Motores E39 BMW
Motores E39 BMW
Motores E39 BMW
NOTE-
VANOS is an acronym based on the German words Variable
Nocltenwellen Steuerung (variable camshaft timing).
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:
System voltage
Digital motor electronics (DME) requires that the system (bat-
tery) voltage be maintained within a narrow range of DC volt-
age. DC voltage levels beyond or below the operating range,
or any AIC voltage in the electrical system can cause havoc.
When troubleshooting an illuminated MIL, make sure the bat-
tery is fully charged and capable of delivering all its power to
the electrical system. An undercharged battery can amplify
AIC alternator output ripple.
NOTE-
For instructions on conducting a voltage drop test and other
general electrical troubleshooting information, see 600 Elec-
trical System-General.
Main grounds
Good grounds are critical to proper DME operation. If a
ground connection has no visible faults but is still suspect.
measure the voltage drop across the connection. A large volt-
age drop means high resistance. Clean or repair the connec-
tion and retest.
LBuntr.yP~sbhnllcn.can#-AIIA , ~ i l t Rcsrwsd
l
100-6
( Engine-General
The main grounds for the fuel and ignition circuits of the DME
system are illustrated below; see 610 Electrical Component
Locations for additional ground and component locations.
NOTE-
Ground location for sedan shown, wagon models may
differ.
110 Engine Removal and installation
020 Maintenance
0 121 Battery, Alternator, Starter
170 Radiator and Cooling System
180 Exhaust System
4 230 Manual Transmission
0 240 Automatic Transmission
410 Fenders, Engine Hood
Special tools
Some special tools are required for engine removal and in-
stallation. Be sure to have the necessary equipment on hand
before starting the job.
CAUTION-
Disconnecting the battery may erase fault code@)storedin
memoiy Check for fault codes prior to disconnecting the
battery cables.
If the MIL (Malfunction Indicator Light, also may be
called "Check Engine" or "Service Engine Soon" light)
is illuminated, see OBD On-Board Diagnostics for
DME fault code information.
It orhersysrem faults have been detected, as indicated I
by an ~llum~nated ABS, SRS orASC/DSC ~ a r n i n g light,
see the appropriate repair group in this manual or an
authorized BMW dealer for more information on fault
codes.
NOTE-
Engine removal procedures are similar for all 6-cylinder
models. When differences exist, they are noted at the be-
ginning of each step. Engine are referred to by engine
code. See 100 Engine-General for engine code and appli-
cation information.
@Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse gaskets, O-rings or seals during reassembly.
The intake manifold must be removed on &cylinder mod-
els before the engine can be removed.
WARNING-
Due to risk of personal injury, be sure the engine is cold be-
fore beginning the removal procedure.
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 a n d Warnings.
CAUTION-
Be sure to mark oxygen sensor harness connectors so that
they can be reassembled correctly Do not interchangecon-
nectors.
WARNING -
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) andmay be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Alwavs unscrew the Fuel tank cao to release oressure
I in the tank before working on the tank or lines. I
- Raise car and support in a safe manner.
WARNING-
Male sure the car is stable and we/ supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor jack is not adequate support
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.
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.
110-8
1 Engine Removal and Installation
NOTE-
* M52 TU engine shown. M54 engine is similar.
M52 engine: Fuel rail is removed with intalte manifold.
.-
NOTE-
M52 TU engine shown. M52 and M54 engines are similar.
CAUTION-
Stuff clean rags into open intake ports to prevent any parts
from falling into the engine intake.
NOTE-
Drain plug for M52 TU and M54 engine shown. Plug for M52
located between cylinders 4 and 5.
WARNING-
Use extreme caution when draining and disposing of engine
coolant Coolant is poisonous andlethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediatelyif coolant is ingest-
ed.
NOTE-
Catch and dispose of drained coolant according to local,
state, and federal laws.
110-12
Engine Removal and Installation
NOTE-
Two different types of hose fasteners are used on the E39
car; lock clamp type as shown above or standard band
clamps.
CAUTION-
32 mm radiator fan mountingnut has left hand threads.
NOJE-
Detach automatic transmission cooler lines from radiator, re-
move brackets holding lines to side of engine, andstore lines
in a clean environment.
CAU T I O W
Be sure to mark oxygen sensor connectors so that they can
be assembled correctly Do not interchange connectors.
- Carefully raise engine out of car, checking for any wiring, fuel
lines, or mechanical parts that might become snagged as en-
gine is removed. -
. ..
.-
-
-
-
110-15
Engine Removal and lnstallation
CAUTION--
When reattaching throttle assembly harness connectoc con-
nector is fuNy tightened when arrows on connector and plug
line up.
Tightening torques
Coolant drain plug to cylinder block 25 Nm (18 ft-lb)
Engine mount to subframe (M10) 45 Nm (33 ft-ib)
Exhaust manifold to cylinder head
M6 10 Nm (89 in-lb)
M7 or ME 20 Nm (15 ft-lb)
Intake manifold to cylinder head
M7 15 Nm ( I 1 ft-lb)
ME 22 Nm (16 ft-lb)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb)
Radiator drain screw to radiator 2.5 Nm (22 in-lb)
110-16
Engine Removal and Installation
ENGINE,REMOVALAND
INSTALLATION
(V-8 MODELS)
NOTE-
Engine removal procedures are similar for all V-8 models.
When differences exist, they are noted at the beginning of
each step. Engine are referred to by engine code. If neces-
sary, See 100 Engine-General for engine code andappli-
cation information.
Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse gaskets, O-rings or seals during reassembly
WARNING-
Due to risk ofpersonal injury, be sure the engine is cold be-
fore beginning the removal procedure.
Tightening torques
Coolant drain plug to cylinder block (M14) 25 Nm (18 ft-ib)
Radiator drain screw to radiator 2.5 Nm (22 in-lb)
I Engine Removal and Installation
--- WARNING -
Use extreme caution when draining and disposing of engine
coolant. Coolant is poisonous andlethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingest-
-
-
Remove oil filter housing assembly from fender:
Remove oil filter housing mounting fasteners.
Use stiff wire to secure oil filter housing to engine.
NOTE-
Do not disconnect oil lines from filter housing.
NOTE-
BMW uses three styles of fuel line connections; a slngle use
clamp, a locking fitting that uses special tool 16 7 050 to re-
lease, and a quiclc release sleeve (arrows) that disconnects
the line when depressed.
WARNING-
Fuel In fuel line is under pressure (approx. 3 - 5 bar or45 -
75 psi) and may be expelled. Do not smoke or worlc near
heaters or other fire hazards. Keep a fire extinguisher
handy. Before disconnecting fuel hoses, wrap a cloth
around fuel hoses to absorb any lealcing fuel. Catch and
dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before worlcing on the tank or lines.
< Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor ( A )and intalte air temper-
ature sensor ( 6 )electrical harness connectors.
. Remove air filter housing mounting fastener (arrow).
Loosen intake hose clamp (C).
M62 engine: Remove hose at idle air stabilizer.
Remove air filter housing with mass air flow sensor.
Remove intalte hose from throttle body.
110-19
Engine Removal and Installation
CAUTION-
Male sure the car is stable and well supported at aN times.
Use a professionalautomotivelifi orjackstands designed for
I the ouroose. A floor jack is not adequate support.
