gas type BMW 528i 2000 E39 Workshop Manual

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General
WARNING-
Never run the engine in tile work area unless it is well-ven-
tilated. The exhaust should be vented to the outside. Car-
bon monoxide (CO) in exhaust kills.
Remove all neckties,
scarfs, loose clothing, or jewelry
when working near a running engine or power tools.
Tuck in shirts. Tie long hair and secure it under a cap.
Severe injury can result from these things being
caugiit
in rotating parts.
Remove rings, watches, and bracelets. Aside from the
dangers of moving parts, metallic jewelry conducts
electricity and may cause shorts, sparks, burns, or
damage to the electricalsystem when accidentally con-
tacting the battery or other electrical terminals.
Disconnect the battery negative
(-) cable whenever
working on or near the fuel system or anything that is
electrically powered. Accidental electrical contact may
damage the electrical system or cause a fire.
Fuelis highly flammable. When working around fuel, do
not
smoke or work near heaters or other fire hazards.
Keep an approved fire extinguisher handy.
The fuel system is designed to retain pressure even
when the ignition is off When worlcing with the
fuelsys-
tem, loosen the fuel lines slowly to allow the residual
pressure to dissipate gradually. Take precautions to
avoid spraying fuel.
. Illuminate the worlc area adequately and safely Use a
portable safety light for worlcing inside or under the car.
A fluorescent type
light is best because it gives off less
heat. If using a light with a normal incandescent bulb,
use rough service bulbs to avoid
breakage. The hot fil-
ament of an accidentally broken bulb can ignite spilled
fuel or oil.
Keep sparks, lighted matches, and any open flame
away from the top of the battery. Hydrogen gas
emitted
by the battery is highly flammable. Any nearby source
of ignition may cause the battery to explode.
Never lay
tools or parts in the engine compartment or
on top of the battery. They may
fallinto confinedspaces
and be difficult to retrieve, become caught in belts or
other rotating parts when the engine is started, or
cause electrical shorts and damage to the electrical
system.

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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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Cylinder Head Removal -- and lnstallati~i
4 Cylinder head bolt loosening sequence.
- Using BMW special tool 11 2 250 or an equivalent tool, loos-
en cylinder head bolts in sequence. Discard head bolts.
- Separate the cylinder head from the block and remove head.
Evaluate head as described in
116 Cylinder Head and Val-
vetrain.
Cylinder head, installing, M52 engine
If the camshafts were removed and installed while the cylin-
der head was off, a minimum waiting time is required after in-
stalling the camshafts. When the camshafts are removed, the
hydraulic lifters can expand. This expansion can cause in-
creased valve lift when the camshafts are bolted down, result-
ing in open valves.
Camshaft installation waiting times
68" F (20" C) and higher 4 minutes
50.68' F (1 0-20" C) 11 minutes
32-50' F (0-1 0" C) 30 minutes
- Clean cylinder head and gasket surfaces of cylinder block
and all timing chain covers.
CAUTION-
Do not use a metal scraper or wire brush to clean the alumi-
num cylinder head orpistons. If necessary, use a hard wood-
en orplastic scraper. Also available are abrasive discs to be
used in conjunction with an electric drill. Be sure to use the
correct disc for the type of metal being cleaned.
- Remove all debris and fluids from bolt holes and clean with a
thread chaser.
- Check gasket surface of cylinder head and cylinder block for
warpage using a straight edge.
NOTE-
If the cylinder head has been machined, a special 0.3 mm
thicker gasket should be installed. The thicker
gasket is avail-
able from an authorized
BMW dealer.

