light control BMW 528i 2000 E39 Workshop Manual

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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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Maintenance
Service Interval lndicator (Sll)
The BMW Service Interval lndicator (SII) notifies the driver
when oil change and other service is required. The
Sll dis-
plays the phrase "OIL SERVICE"
or"INSPECTI0N" and 7
light emitting diodes (LEDs) in the Instrumentcluster: 5green,
one yellow and one red.
For the
1997 and later 5 Series, BMW introduced an oil
change interval based on fuel consumption. The advantages
of this system are:
Fuel consumption is an accurate method of determining
engine load and the need for service.
The processing electronics are simple.
Resetting of indicator before the scheduled time will not
affect the time to the next service.
4 The Sll is programmed to measure a set volume of con-
sumed fuel. This volume varies between models, dependent
on vehicle and engine size. The
Sil control unit receives a
signal from the engine control module (ECM) when the vehi-
cle is in use. As
20% of the programmed fuel volume is con-
sumed, one of the green LEDs will go out. Each successive
20% of fuel consumption will cause the next LED to go out
until
100% of the measured volume has been consumed. At
this point the yellow LED will come on, indicating that service
is due. When
108% of the measured volume has been con-
sumed, the red LED will illuminate, indicating that service is
overdue.
Service Interval Indicator (SII), resetting
After the specified maintenance has been carried out, the Sll
memory should be reset.
NOTE-
For reference, the BMW oil service requirements are approx-
imately equivalent to the maintenance tliat other European
manufacturers specify at intervals with a maximum of every
15.000 miles or I2 months.

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Maintenance
< Remove NC compressor belt:
Loosen tensioner mounting fasteners (arrows)
Swing tensioner down to remove belt.
4 To reinstall compressor belt:
Route belt over pulleys.
* Pretension belt by turning adjuster clockwise (arrow) to
stop.
- Tighten tensioner mounting bolts (A).
Tightening torques
Fan clutch to coolant pump (left- hand thread)
with BMW tool
11 5 040
30 Nm (22 ft-lb)
without BMW tool 11 5 040
40 Nm (29 ft-lb)
Tensioner to engine block
8.8 grade
22 Nm (16 ft-lb)
10.9 grade (Ilquid-cooled alternator) 30 Nm (22 ft-lb)
Idle speed
Engine idle speed can change due to a number of factors, in-
cluding normal wear. The idle speed is electronically adaptive
and not adjustable. See
130 Fuel Injection for more informa-
tion.
Catalytic converter and oxygen sensors
OBD II enhanced emission standards require the engine
control module (ECM) to monitor the oxygen content in the
exhaust with oxygen sensors placed before and after the cat-
alytic converter. This allows for tighter control of tail pipe
emissions and also allows the ECM to diagnose converter
problems. If the ECM detects that catalytic converter or oxy-
gen sensor efficiency has degraded past a certain
prepro-
grammed limit, it will turn on the malfunction indicator light
(MIL), and store a diagnostic trouble code (DTC) in the ECM.
See OBD On-Board Diagnostics for more information on
OBD
ll systems.
Replacement of oxygen sensors at the specified intervals
he engine and emission control system will

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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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Cylinder Head and Valvetrain
< Remove oil baffle cover from above intake camshaft(s)
- Rotate engine at crankshaft vibration damper center bolt in
normal direction of rotation (clockwise) until camshaft lobe of
lifter to be tested points away from the lifter, allowing valve to
be completely closed.
Use a plastic or wooden stick to press down on top of lifter
with approximately 3.5 Nm
(2.25 ft-ib) of force.
If the lifter collapses slightly as though spring loaded, air
may be trapped in the lifter.
NOTE-
Air trapped in hydraulic lifters may result from oil foaming (air
being drawn
in by the oil pump). This may be caused by a
faulty oil pump control valve O-ring; leaking oil pump pickup
gaslcet; or by oil starvation to pump.
Press down on top of lifter for
10 to 15 seconds uslng approx-
lmately 6 to 9 Nm (4.5 to 6.75 ft-lb) of force.
If anv clearance is created between the lifter and the
cam-
shafi lobe, the check valve in the lifter is not closing. Re-
place lifter.
- To replace a hydraulic lifter, remove appropriate camshaft.
Refer to camshaft removal procedures given in Camshaft
and lifter removal and installation.
Once camshaft is removed, withdraw faulty
lifter(s) and re-
place with new
lifter(s). Inspect lifter bores for wear and scor-
ing at arrows.
- Reinstall camshafts. See Camshaft and lifter removal and
installation.