-
Working beneath car:
Remove engine splash shield.
Remove right and left heat shield from front suspension
subframe.
CAUTION-
Do not interchange knoclc sensor harness connectors. Seri-
ous engine damage may result
Engine Removal and Installation
Tightening torques
ATF cooler lines to radiator
(use new O-rings)
M I 8 cap nut 20 Nm (15 ft-lb)
M22 cap nut 22 Nm (17 ft-lb
Coolant drain plug to cylinder blocic (M14) 25 Nm (18 ft-lb)
Engine mount to engine bracket or 47 Nm (35 ft-lb)
subframe (M10)
Exhaust flange nuts (8mm) 25 Nm (18 ff-ib)
Radiator cooling fan to coolant pump 40 Nm (30 ft-lb)
(left-hand threads)
Radiator drain screw to radiator 2.5 Nm (22 in-lb)
Wirino to alternator (ME nut) 13 Nm (9.5 ft-lb)
113-1
020 Maintenance
116 Cylinder Head and Valvetrain
117 Camshaft Timing Chain
170 Radiator and Cooling System
610 Component locations
NOTE-
I f 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.
113-3
Cylinder Head Removal and Installation
>
NOTE-
Performing a compression test may cause a fault to set in the
ECM and may illuminate the Malfunction Indicator Light
(MIL). The light can only be turned out using either BMW
special service scan tools or an equivalent aftermarket scan
tool. Disconnecting the battery will not erase the fault memo-
ry or turn out the light. See OBD On-Board Diagnostics.
113-6
Cylinder Head Removal and Installation
.
WARNING-
The ignition system produces high voltages that can be fa-
tal. Avoid contact with exposed terminals and use exfreme
caution when working on a car with the ignition switched on
or the engine running.
Do not touch or disconnect ignition components while
the engine is running or being cranked by the starter.
,.,. , I -
.*,.,,&- Remove coil grounding straps.
I CAUTION-
I nition system components. I
- Remove coils.
NOTE-
Check the spark plugs for oil deposits that may indicate poor
cylinder sealing, then set them aside in order. Used spark
plugs should be reinstalled in the same cylinder from which
they were removed.
NOTE-
* The compression gauge reading should increase with
each compression stroke and reach near its maximum
reading in about 4-6 strokes.
All cylinders should reach maximum compression in the
same number of strolces. If a cylinder needs significantly
more strokes to reach maximum compression, there is a
problem.
-- . .- .
L r -- - - - --
Cylinder Head Removal and Installation
-
I
- Release pressure at compression gauge valve, then remove
gauge from spark plug hole. Repeat test for each cylinder
and compare results with values given in Table a.
NOTE-
Used spark plugs should be reinstalled in the same cylinder
from which they were removed.
Tightening torque
Spark plug to cylinder head 25 Nm (18 ft-lb)
lanition coils to cylinder head 10 Nm (7.5 ft-lb)
~ Y L ~ N D EHEAD
R REMOVALAND
~NSTALLATION(M52 ENGINE)
WARNING-
Due to rislc of personal fnjur~:be sure the engine is cold be-
fore beginning the removal procedure.
CAUTION-
Prior to disconnecting the battea read the battery discon- -
nection cautions in 001 General Cautions and Warnings.
113-9
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.
CAUTION-
Be sure to mark oxygen sensor harness connectors so that
they can be reassembled correctly Do not interchange con-
nectors.
.
WARNING-
Fuel in fuel line is underpressure (approx. 3 - 5 bar or 45 -
75 psi) and may be expelled. 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. Catch and
NOTE-
BMW uses three styles of fuel line connections; a one-time
use clamp; a locking fitting that uses BMWspecial tool 16 1
050 to release; and a quick release sleeve (above) that dis-
connects the line when depressed.
..
Cylinder Head Removal and Installation 1
< Remove intake throttle valve and ASC throttle assemblies:
NOTE-
It i s not necessary to disconnect coolant hoses (C) 01
bowden cables (D).
NOTE-
Fuel rail is removed with intake manifold,
CAUTIOI\C
Stuff clean rags into open intake ports to prevent any parts
from falling into Nie engine intake.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
l e t s should be reinstalled in their original locations. Make
note of their arrangement during removal.
,I
- -
-
.
Cylinder Head Removal and lnstallatio~
rCAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
eninq or tiqhteninq sprocl(et mounting fasteners.
NOTE-
Some tensioners may have a single hole for special tool.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
WARNING -
Remove tensioner slowly -it is under springpressure. I
- Working at the intake side of cylinder 1:
Detach electrical harness connector for camshaft position
sensor and remove sensor.
Detach electrical harness connector for coolant tempera-
ture sensor.
CAUTION-
Hold the camshaft stationary (at hex on camshaft) when loos-
ening or tightening sprocket mounting fasteners.
NOTE-
Where applicable, make note of thrust washerpositions. The
thicker (0.4 mm) washer is mounted outermost.
CAUTION-
The camshafts must be locledin the TDCposition using the
special service tool as described earlier: The arrows on the
sprockets should not be used to accurately set the engine to
TDC. The tool holds the camshafts parallel to each other and
NOTE-
Do not remove the sprocl<ets from the chain unless these
parts are being replaced. Wire tie each sprocket to the chain
to Iceep the sproclefs timed to each other:
CAUTIOI\C
The crankshaft must not be allowed to rotate once the cam-
shaft timing chain is removed. The pistons can contact the
valves.
NOTE-
Photo shows timing chain guide in place; it should first be re-
moved as described previously.
- Separate the cylinder head from the block and remove head.
Evaluate head as described in 116 Cylinder Head and Val-
vetrain.
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.
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.
I Cylinder Head Removal and Installation
4 Check that two locating dowels are correctly positioned in
block and are not damaged.
NOTE-
The word "OBEN" or 'TOP': printed on the gasket, should
face up. The cylinder head gasket will fit correctly in only one
orientation.
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.
.
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).
Tightening torques
Cylinder head to cast iron bloclc
Staoe 1
staie 2
Stage 3
Cyllnder head to aiumlnum block
Stage 1 40 Nm (30 it-lb)
Stage 2 +90°
Staoe 3 -80"
Tightening torques
cylinderhead to lower timing chain cover 10 Nm (89 in-lb)
NOTE-
Inspect timing chain sprocl(ets. Sprockets that have worn
or missing teeth should be replaced.
* If any of the sprockets are being replaced due to wear, the
chain should also be replaced.
If the crankshaft sproclet requir?s replacement, the oil
pump drive sprocket and chain must be removed as de-
scribed under 119 Lubrication System.
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the hydraulic
tensioner.
CAU T I O G
Hold the camshaft stationary (at hex on camshaft) when loos-
I
2 h m thrust washer
I enino or tiahtenino sorocket mounting bolts and studs.
Tightening torque
Intake s~rocketnuts to studs 10 + l Nm (89 +9 in-lb)
CAUTION-
The camshafts andcranlshaft must be lockedin the TDCpo-
sition using BMW special tools 11 2 300 and 11 3 240. If the
camshafts and cranl(shaft are not at TDC, the valves can
contact the pistons.
- -.
NOTE-
B e Sure the secondary timing chain tensioner is locked down
and the exhaust camshaif mounting bolts are loose before
proceeding.
CAUTION--
Incorrect installation ofthe VANOS controlmay result in dam-
age to the engine valvefrain.