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I Cylinder Head Removal and Installation
4 Check that two locating dowels are correctly positioned in
block and are not damaged.
- Apply permanently elastic sealing compound Three Bond
1209 8 to joints where cylinder block joins timing case cover.
- Place new cylinder head gasket on cylinder block.
NOTE-
The word "OBEN" or 'TOP': printed on the gasket, should
face up. The cylinder head
gasket will fit correctly in only one
orientation.
- With camshafts locked in TDC oosition with BMW soecial
tools as described during cylinder head removal,
seicylinder
head in position, guiding primary chain through cylinder head
opening.
NOTE-
* The camshafts must be locl(ed in the TDC position at the
rear of the cylinder head with
BMW special tool I1 3 240
before installing the cylinder head.
Make sure the
cranksha% which had been rotated approx-
imately
30" opposite the direction of engine rotation, is still
in that position before lowering the cylinder head into posi-
tion.
- Lightly lubricate new cylinder head bolts. Loosely install bolts
and their washers, then thread them in until they are finger
tight.
NOTE-
. Torx-type cylinder head bolts should not be reused. They
are stretch-type bolts and must always be replaced when-
ever loosened.
Check that all washers for the cylinder head bolts are in
place before installing the bolts. Some of the washers may
be
stalced to the cylinder head.
CAUTIOI\C
Cylinder head bolts for a cast iron engine block are different
length and require different tightening torque than bolts for an
aluminum cylinder bloclc engines
(95 rnm versus 110 rnm
bolts).
- Install cylinder head-to-lower timing chain cover bolts finger
tight.
< Tighten cylinder head bolts in correct sequence to initial
torque value.

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. - -- -
Cylinder Head Removal and Installation --
Remove bolts (arrows) holding timing chain cover to cylinder
head. (Photo shows camshafts and camshaft bearing caps in
place).
4 Using BMW special tool 11 2 250 or equivalent, loosen cylin-
der head bolts in several stages, in sequence shown. Discard
head bolts.
NOJE-
BMW special tool 11 2 250 is a thin-walled Torx El2 socket
with an extended reach. The cylinder head bolts are re-
cessed into the head below the
camshaft towers with little
working space.
- Lift off cylinder head. Refer to 116 Cylinder Head and Val-
vetrain for cylinder head reconditioning information.
Cylinder head, installing, M52 TU and M54
engines
Clean cylinder head and gasket surfaces of cylinder bloclc
and all timing chain covers.
CAUTION- Remove foreign matter and liquid from bolt holes. Trapped oil
or coolant in bolt holes can cause damage to
blocl~,
CAUJION-
Do not use a metal scraper or wire brush to clean the alumi-
num cylinder head or pistons. If necessary, use a hard wood-
en orplastic scraper. Also available are abrasive discs to be
used in conjunction with an electric drill. Be sure to use the
correct disc for the type of metal being cleaned.
Evaluate cylinder head as shown in
116 Cylinder Head and
Valvetrain.
NOTE- If the cylinder head has been machined, a special 0.3
mm
(0.01 1 in.) thicker gasket should be installed. The thicker
gasket is available from an authorized
BMW dealer and
should be marked accordingly
Cylinder head and valve specifications are covered in 116
Cylinder Head and Valvetrain.

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11 3-40
I Cylinder Head Removal and Installation
Lubricate camshafts, camshaft carriers, bearing caps, hy-
draulic lifters, friction washers, splined shafts and spline hubs
with assembly lubricant before installation.
4 Check that two cylinder head aligning sleeves (arrows) are
correctly positioned in block and are not damaged.
- Apply elastic sealing compound Three Bond 1209 8 to cor-
ner joints on cylinder block to timing chain cover.
- Place new cylinder head gasket on cylinder block.
NOTE-
The word "OBEN" or "TOP printed on the gasket, should
face up. The cylinder headgaslet will fit correctly in only one
orientation.
- Set cylinder head in position, guiding primary chain through
cylinder head opening.
CAUJION-
Make sure the crankshaft, which had been rotated approxi-
mately 30" opposite the direction of engine rotation from
TDC, is still in thatposition before lowering the cylinder head
into position. All pistons must be out of TDC position to pre-
vent
valve/piston interference when the camshafts are in-
stalled.
- Lightly lubricate new cylinder head bolts and washers with
oil. Install bolts and washers finger tight. Install cylinder head
to lower timing chain cover bolts finger tight.
NOJE-
Cylinder head bolts should not be reused. They are
stretch-type bolts and must be replaced whenever loos-
ened.
* Aluminum cylinder blocls use different length cylinder
head bolts and torque values than cast iron blocks.
Check that all washers for
Nle head bolts are in place be-
fore installing the bolts. Some of the washers may be
staked to the cylinder head.
I 12 10 4 2 6 8 141 Tighten cylinder head bolts in correct sequence (1-14)
CA U TIOW-
The bolts should be tightened in three stages as listed below
The final stages require the use of a BMW special tool
11 2
110 or a suitable protractor to tighten the bolts to a specified
torque angle.

