator (alternator).
E39 vehicles are equipped with sophisticated self-diagnostic
engine management systems. These systems monitor and
store diagnostic fault information. If the malfunction indicator
lamp (MIL) illuminates, the first diagnostic test should be to
connect a dedicated scan tool for BMW automobiles and in-
terrogate the fault memory.
If the malfunction indicator light (MIL) comes on orflashes, it
indicates that an emissions-related fault has occurred and
that fault information is stored in memory within the ECM.
4 The MIL in E39 cars displays one of these warning graphics
in the instrument cluster.
The diagnostic capabilities of these systems have the poten-
tial to save hours of diagnostic time and prevent incorrect
5 placement. See OBD On-Board Diagnostics.

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11 0-4
/Engine Removal and Installation
- Disconnect negative (-) cable from battery.
CAUTION- Prior to disconnecting the
batteg read the battery discon-
nection cautions
in 001 General Cautions and Warnings.
- Remove engine hood, or place in service position. See 410
Fenders, Engine Hood.
4 Remove left and right interior ventilation ducts (lefl side
shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic loclting tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclocltwise to
unloclt from bulkhead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring
loclt (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel:
Remove rubber sealing gasket (arrow).
- Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift off panel.
Remove complete air filter housing:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intalte duct
(6) and (where applicable) disconnect idle speed control
valve electrical harness connector.
Disconnect harness connector (C) from mass air flow sen-
sor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

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Engine Removal and lnstallationl
NOTE-
BMW uses three styles of fuel line connections; a one-time
single use clamp, a locking fitting that uses special tool
16 1
050 to release, and a quick release sleeve (arrow) that dis-
connects the line when depressed.
WARNING-
Fuel may be expelled under pressure. Do not smoke or work
near heaters or other fire hazards. Keep a fire extinguisher
handy Before disconnecting fuel hoses, wrap a cloth around
fuel hoses to absorb any leaking fuel. Plug all
oDen fuel lines.
< M52 engine: Remove throttle valve and ASC throttle
assemblies.
Disconnect ASC throttle cable
(A).
Remove ASC throttle housing mounting fasteners (El).
Clamp off, disconnect, and plug coolant hoses (C).
Disconnect throttle and cruise control cables (D).
Remove throttle housing mounting hardware and throttle
valve.
NOTE-
M52 TU, M54 engine: Throttle body is removed with intake
manifold.
< M52 TU engine: Pull throttle cable out of rubber retainer (A)
and unloclc ball end of cable (6) from throttle actuator.

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110-8
1 Engine Removal and Installation
4 M52 TU, M54 engine: Remove fasteners (arrows) retaining
wiring harness conduit to throttle body.
4 M52 TU, M54 engine: Working at throttle housing, rotate har-
ness plug (arrow) counterclockwise and remove.
4 M52 TU, M54 engine: Disconnect electrical harness connec-
tor at idle speed control valve (arrow), directly above throttle
valve.

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11 3-2
Cylinder Head Removal and Installation
This group covers cylinder head removal and installation as
well as cylinder
headlvalve diagnostic procedures.
In the procedures in this repair group, engines are referred to
by engine code. If necessary, see
100 Engine-General for
engine code and application information.
The information given in this repair group assumes that the
engine is installed in the engine bay. On the
6-cylinder en-
gines, the VANOS control unit must be removed in orderto re-
move the cylinder head from the engine block. On
M52TU
and M54 engines, camshafts must be removed from the cylin-
der head before the head is removed.
The cylinder head removal and installation procedures for the
M62 V-8 are also included, butthe proceduresforthe M62TU
V-8 with VANOS are not provided.
For cylinder head and valvetrain reconditioning information,
see
116 Cylinder Head and Valvetrain.
For specific repair procedures, refer to the appropriate repair
group:
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
If a head gasket problem is suspected, a compression test or
leak-down test will usually detect the fault See Diagnostic
Testing later
in this group.
Special tools
Special BMW service tools are required to properly remove
and install the cylinder head on engines covered by this man-
ual. The special tools are used to time the valvetrain to the
crankshaft, and to remove the VANOS control unit, the cam-
shafts and the
Tom (El2) head bolts. Read the entire proce-
dure through before beginning the job.