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 (30ft-lb)
Radiator drain screw to radiator 2.5 Nm (22 in-lbl
113-22
Cylinder Head Removal and Installation
CYLINDERH E A D REMOVALAND
~NSTALLATION(M52 TU AND N154
ENGINES)
WARNING -
Due to risk ofpersonal injur)c be sure the engine is cold be-
fore beqinning the removalprocedure.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions in 001 General Cautions a n d Warnings.
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.
. .- -
WARNING-
Fuel is underpressure (approx. 3 - 5 bar or 45 - 75psi) and
may be expelled. Do not smoke or work near heaters or
other fire hazards. Keep a fire extinguisher handy Before
d~sconnectingfuel hoses, wrap a cloth around fuel hoses
to absorb any leaking fuel. Catch and dfspose of escaped
fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
I in the tank before working on the tank or lines.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professionalautomotive lift orjack stands designed for
the purpose. A floorjack is not adequate support.
NOTE-
M54 engines use a single fuel line to the non-return fuel rail.
CAUTION--
Fuel may be expelled underpressure. Do not smoke or worlc
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 open fuel lines.
NOJE-
BMW uses various styles of line connections; a one-time
band clamp; a self-locl(ing connector (that use BMWspecial
tool 16 1 050 to release); and a quick release connector
(above).
<
-
Remove fuel rail mounting bolts (arrows):
Carefully pry fuel rail off manifold.
Separate fuel line support bracket at rear of intake mani-
fold.
Guide fuel line(s) out of rear of engine compartment while
lifting fuel rail out.
NOTE-
Catch and dispose of drained coolant according to local,
state, and federal laws.
rCAUTIOI\C
32 mm radiator fan mounting nut has left hand threads.
CAUTIOI\C
Note location of all ground wires. Failure to reinstallgrounds
can result in permanentdamage to engine controlmodule or
ignition system components.
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.
4 Remove banjo bolt from VANOS unit oil pressure line. Use
banjo bolt to attach BMW special tool 11 3 450 (compressed
air fitting) to VANOS control unit.
CAUTIOI\C
Oil will drain from pressure line. Have a drain container and
rags ready Do not allow oil to run onto drive belts.
4 Cover oil hole (arrow) in VANOS unit with shop towel to cap-
ture oil which will spray when compressed air is applied.
CAUTION--
Do not rotate engine counterclocltwise to reach the top dead
center position. If engine rotated beyond top dead center;
complete another two complete rotations.
11 3-31
Cylinder Head Removal and Installation
Remove sealing plug from special tool bore on lower left side
of engine block near flywheel. Secure crankshaft in TDC po-
sition with BMW special tool l l 2 300 (arrow).
Pull sealing caps straight out of VANOS unit using short nee-
dle nose pliers.
NOTE-
Additional oil may drain from VANOS unit.
CAUTION-
Set screws have left-hand threads. Loosen in clocltwise di-
rection.
--
-- .-
Cylinder ~ e a- d-.
~ e r n o vand
a l Installation I
Remove VANOS unit:
CAUTION-
Do not crank the engine with VANOS unit removed. Pis-
tonhalve inteiference may result.
NOTE-
The VANOS unit will contain a small quantity of oil. Place
shop towel to catch oil as unit is removed or tilted.
CAUTION-
If the VANOS adjustment unit is replaced, or if operations are
completed that may change the timing of the camshafts, the
camshaft timing must be checked. See 117Camshaft Timing
Chain.
- cylinder
-
Head Removal and Installation]
< Lift off exhaust and intake sprocltets together with secondary
chain, thrust spacer (A), and splined shafl (B).
CAUTION-
Splined shafts share the same part number for both intake
and exhaust camshafts. Used splined shafts must be rein-
stalled in their original positions.
Lift primary chain and hold under tension, then rotate engine
at vibration damper in opposite direction of normal rotation
(counterclocltwise) approximately 30".
CAUTION-
By turning crankshait3O0,pistons are movedaway from top
dead center, to prevent possible valve interferenceto pistons
during camshaft servicing.
4 Fit BMW special tools 11 3 260 (A) and 11 3 270 (B) to cyl-
inder head and screw long bolts (arrows) into spark plug
threads. Tensioning pins on tool will align with the bearing
caps on the intake camshaft.
CAUJION-
Do not over torque bolts into sparkplug holes.
113-38
I Cylinder Head Removal and Installation
< Turn eccentric shaft of special tool to pretension intake cam-
shaft bearing caps. Remove nuts on all intake camshaft bear-
ing caps.
Use care to not let hydraulic lifters fall out as camshaft car-
rier is removed.
Hydraulic lifters should be stored ln an uprightpositlon.
Used hydraulic lifters must be reinstalled into their orig-
inal lifter bores.
NOJE-
BMW special tool 11 2 250 is a thin-walled Torx E l 2 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.
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.
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.
113-40
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.
NOTE-
The word "OBEN" or " T O P printed on the gasket, should
face up. The cylinder headgaslet will fit correctly in only one
orientation.
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.
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.
Tightening torques
Cylinder head to engine block
(aluminum block)
Stage 1 40 Nm (30 it-lb)
Stage 2 +90°
Stage 3 80'
Tightening torque
Secondary chain guide to cylinder head 10 Nm (89 in-lb)
Cylinder head to lower timing chain cover
M6 10 Nm (89 in-lb)
M7 15 Nm (1 1 it-lb)
1 13-42
I Cylinder Head Removal and Installation
Note marks on carriers: (E) for intake side and (A) for exhaust
side.
Lift timing chain and put exhaust cam onto exhaust camshaft
carrier. Place intake camshaft on camshaft carrier.
.-
Cylinder Head Removal and Installation
CAUTION-
Be sure that cranlcshaft is stillpositioned at least 30" away
from TDC.
CAUTIOI\C
Do not overtighten bolts in spark plug holes.
Tightening torque
Camshaft bearing cap to cylinder head (M7) 14 Nm (10 ft-lb)
CAUTION-
After the camshafts are installed, a minimum waiting time is
required for the hydraulic lifters to 'bleed down" before bring-
ing the crankshaft andpiston back to top deadcenter. When
the camshafts are removed, the hydraulic lifters can expand.
This expansion can cause increased valve lift when the cam-
shafts are bolted down, possibly resulting in piston interfer-
ence.
Tightening torque
Impulse wheel studs to intake camshaft) 20 Nm (15 ft-lb)
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the tensioner.
Tightening torques
Exhaust camshaft locating stud 20 Nm (15 ft-lb)
I Cvlinder Head Removal and Installation
4 Install secondary chain tensioner on cylinder head (arrows).
Keep tensioner compressed using BMW special tool 11 3
291 or suitable pin.
CAUTIOI\C
Do not alter position of sprockets with respect to chain when
removing from special tool 11 6 180.
NOTE-
I f Fmark is no longer visible, install spring plate as shown in
inset.
Tightening torque
Primary chain tensioner preload 0.7 Nrn (6 in-lb)
CAUTION-
Make sure all gasket material is removed from face of cylin-
der head. Clean sealing face and keep free of oil. If any for-
eign material is present on the sealing sudace, the camshait
timina will be incorrect.