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130-59
Fuel Injection
:-- -i. Evaporative emissions
1.
control diagram (M5.2.1)
i 1
i I @ 1. ECM r.=.:-:, 2. Purge valve
3. Leak detection pump (LDP)
4. Liquid vapor separator
5. Purge canister
6. Filter
Bosch M5.2 ECM pin assignments
(M62 up to 911997)
Tabled. Bosch M5.2 ECM pin assignments
I' 1- 1. . . -
4 1 output / Cyl. 4 fuel injection valve I Cyl. 4 fuel injection valve (cycled ground)
Pin
1
2
3
i I
I
7 / output I Cyl. 6 fuel injection valve I Cyl. 6 fuel injection valve (cycled ground)
Type
output
output
output
I I ,
8 1 output I Malfunction indicator light (MIL) (USA only) I lliumlnated for exhaust gas related diagnostic trouble code
5
Component/function
Oxygen sensor heater signal
Idle speed control -closing winding
Cvl. 1 fuel iniection valve Note
DME heated oxygen sensor
1 splice
idle speed control valve (cycled ground)
Cvl. 1 fuel iniection valve lcvcled around)
6 1 ground I Fuel injection valve ground 1 Ground
output
9
Not
used
Not used
11
12
13
Cyl. 5 fuel injection valve
10 1 input I Electronic immobilizer (EWS) / Electronic immobilizer (EWS) control unit
input
Heated oxygen sensor signal Cyl.
5 fuel injection
valve (cycled ground)
output
input
input
16
Start signal Starter relay
NC compressor signal
Terminal
50 signal
Knock sensor signal
17 1 ground I Hot film mass air flow (MAF) sensor ground I Hot film mass air flow (MAF) sensor ground
output Heating and
A/C control module
Ignition switch
Knock sensor
Intake air temperature intake air temperature sensor (voltage value)

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130-72
Fuel Injection
I Oxygen sensors, replacing
4 Four Bosch oxygen sensors (2 precatalytic converter sen-
sors and
2 post-catalytic converter sensors) provide a vary-
ing voltage signal
[0.2 vdc (max. lean) to 0.8 vdc (max. rich)]
to the ME
7.2 ECM representing oxygen content in the ex-
haust gas.
WARNING-
Exhaust manifolds and pipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
- Using a special oxygen sensor socltet, remove the threaded
sensors from the exhaust system.
- If not already applied, coat the new oxygen sensor threads
with an anti-seize compound before installation. Do not get
compound on the sensor tip.
Tightening torque
Oxygen sensor to exhaust system
50 Nm (37 ft-lb)
Fuel injectors, removing and installing
The ME 7.2 system uses ball seat type fuel injectors. This de-
sign
prov:des precise seal'ng when the iniector is closed
therebv eiminalinq raw HC (unb~rned fue ) formalion in tne
intake.-~he fuel inkctors areswitched on and off by the ECM
at the ground side.
- Remove plastic cover from above fuel rail. See100 Engine
Removal and Installation.
- Disconnected battery negative (-) cable.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given at the front of this manual. See 001
General Warnings and Cautions.
- Remove both ignition coil covers.
Disconnect ignition coil connectors.
Remove left and right ignition coil ground wires,
4 Remove fuel injector loom boxes.
Loosen mounting fasteners
(A).
Disconnect electrical plugs (B and D).