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11 9-26
/Lubrication System
< Use Allen wrench to adjust chain slaclc (B) by turning thread-
ed spacer
(A).
Oil pump chain adjustment
Slack
10 52 mrn (0.394i0.079 in)
- Coat remaining oil pump mounting fastener with Loctite 03. In-
stall and tighten.
- Remainder of assembly is reverse of disassembly.
- After adding engine oil, start and run engine. Raise engine
speed to
2,500 rpm until oil pressure warning light goes out
(about
5 seconds).
Tightening torques
Lower oil pan to upper oil pan
M6 (8.8 grade) 10
Nm (89 in-ib)
M6 (10.9 grade) 12
Nm (9 ft-lb)
M8 (8.8 grade) 22
Nrn (1 6 ft-lb)
Oil drain plug to oil pan (M12) 25 Nm (I8 ft-lb)
Oil pump cover to oil pump
(M6) 10 Nrn (89 in-lb)
Oilpump sprocket to shaft TKO) 45 Nm (33 it-lb)
Oil pump to engine bloclc
M8 (8.8 grade) 22 Nrn (16 ft-lb)
Oil pressure relief valve (&cylinder)
Remove oil
pump as described earlier. The oil pump pressure
relief valve is held in the side of the
oil pump with a circlip.
< Inspect oil pump relief valve components and bore for scor-
4. Sleeve
5. Circlip
- Install using a new circlip.
Oil
pressure relief valve assembly
,- ..., !~. -.-~. - ~- -~!~~-% h. .- .,, /to-cy~~noer engrnej ing or other damage.
1. Control plunger
2. Spring
3. Sealing O-ring

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120-3
Ignition System
Warnings and cautions
The ignition system produces dangerous high voltage. In ad-
dition the sensitive electronic components can be damaged
if
proper precautions are not adhered to.
WARNING-
* Do not touch or disconnect any cables from the coils while
the engine is running or being
cranked by the starter.
The ignition system produces high voltages that can be
fatal. Avoid contact with exposed terminals. Use ex-
treme caution when working on a car with the ignition
switched on or the engine running.
- Connect and disconnect tlie DME system wiring and
test equipment leads only when the ignition is
OFF:
Before operating the starter without starting the engine
(for example when
making a compression test) always
disable the ignition.
CA
U TIOW-
Do not attempt to disable the ignition by removing the coils
from the spark plugs.
Connect or disconnect ignition system wires, multiple
wire connectors, and ignition test equipment leads only
while the ignition is
off Switch multimeter functions or
measurement ranges only with the test probes discon-
nected.
* Do not disconnect the battery while the engine is run-
ning.
A high impedance digital multimeter should be used for
all voltage and resistance tests. An LED test light
should be used in place of an incandescent-type test
lamp.
In general, make test connections only as specified by
BMW as described in this manual, or as described by
the instrument manufacturer.
Engine management
BMW €39 engines use an advanced engine management
system known as Digital Motor Electronics (DME). DME in-
corporates on-board diagnostics, fuel injection, ignition and
other engine control functions. DME variants are listed in
Table a. Engine management systems.
Second generation On-Board Diagnostics
(OED II) is incor-
porated into the engine management systems used on the
cars covered by this manual. Use a BMW-specific electronic
scan tool, or a "Generic"
OED II scan tool to access Diagnos-
tic Trouble Codes (DTCs). DTCs can help pinpoint ignition
ine management problems.