. .- --
Cylinder Head Removal and Installation
Tightening torques
sprocket assembly to camshaft
initial torque 5 Nm (44 in-lb)
-
CAUTION-
If the exhaust side of the tool (A) is not flush with tlie head,
camshaft timing is incorrect Reset camshaft timing as de-
scribed in 117 Camshaft Timing Chain.
* Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft tim-
ing is set correctly, the intake side of special tool 11 3
240 (6)may be up to 1 mm (0.04 in.) above the surface
of the cylinder head. This is normal. Reassemble en-
gine. Othe~lise,reset camshaft timing as described in
117 Camshaft Timing Chain.
CAUTION-
Check locating dowel (A) and dowel sleeve (B) at top of
cylinder head for damage or incorrect installation.
Make sure all gasket material is removed from face of
cylinder head. Clean sealing face and keep free of oil.
I f any foreign material is present on the sealing surface,
the camshaft timing will be incorrect.
NOTE -
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in 117 Camshaft Tim-
ing Chain.
Tightening torque
VANOS unit to cylinder head
M6 nut l o Nm (89 in-lb)
M7 nut 14 Nrn (10 it-lb)
CAUJION-
Set screws have left hand tliread. Tighten counterclockwise.
Tightening torque
Hydraulic piston to splined shaft 10 Nm (89 in-lb)
< Replace sealing caps inside VANOS unit with short needle
nose pliers.
. ." " .
[CylinderHead Removal and Installation - .. ---1
4 Insert and secure VANOS sealing plugs (arrows) with new
sealing O-rings.
Tightening torque
Sealing plug to VANOS 50 Nm (37 ft-lb)
NOTE-
Use new sealing O-ring on coolant pipe.
- lnstall VANOS oil line banjo bolt with new seals. Attach oil
line to VANOS unit.
Tightening torque
Oil line to VANOS unit
(banjo bolt) 32 Nm (24 ft-ib)
Tightening torque
Primary chain tensioner cylinder to
cylinder head 70 Nm (52 fi-ib)
Tightening torque
Cylinder head cover to cylinder head (M6) 10 Nm (89 in-lb)
Cylinder Head Removal and Installation
Tightening torque
Exhaust maniiold to cylinder head (M7) 20 Nm (15 ft-lb)
CA UTIOPI-
When reattaching throttle assembly harness connector, con-
nector is fully tightened when arrows on connector andplug
line up.
Tightening torque
lntalte manifold to cylinder
head (M7) 15 Nm (11 it-lb)
~ ~-
-
ing the following:
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.
a Reconnect battery.
CAUTION-
To prevent damaging the engine electronic systems, installall
ground wire previously removed, including the ground wires
for the ionition coils.
Tightening torque
Coolant drain pluq to cylinder bloclc 25 Nm (18 ft-lb)
Radiator cooling
- fan to coolant pump 40 Nm (30 ft-lb)
CYLINDERMEAD REMOVALAND
INSTALLATION
(M62 ENGINE)
This procedure covers cylinder head removal and installation
for the M62 V-8 engine. Procedures forthe M62 TU VANOS
engine are not covered in this manual.
Intake manifold, left cylinder head, and right cylinder head re-
moval and installation are written as separate procedures.
The intake manifold must be removed before the cylinder
heads can be removed.
WARNING -
Due to risk of personal injuv be sure the engine is cold be-
fore beginning the removal procedure.
CAUTION-
Prior to disconnecting the batterj read the baitery discon-
nection cautions in 001 General Cautions a n d Warnings.
Cylinder Head Removal and Installation /
4 Remove top engine cover by releasing quick release fasten-
ers (arrows) by pressing down.
NOTE-
Earlier models may have an engine cover with pry off caps
and fasteners In place of quick release fasteners.
Pry out ignition coil cover trim caps, remove fasteners and
covers from lefl and right sides.
< Disconnect throttle cables from throttle shafl (A) and remove
cables from support bracket (B).
< Disconnect cable from jump start post (arrow) on left cylinder
head cover.
- .-
.
.
Cylinder Head Removal
-
and Installation I
< Disconnect the following electrical harness connectors:
Knock sensors (A).
Thermostat (6).
Throttle position sensor and idle valve (C).
Camshaft position sensor (D).
Ignition coils (E).
Label and disconnect fuel lines from fuel rail by pressing lock-
ing sleeves (arrows) in to release lines.
NOTE-
BMW uses three styles of fuel line connections; a single use
clamp; a locking fitting that uses special tool 16 1 050 to re-
lease; and a quick release sleeve (arrow) that disconnects
the line when depressed.
CAUTION-
Fuel may be expelled under pressure. Do not smoke or
work near heaters or other fire hazards. Keep a fire exfin-
guisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb leaking fuel. Plug all
I ooen fuel lines. I
Always unscrew fuel tank cap to release pressure in
tank before removinq fuel lines.
Carefully lift intake manifold off engine while checking that all
hoses and harnesses have been disconnected.
WARNING -
Use extreme caution when draining and disposfng of eng~ne
coolant. Coolant is poisonous and lethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek med~cal attention immediately if coolant is ingest-
ed.
NOTE-
Engine shown removed from engine bay
[Cylinder ~ e a Removal
d and Installation
NOJE -
Number one cylinder is at valve overlap when both the intake
and exhaust valves are starting to open (camshaft lobes fac-
ing down).
< Remove upper timing chain cover fasteners (A) and cover
from left cylinder head.
NOTE-
Allen screw secures crankcase vent tube in cylinder head.
CAUTIOI\C
When removing the cylinder head carefully press oil separa-
tor outwards.
Lift cylinder head off engine block while pressing out on oil
separator.
CAUTIOI\C
Be careful not to damage oil separator while removing cylin-
der head.
..- --
I Cylinder Head Removal and Installation
- Evaluate cylinder head as described in 116 Cylinder head
and valvetrain.
CAUJION-
Male sure the crankshaft, which had been rotated approxi-
mately 45" opposite the direction of engine rotation from
TDC, is still in thatposition before installing the cylinder head.
All pistons must be out of TDCposition to prevent valvelpis-
ton contact.
Tightening torques
Stage I 30 Nrn (22 ft-lb)
Stage II +80°
Stage Ill +80°
NOTE-
Photo shows lower timing case cover removed.
< Remove old O-ring and install new O-ring (arrow) in angle
section.
- Press oil separator into angle section and install guide rail re-
taining screws.
NOTE-
Allen screw secures crankcase vent tube in place. Do not
torque down.
113-68
Cylinder Head Removal and Installation
I I < Install camshaft locltina tool set (BMW soecial tool set 11 2
440) on right cylinder head (cylinders 1-4). Fit on cylinde~
head without gaps.
?-I I 4 Install BMW special tool 11 3 390 into right timing case cover.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
Tightening torques
Sprocltet bolts to camshait flange 15 Nm (11 ft-lb)
Tightening torques
Sprocket bolts to camshaft flange 15 Nm (11 ft-lb)
11 3-70
Cylinder Head Removal and Installation
Tightening torque
Chain tensioner cylinder to timing cover 65 Nm (48 ft-lb)
Tightening torque
Oil supply line nuts 10 Nm (7.5 ft-lb)
- Remove old gasket from lefl timing cover, and clean gasket
surface.
Using a new gasket, install lefl timing cover with lower inner
fastener inserted in cover (arrow). Position cover in place
and tighten cover fasteners finger tight.