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11 3-9
Cylinder Head Removal and Installation
< Remove left and right interior ventilation ducts (left shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic locking tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclockwise to unlock from bulkhead and
remove (arrow).
Disconnect electrical connector from hood switch
(C).
Release spring lock (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel: Remove rubber sealing
gasket (arrow).
0 Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift out panel.
< Remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from
~ntake
duct (6) and disconnect Idle speed control valve electr~cal
harness connector.
Disconnect
electr~cal harness connector (C) from mass alr
flow sensor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.
4 Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jumper post (A).
Loosen and remove battery lead mounting nut.
Remove battery lead and push down through intake mani-
fold.
Remove trim caps (arrows) from fuel injector cover.
Remove cover hold down fasteners and lift off cover.

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- -.
Cylinder Head Removal and lnstallation
NOTE-
Be Sure the secondary timing chain tensioner is locked down
and the exhaust
camshaif mounting bolts are loose before
proceeding.
- Install VANOS control unit. See VANOS control unit, install-
ing
(M52 engine) in 117 Camshaft Timing Chain.
CAUTION--
Incorrect installation ofthe VANOS control may result in dam-
age to the engine valvefrain.
- Install exhaust manifolds using new gaskets and nuts. Coat
manifold studs with copper paste prior to installing nuts.
Install intake camshaft cover and cylinder
head cover.
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209
O or equivalent
sealant at corners
(6) of half-moon cutouts.
Seat gasket and seal corners in front of cylinder head at
VANOS unit.
- Installation of remaining parts is reverse of removal, noting
the following:
Reinstall electrical harness connectors for oil pressure
switch and coolant temperature sensor before installing in-
take manifold.
Refill cooling system as described in 170 Radiator and
Cooling System.
Change engine oil and filter as described in 020 Mainte-
nance.
If necessary, adjust accelerator cable.
Reconnect battery last.
Tightening Torques
VANOS oil line
32 Nm (24
ft-lb)
VANOS solenoid to control unit 30 Nm (22 ft-lb)
Coolant drain plug to cylinder
block 25 Nm (18 ft-lb)
Cylinder head cover to cylinder head
10 Nrn (89 in-lb)
(M6 bolts)
intake manifold to cylinder head 15 Nm (I 1 ft-lb)
Radiator cooling fan to coolant pump
40 Nm (30 ft-lb) - . .
Radiator drain screw to radiator 2.5 Nm (22 in-lbl

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- --
Cylinder Head Removal and Installation 1 --
< Remove complete air filter housing assembly with mass air
flow sensor:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intake duct
(B) and disconnect idle speed control valve electrical har-
ness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
. Loosen air intalte duct clamp (F).
Carefully lifl air filter housing, mass air flow sensor, and in-
take duct hose out of engine bay.
4 Disconnect positive battery cable and remove intake rnani-
fold cover:
Remove protective cover from positive (+)jumper post.
Loosen and remove battery lead mounting nut (A).
Remove lead and push down through intake manifold.
* Remove trim covers (arrows) from fuel injector cover.
Remove cover hold down fasteners and lifl off cover.
4 Worlting above engine, disconnect the following:
Vent line from cylinder head cover. To remove, pinch clips
(arrows).
Electrical harness connector from VANOS solenoid valve
(A).
- Remove oxygen sensors and exhaust manifolds. See 180
Exhaust System.
CAUTION-
Remove oxygen sensors before removing exhaust mani-
fold to prevent damage.
Label oxygen sensor harness connectors so that they
can be reassembled correctly Do not interchange con-
nectors.
NOTE-
Front exhaust manifold must be removed before rear
manifold.

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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.