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120-1 2
ignition System
Crankshaftspeedsensor
Crankshaft speed sensor, replacing (M52, M52 TU and
M54 engines)
4 Crankshaft speed sensor for 6-cylinder engine is mounted in
the left rear side of the cylinder block below the starter (ar-
row). The sensor reads a toothed pulse wheel mounted to
the end of the crankshaft.
- if the Engine Control Module (ECM) does not receive a signal
from the crankshaft speed sensor during cranking, the en-
gine will not start.
- If the OBD II svstem misfire detection ~rotocol detects a cat- - - ~~
alysr oarnagin; faLlt oJe to a ma I-nclion in crandshafi speeo
sensor components. Ine Check Engine
lignr (Malfuncrion In-
dicator Light or MIL) will be illuminated.
NOTE-
If the crankshaft speed sensor pulse wheel is damaged, the
engine will have to be disassembled down to the crankshaft
to
reolace the wheel.
- Make certain ignition has been turned off.
- Raise car and support in a safe manner.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjacltstands designed for
the ouroose.
A floor iaclc is not adequate support.
- Remove under engine splash guard
4 Working underneath starter:
Cut off wire tie securing crankshaft speed sensor harness
connector (arrow) to sensor.
* Disconnect harness connector.
4 Remove sensor mounting fastener (arrow) and remove sen-
sor from cylinder block.
- Installation is reverse of removal, noting the following:
Use a new O-ring when installing sensor.
Be sure wiring is routed in same orientation.
Secure sensor using new wire ties.
Use scan tool to read out and clear ECM fault memory.

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ignition System
Crankshaft speed sensor, replacing (M62 and M62TU
engines)
The crankshaft speed sensor reads a toothed pulse wheel
mounted on the flywheel.
If the Engine Control Module(ECM)
does not receive an impulse signal from the crankshaft speed
sensor during
cranking, the engine will not start. If the OBD II
system misfire detection protocol detects a catalyst damag-
ing fault due to a malfunction in the crankshaft speed sensor
components, the Check Engine light (Malfunction
Indicator
Light or MIL) will be Illuminated.
4 The crankshaft speed sensor (arrow) is mounted in the right
lower side of the bell housing.
- Remove speed sensor by disconnecting electrical harness
connector and unbolting sensor from bell housing. Do not
discard shims, if present.
- Installation is the reverse of removal. Clean mounting surface
before installing new sensor, and install shims, if present.
< If the flywheel was replaced, the speed sensor must be
checked for correct installation depth.
* Crank engine in direction of rotation using crankshaft bolt
until a full pulse tooth is centered in the opening for the re-
moved speed sensor.
Measure depth ro top of tooth from speed sensor p~lse
generator mounting s~rface on transmission.
4 Measure length of pulse generator from mounting surface to
end (A).
- Subtract length of pulse generator (A) from distance to pulse
tooth from mounting area on transmission. This measure-
ment is the gap between the pulse sensor and flywheel. Use
shims available from BMW to increase gap as needed to
reach specification.
Pulse sensor
gap
End of sensor to flywheel teeth 0.55 + 0.2 rnrn
(0.0217 t 0.008 in)

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Battery, Starter, ~lternatorl
@ TO fuse & relay panel Battery Safety Terminal
A Battery Safety Terminal (BST) controlled by the Multiple
Restraint System (MRS) control unit was introduced for mod-
el year 1998
vehicles. The system will disconnect electrical
power to the engine compartment
in the event of a significant
impact. The MRS system fires an encapsulated pyrotechnic
device
in the positive (+) battery terminal that disconnects
power to the engine compartment, but maintains power to
the exterior lights and interior of the vehicle.
point
002125~1
Table a. Battery, alternator and starter troubleshooting
1-
/Starter motor or solenoid faulty. l~est starter.
Symptom
Engine does not crank
Engine cranks slowly or
not at all, solenoid
clicits
when starter is operated.
I I
Battery will not stay IShort circuit draining battery. l~est for excessive current drain with everything
Probable cause
Fault
in immobilizer system (EWS)
-Clean Battery cables loose, dirty or corroded.
Battery discharged.
Battery to body ground cable in trunk
loose,
dirty or corroded
Poor connection at starter motor terminal
30.
Corrective action
Try another ignition key. If problem persists, contact
your authorized BMW dealer.
or replace cables. See 020
~aintenance.
Charge battery and test. Replace if necessary.
inspect ground cable. Clean, tighten or replace if
necessary.
Checlc connections, test for voltage at starter. Test for
voltage at neutral safety or clutch
interloclc switch.
charged more than a few
days.
I~atter~ faulty. /Test battery and replace if necessary.
Short driving trips and high electrical drain
on
charging system does not allow battery to
recharge.
. I
I Battery cables loose, dirty or corroded. Iclean or replace cables. See 020 Maintenance.
Evaluate driving
style. Where possible, reduce
electrical
consumption when malting short trips.
Drive
belt@) loose, worn or damaged.
IAlternator or voltage regulator faulty. /Test alternator and voltage regulator.
Inspect
or replace ribbed
belt@). See 020
Maintenance.