NOTE-
It is not possible to install lower inner fastener after cover is
in place.
. ." . .
I - -
Cylinder Head Removal and i n --
stard
4 Remove left cylinder head cover gasket and install spacing
tool (BMW 11 1 412) in place of gasket.
Tightening torque
Cylinder head cover nuts 10 Nrn (7.5 it-lb)
Tightening torque
Timing chain cover to head 10 Nrn (7.5 ft-lb)
CAU T I O G
To prevent damaging engine electricalsystems, be sure to in-
stall all ground wires previously removed.
Tightening torques
Camshaft sprocket to camshaft 15 Nm (11 H-lb)
Coolant manifold to cylinder head 10 Nm (7.5 H-lb)
Cylinder head cover nuts 10 Nm (7.5 ft-lb)
Exhaust manifold to head 22 Nm (17 ft-lb)
Engine mounts to subirame 42 Nm (30 ft-lb)
Spark plugs to cylinder head 22 Nm (17 ft-lb)
WARNING-
Use extreme caution when draining and disposing of engine
<
coolant. Coolanl is poisonous andlellial lo liumans andpels.
Pets are altracled to coolant because of 11ssfieet smell and
fasle. Seelc medcal anenfion immed~alelyif coolant is ingesl-
. .-
1
i
Remove sparlc plugs.
CAUTIOW-
To prevent valve to piston contact when tightening camshaft
sprocket fasteners, counterhold camshaft with 27 mm open-
end wrench. If necessarq: grind outer side of wrenchjaws to
prevent damaging cylinder head.
CAUTION-
Male sure the crankshaft, which had been rotated approxi-
mately 45" opposite the direction of engine rotation from
TDC, is stillin thatposition before installing the cylinder head.
All pistons must be out of TDCposition to prevent valve/pis-
ton contact
-
Tiahtenina
- toraues
.
Stage I 30 Nm (22ft-lb)
Stage I1
Stage Ill
NOTE-
Special tool boss located at the rear of upper engine oil pan.
!
I
NOTE-
I f necessary, remove sprocl<etand realign position.
NOTE-
BMW special tool 00 9 250 is a flexible shaft torque wrench.
Tightening torque
Sprocitet bolts to camshaft flange 15 Nm (11 ft-lb)
Tightening torque
Sprocket bolts to camshaft flange 15 Nm (11 ft-ib)
4 Install oil supply lines and mounting nuts on both heads (ar-
rows).
Tightening torque
Cylinder head cover fasteners 10 Nm (7.5 ft-lb)
Tightening torque
Chain tensioner to timing cover 65 Nm (48 ft-lb)
Tightening torque
Cvlinder head cover fasteners 10 Nm (7.5It-lb)
CA UTIOW-
To prevent damaging engine electricalsystems, be sure to in-
stall all ground wires previously removed.
Tightening tOrqUeS
Camshaft sprocket to camshaft 15 Nm (1 1 ft-lb)
Coolant manifold to cylinder head lo Nm (7.5It-lb)
Cylinder head cover nuts 10 Nm (7.5ft-lb)
Exhaust manifold to head 22 Nm (17ft-lb)
NOTE-
For timing chain and VANOS repair information, see 117
Camshaft Timing Chain.
If it is determined that the cylinder head will require signif-
icant reconditioning work, a remanufactured cylinder head
may be a good alternative. Remanufactured cylinder
heads are available from an authorized BMW dealer.
* 020 Maintenance
100 Engine-General
113 Cylinder Head Removal and Installation
117 Camshafi Timing Chain
= 170 Radiator and Coo!ing System
Special Tools
Special BMW tools are required for most cylinder head ser-
vice described in this repair group. Many of these tools are ex-
pensive and only available through an authorized BMW
dealer. If the special tools are not available, have the cylinder
head removed and disassembled by an authorized BMW
dealer. Be sure to read each procedure thoroughly before
starting a job to determine which special tools and equipment
will be necessary.
CYLINDERHEAD
This section provides the specifications and special recondi-
tioning information necessary to repair the cylinder heads
covered by this manual.
NOJE-
When disassembling and inspecting the cylinder head, be
sure to checlc the camshaft carrier bearing surfaces using a
straight edge for warpage, and check the lifter bores for wear.
NOTE-
6 cylinder and V-8 engines share cylinder head height spec-
ifications.
Camshaft wear
Camshaft wear is usually caused by insufficient lubrication.
Visually inspect camshaft lobes and journals for wear. Cam- . ~~
CAUTIOI\C
If the camshaft is being replaced due to cam lobe wear, it is
recommended that the correspondinglifters should also be
replaced to avoid damaging the new camshaft
NOTE-
Before checking hydraulic lifters, male sure engine oil is
fresh and at the proper level. Sticky lifters can be the result of
sludge build up in the cylinder head and lifters.
CAUTION-
Prior to disconnecting battery cable, read the baltery dls-
connection cautions given In 001 General Cautions a n d
Warnings.
Disconnecting the battery may erase fault code(s)
stored in control module memory Check for fault codes
--
&cylinder models: remove plastic top covers:
Pry out caps (arrows).
Remove fasteners and covers.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
-
--
-
-
116-9
Cvlinder Head and valvetrain1
- 6-cylinder models: remove oil filler cap and unclip vent con-
nection from cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
Icets should be reinstalled in their original locations. Make
note of their arrangement during removal.
Cylinder Head and Valvetrain
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.
4 Install intake camshaft oil baffle cover and cylinder head cov-
er:
= Checlc for correct seating of half-moon seals (A) in back of
cylinder head cover.
Use a small amount of Three Bond 1209 @or equivalent
sealant at corners (B)of half-moon cutouts and corners in
front of cylinder head at joint to timing chain cover.
Align cover at front and rear, then alternatively tighten fas-
teners from inside to outside.
Tightening torque
Sparic plug to cylinder head 25 Nm (18 it-lb)
Ignition coils to cylinder head 10 Nrn (7.5 ft-lb)
Cylinder head cover to cylinder iiead 10 Nrn (89 in-lb)
fM6 screws)
AND LIFTERREMOVAL
CAMSHAFT
AND ~NSTALLATION
The camshafts can be removed with the cylinder heads
mounted on the engine (in the car).
WARNING -
The process of evenly loosening the camshaft bearing cap
nuts is NOT an acceptable method of removing the cam-
shafts. Special tools should always be used to remove the
camshafts. Be sure to read the procedure tlirough before
starting a job.
I Allow engine to cool before beginning this procedure. /
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the batfew read the battery discon-
nection cautions given in 001 General Cautions and
Warnings.
I I < Remove outer thrust washer, sprinq plate, and inner thrust
washer.
NOTE-
Keep chain and sprockets together as an assembly for easier
installation.
CAUTION-
Primary timinq chain tensioner is under sarina aressure.
-
counterclockwise 30" from TDC.
Suspend timing chain with mechanic's wire
.
< Remove spark plugs and install BMW special tool 11 3 260
(A) and 11 3 270 (6) to cylinder head. Tighten tool retaining
bolts in spark plug bores. Do not overtighten bolts.
Tightening torque
BMW special tool 11 3 260 I 1 1 3 270 to 23 Nm (17 It-lb)
cylinder head
CAU T I O G
Intake camshaft bearing cap 1 is centered with adapter
sleeves. To avoid can~sllaftdaniage, it must be removed bs-
fore any other caps.
CAUTION-
Camshaft bearing caps must be reinstalledin their original lo-
cations.
NOTE-
The camshaft bearing caps are coded with a letter anda
number. For example, 'XI" is the first exhaust camshaft
bearing cap at the front of the engine, and "El "is the intalce
camshaft bearing cap at the front of the engine.
0 The camshafts are stamped with a code letter - "E" for the
intake side and 'MA"for the exhaust side.
0 " E is for Einlap, (German for intake) and 'XA"isfor Auspuff,
(German for exhaust).
Cylinder Head and Valvetrain
NOTE-
Do not let hydraulic lifters fall out as the camshaft carrier is
removed.
Hydraulic lifters should be stored in an upright position.
Used hydraulic lifters must be replaced into original lifter
bores.
CAUTION-
A minimum waiting time is required for the hydraulic lifters to
'bleed down" after installing the camshafts into the cylinder
head, before bringing the pistons to TDC. When the cam-
shafts are removed, the hydraulic lifers can expand. This ex-
pansion can cause increased valve lift when the camshafts
are bolted down, possibly resulting in piston interference.
Tightening torques
Camshaft bearing caps to cylinder head (M7) 15 Nm (11 ft-lb)
Cylinder head cover to cylinder head (M6) 10 Nm (89 in-lb)
Sparic plugs (M12) 23 Nm (17 ft-lb)
WARNING-
Allow engine fo cool before beginning this procedure.
CAUTION--
Prior to disconnecting the battea read the battery discon-
nection cautions in 001 General Cautions and Warnings.
CAUTION-
Primary timing chain tensioner is under spring pressure. 1
/Cylinder Head and Valvetrain
CAUTIOf+
Splined shafts share the same part number for both intake
and exhaust camshafts. Usedsplined shafts must be rein-
stalled in their oriqinal locations.
NOTE-
Counterhold camshafts when loosening.
CAUTION-
The end spline retaining screws precisely locate the end
splines to the camshafts. Do not loosen these screws.
CAUTION--
Do not over torque bolts into spark plug holes. 1
CAU TIOW-
Camshaft bearing caps must be installedin their original lo-
cations.
Cylinder Head and Valvetrain
NOTE-
The camshaft bearing caps are coded with a letter and a
number. For example, "A1" is the first exhaust camshaft
bearing cap at the front of the engine, and "El "is the intake
camshaft bearing - cap
. at the front of the engine.
-
The camshafts are stamped with a code letter - " E for the
intake side and 'X" for the exhaust side.
" E is for Einlap. (German for intake) and 'XA7sfor Auspuff.
(German for exhaust).
< Secure hydraulic lifters in lifter bores using BMW special tool
11 3 250, or remove lifters using a magnetic pick-up tool.
I CAUTION-
1 Used liydraulic lifters must be reinstalled in original lifter
bores.
NOTE-
Do not allow hydraulic lifters to fall out of camshaft carriers.
Hydraulic lifters should be stored in an upright position.
CAUTION-
Make sure the crankshaft, which had been rotated approxi-
mately 30"opposite the direction of engine rotation from
TDC, is stillin thatposition before lowering the camshafts into
position. Allpistons must be out of TDCposition to prevent
valve/piston inteiference when the carnshafis are installed.
- Lift timing chain and place exhaust cam onto exhaust cam-
shaft carriers. Place intake camshaft on camshaft carrier.
116-26
I Cylinder Head and Valvetrain
4 Before installing camshaft carriers, examine bearing bores
(arrows) on hydraulic lifter bores for signs of wear.
CAUJION-
A minimum waiting time is requiredfor the hydraulic lifters to
'bleed down"after installing the camshafts into the cylinder
head, before bringing the piston to TDC. When the camshafts
are removed, the hydraulic lifters can expand. This expan-
sion can cause increased valve lift when the camshafts are
bolted down, possibly resulting in piston interference.
4 Fit BMW special tool 11 3 260 (A) and 11 3 270 (B)to cylinder
head over intalte camshaft and screw long bolts (arrows)
into spark plug threads.
CAUTION-
Do not overtighten bolts into spark plug holes.
Tightening torque
Camshaft bearing cap to cylinder head (M7) 14 Nm (10 it-ib)
NOTE-
Observe waiting time for lifter bleed down before continuing
with camshaff installation.
Fit thrust spacer (A) to intalte camshaft and tighten down with
threaded locating studs (arrows). Place longer threaded por-
tion of studs into camshaft.
Tightening torque
Impulse wheel studs to intake camshaft (M7) 20 Nm (15 ft-lb)
116-31
Cylinder Head and Valvetrain
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner and simulates the function of the tensioner.
Tightening torques
Exhaust camshaft locating stud 20 Nm (15 ft-lb)
116-32
Cylinder Head and Valvetrain
< Remove chain and sprockets from tool and slide sprockets
on camshafts. Confirm that gap in intalte sprocket splines
lines up with corresponding gap in camshaft splines (arrow).
CAUTIOI\C
Do not alter position of sprockets with respect to chain when
removinq from saecial tool 11 6 180.
NOTE-
If F marlc is no longer visible, install spring plate as shown in
inset.
..
-
Preload primary chain:
Tighten adjusting screw on BMW special tool 11 4 220 to
specified torque.
Tightening torque
Primary chain tensioner preload 0.7 Nm (6 in-lb)
116-36
I Cylinder Head and Valvetrain
4 Preload exhaust camshaft spring plate by pressing on im-
pulse wheel while tightening mounting nuts (arrows) fingel
tight.
CAUTION--
Male sure aNgas1ef material Is removed from face of cyiin-
der head. Clean sealing face and keep free of oil.
Tightening torques
Sprocket assembly to camshaft initial torque 5 Nm (44 in-lb)
NOTE-
@If the exhaust side of the tool (A) is not flush with the head,
camshaft timing is incorrect. Reset camshaft timing as de-
scribed in 117 Camshaft Timing Chain.
Due to flexible sprocket design, VANOS unit tolerances
and play in the VANOS splines, when the camshaft timing
is set correctly, the intake side of special tool set 11 3 240
(B) may be up to 1 mm (0.04 in.) above the suiface of the
cylinder head. This is normal. Reassemble engine. Other-
wise, reset camshaft timing as describedin 1l?Camshaft
Timing Chain.
CAUTION-
Male sure all gasket material is removed from face of cyl-
inder head. Clean sealing face and keep free of oil.
Check locating dowel (A) and dowel sleeve (B) at top
of cylinder head for damage or incorrect installation.
NOTE-
If VANOS control unit is being replaced, be sure to check and
adjust camshaft timing as described in 117 Camshaft Tim-
ing Chain.
Tightening torque
Primary chain tensioner cylinder to 70 Nm (52 ft-lb)
cylinder head
Tightening torque
Cylinder head cover to cylinder head (M6) 10 Nm (89 in-lb)
Tightening torque -
Radiator cooling fan to coolant pump 40 Nm (30 ft-ib)
Spark plug to cylinder head 25 Nm (18 ft-ib)
Cylinder Head and valvetrain1
NOTE-
Cylinder bank 1-4 is referred to as the right cylinder bank
and is located on the passenger side. Cylinder bank 5-8 is
referred to as the left cylinder bank and is located on the driv-
er's side.
WARNING-
Allow enqine to cool before beqinninq this procedure. 1
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions in 001 General Cautions a n d Warnings.
v
--.-- -----
- cal harnesses.
Remove air filter housing mounting fastener (arrow).
Loosen hose clamp at throttle body.
Remove air filter housing with mass air flow sensor and
duct.
4 Remove right and left side ignition coil mounting nuts (ar-
rows) and coils.
NOTE-
M a l e note of location for ground straps (arrow A).
- sprocket.
Slide primary timing chain off sprocltet and suspend chain
with stiff wire to prevent it from dropping into lower timing
chain cover.
..
ICylinder Head and Valvetrain -.
4 Counterhold left intake camshaft and remove sprocket
mounting bolts (arrows) from left cylinder head.
Remove primary chain sprocket.
Slide primary timing chain off sprocket and supend timing
chain with stiff wire to prevent it from dropping into lower
timing chain cover.
NOTE -
Keep camshaft bearing caps in order. Usedcaps must not be
interchanged.
CAUTION--
Do not mix up camshafi bearing caps between cylinder
banks.
1 Cvlinder Head and valvetrain1
Tightening torque
Camshaft bearing cap 14 Nm (10 ft-lb)
CAUTIOI\C
Do not mix up camshaft bearing caps.
Tightening torque
Camshaft bearing cap 14 Nrn (10 ft-lb)
I Cylinders 5-8
11 2 242 11 2 446
Align camshafts w~thopen-end 27 mm wrench so BMW
special tools fit on cylinder heads without gaps. Secure
tool using number 8 cylinder spark plug hole.
CAUTION-
Do not damage the cylinder head. If necessary, machine
open-end wrench to fit.
. .
- -.
Tightening torques
Sprocket to camshaft flange 15 Nm (I 1 ft-lb)
NOTE-
BMW special tool 11 1 41 1 presses upper timing chain cover
to level of cylinder head.
Tightening torque
Cylinder head cover nuts 10 Nm (7.5 n-lb)
Tightening torque
Timing chain cover to head 10 Nm (7.5 ft-lb)
116-55
Cvlinder Head and valvetrain1
Tightening torque
Cylinder head cover nuts 10 Nm (7.5 it-lb)
Tightening torque
Timing chain cover to head 10 Nm (7.5 ft-lb)
CAUTIOI\C
(M52 TU/M54 engines only) Do not let the hydraulic lifters
fall out as the camshaft carrier is removed. Specialsuction
cups are available from BMW to hold the hydraulic lifters in
place during carrier removal.
* Hydraulic cam lifters should be stored m an uprfght po-
sition. I f necessary, use a magnetic tool to aidin remov-
a l of the lifters.
CAUTIOI\C
Label each valve assembly as it is removed so it can be in-
stalled in its originalposition.
-
- Remove and discard valve stem oil seals from valve guides.
See Valve stem oil seals later in this section.
Exhaust 6.1 mm .O.O4O ..,,,, 6.1 mm -0.040 -0.055 6.1 mm -0.040 .0,055
Exhaust 6.2 mm -0.040 -0.055 6.2mm -0.040 .o.055 6.2mm -O."o .o,055
Valve guides
BMW does not supply valve guides as replacement parts. If a
valve guide is excessively worn, it should be reamed to ac-
cept oversized valve stems. Valve guide specifications are
listed in Tabled. Valve guide specifications.
NOTE-
International Organization for Standardization (1.30) toler-
ance classes are listed in Table c. I S 0 allowances are
based on nominal sizes and should be used to determine
proper fit. Most machine shops should have this informa-
tion available.
Replacement valve guides may be available through after-
market suppliers. Valve guide replacement requires spe-
cial tools and a press. It is also necessary to heat the
cylinder head and chill the valve guides when replacing the
guides.
BMW supplies oversize valves. See Table d. Valve guide
specifications for additional information.
Table d. Valve guide specifications
Specifications All engines (1997-2002)
Valve guide wear, maximum 0.5 mrn (0.020 in)
(valve tilt clearance measured
with new valve)
Valve guide inside diameter, installed
(tolerance per IS0 allowance H7)
Standard 6.0 mm (0.236 in)
Oversize 1 6.1 mrn (0.240 in)
Oversize 2 6.2 mm (0.244 in)
NOTE-
Valve stem oil seals should not be reused. I f valves are re-
moved, new valve stem oil seals should be installed.
NOTE-
BMW special tools are available to remove the valve stem oil
seals. As an alternative, standard valve seal removal tools
are available from most automotive parts stores.
Valve seats
< The valve seats should be resurfaced whenever new valves
or valve guides are installed. Cutters are required to resur-
face the seats. Always check the valves for leaks after recon-
ditioning a valve seat as described above. Table e. Valve
seat specifications lists valve seat dimensions.
- M52 TU,
M54:30.0mrn
(1.181in)
NOTE-
Standard size replacement valve seats are not available from
BMW Replacement valve seats are only available from BMW
in 0.4 mm oversize (oversized in both height and diameter).
The manufacturer does not provide specifications for valve
seat replacement for the engines covered by this manual.
116-60
Cylinder Head and Valvetrain
Valve springs
The valve springs should be checked for fatigue. To quickly
check the springs, line them up in a row. Place astraight edge
across the top of the springs. Any spring that is significantly
shorter than the others is worn and should be replaced.
NOTE-
The M62 TU V-8 engine with VANOS Variable Camshaft
Timing repair information is not included.
NOTE-
See 100 Engine General for engine code and application
information.
020 Maintenance
113 Cylinder Head Removal and Installation
119 Lubrication System
121 Ignition System
170 Radiator and Cooling System
Special tools
Special BMW service tools are needed to perform the service
and repairs procedures covered in this repair group. Many of
these tools are expensive and only available through an au-
thorized BMW dealer. Be sure to read each procedure thor-
oughly before starting a job to determine which special tools
will be necessary.
1 1 3292
4 Protractor
(Tool No. BMW 11 3 460)
. .. -
Camshaft Timing chain/
-
4 Double VANOS setup bracket, M52 TUlM54 6-cylinder
CAUTIOIG
a Disconnecting the battery may erase fault code(s) stored in
control module memory Check for fault codes using spe-
cial BMW diagnostic equipment.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in 001 General Cautions
and Warninqs.
NOTE-
Cooling ian nut (32 mm wrench) has left-hand threads.
,~R,~",,,~"P,,,,!,.,,,.,"?,,m-A,, P,",,,s
Camshaff Timing Chain
NOTE-
Mark direction of belt rotation if reusing belt.
NOTE-
The M52 6-cylinder engine uses a 2-piece vibration damper
and hub assembly.
NOTE -
Be careful while aligning locator pin hole in special tool 11 2
410 with vibration damper locatorpin.
CAUTION-
Do not use flywheel locking tool to hold crankshaft stationary
to loosen or tighten crankshaft hub center bolt Use only the
special tools specified, or equivalent hub holding tool.
NOTE-
The cranlshaft hub center bolt is torqued to 4 10 Nm
(300 ft-16).
4 Install oil seal puller (BMW special tool 11 2 380) and screw
in body of puller until it contacts seal. Tighten center screw to
draw seal out of cover.
4 Coat new seal with oil and position in timing chain cover. Use
BMW special tool 11 3 280 and crankshaft center bolt to draw
seal in flush with timing case cover.
4 Align hub with keyway and tap into place. Insert new center
bolt with washer shoulder (arrow) facing hub.
CAUTION-
Inspect woodruffl<eyfor damage before installing hub.
NOTE-
Be careful while aligning locator pin hole in special tool 1 I 2
410 with vibration damper locator pin.
Tightening torque
Vibration damoer hub to crankshaft 410 Nm (302ft-lb)
Camshaft Timing Chain
Tightening torque
Vibration damper to crankshaft hub (ME) 22 Nm (16 ft-lb)
NOTE-
Cooling fan nut (32 mm wrench) has left-hand threads.
NOTE-
Mark direction of belt rotation if reusing belt.
CAUTIOI\C
Do not use flywheel locling tool to hold crankshaftstation-
ary to loosen or tighten cranl(shaft hub center bolt. Use
only the special tools specified, or equivalent hub holding
tool.
Use care when removing damper/hub assembly, as ~tis
easy to damage the radiator
117-10
/Camshaft Timing Chain
NOTE-
The crankshaft hub center bolt is torqued to 410 Nm
(300 ft-lb).
4 Install oil seal puller (BMW special tool 11 2 380) and screw
in body of puller until it contacts seal. Tighten screw in center
of tool to draw seal out of cover.
Camshaft Timing chain]
4 Coat new seal with oil and position in timing chain cover. Use
BMW special tool 11 3 280 and crankshaft center bolt to draw
seal in flush with timing case cover.
CA U T I O G
Inspect woodruff key for damage before installing hub
assembly.
Tightening torque
Vibration damper hub to crankshaft 410 Nm (302 it-ib)
CAUTIOG
Disconnectingthe battery may erase fault code(s) storedin
control module memory. Check for fault codes using spe-
cial BMW diagnostic equipment.
* Prior to disconnecting the battery, read the battery dis-
connection cautions in 001 General cautions and
warnings.
NOTE -
Cooling fan nut (32 mm wrench) has left-hand threads.
NOTE-
Marlc direction of belt rotation if reusing belt.
1 Camshaft Timing Chain
< Remove all vibration damper perimeter mounting bolts (ar-
row) and remove vibration damper.
NOJE-
Be careful to align hub locator pin to hole (arrow) in special
tool 11 2 450.
< Install seal removing tool (BMW special tool 11 2 380) and
screw in body of puller until it makes firm contact with seal.
Tighten center screw in end of tool to draw out seal.
4 Coat new seal with oil, and use BMW special tool 11 1 220
and crankshaft center bolt to draw seal in flush with timing
case cover.
- Install damper hub and tighten new center bolt finger tight
Tightening torque
Vibration damper hub to cranlrshaft
Stage 1 100 Nm (74 it-lb)
Stage 2 60" Torque angle
Stage 3 60" Torque angle
Stage 4 30" Torque angle
NOTE-
Male sure to align vibration damper with locating dowel pin
in hub.
Tightening torque
Vibration damper to cranltshait hub (ME) 22 Nm (16 ft-lb)
NOTE-
Special BMW service tools are required to remove and in-
stall the VANOS control unit. Read the procedure through
before starting the job.
If the camshafts are notproperly timed, the pistons can
contact the valves.
CAUTION-
Disconnecting the battery may erase fault code(s) stored in
control module memory. Prior to disconnecting the battev,
check for fault codes using special BMW diagnostic equip-
ment.
* Prior to disconnecting the battery, read the battery dis-
connection cautions given in 001 General Cautions
and Warnings.
Camshaft Timina chain1
CAUTlOEIC
The radiator cooling fan nut (32mm wrench) has left- hand
threads.
.
NOTE-
Make note of ignition coil ground strap locations.
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
NOTE-
The cylinder head cover mounting bolt insulators and gas.
kets should be reinstalled in their original positions. Make
note of their arrangement during removal.
Camshaft Timing Chain -- -
-1
Q Remove oil baffle cover from intake camshaft
NOTE-
Two types of secondary timing chain tensioners are used;
one with two holes, and one with a single hole for the locl<ing
pin tool.
CAUTION-
Incorrect installation of the VANOS control unit may result in
damage to the engine.
< Push VANOS piston gear cup (arrow) into VANOS housing
until it bottoms out. Position VANOS control unit in front of
camshafts, but do not engage splines on gear cup.
117-20
Camshaft Timing Chain
CAUTION-
Ensure that the first available tooth engages. It is important
that the exhaust camshaft sprocket be turned only the mini-
mum amount necessary to engage the gear cup. If this pro-
cedure is done incorrectlq: the VANOS system may not fully
function.
Tightening torques
VANOS control unit to cylinder head
M6 nuts 10 Nm (89in-lb)
M8 bolts 22 Nrn (17 ft-lbj
CAUTION-
Timing chain tensioner is under spring tension.
Tightening torques
Secondary timing chain sprocltets to camshafts
Stage 1 5 Nm (44 in-lb)
Stage 2 22 Nm (17 ft-lb)
Tightening torques
Access plugs to VANOS control unit 50 Nm (37 ft-lb)
Primary timing chain tensioner plug to 70 Nm (52 ft-lb)
tensioner sleeve
NOTE-
* Special BMW service tools are required to remove and in-
stall the VANOS control unit. Read the procedure through
before starting the job.
If the camshafts are not properly timed, the pistons can
contact the valves.
CAUTIOG
Disconnecting the battery may erase faultcode(s) storedin
control module memory. Prior to disconnecting the battery,
checlc for fault codes using special BMW diagnostic equip-
ment.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in 001 General Cautions
and Warnings.
CAUTIOG
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
NOTE-
Make note of ignition coil ground strap locations.
Camshaft Timing Chain
NOTE-
Wrap the VANOS oil line fitting with a shop rag to absorb
leaking oil.
NOTE-
The cylinder head cover mounting bolt insulators andgas-
lets should be reinstalled in their original positions. Make
note of their arrangement during removal.
NOTE-
Oil will drain from oil feed line.
CAUTION-
Reversing terminals on special tool will damage diode on
VANOS solenoid valve.
-
Camshaft Timing Chain
-
-.
CAUTION-
I f the adjustment travel is less than 8.5 m m the VANOS ad-
justment unit must be removed and readjusted. See VANOS
control unit, removing (M52 engine) and VANOS con-
trol unit, installing (M52 engine).
Tightening torques
Cylinder head cover 10 Nrn (89 in-lb)
VANOS oil line 32 Nm (24 R-lb)
VANOS solenoid to control unit 30 Nrn (22 ft-lb)
Special BMW sewice tools are needed for timing chain re-
moval and installation procedures. The special tools assure
propertiming of thevalvetrain. Precise marks to setthe timing
on the camshafts are not provided for reassembly. Read the
procedures through before beginning the job.
NOTE-
If the camshafts are not properly timed, the pistons can con-
tact the valves.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original positions. Make
note of their arrangement during removal.
- Drain engine oil, remove oil pan. See 119 Lubrication Sys-
tem.
CAUTION-
Timing chain tensioner is under spring tension. I
- Remove VANOS control unit. See VANOS control unit, re-
moving (M52 engine).
NOTE-
Two types of secondary timing chain tensioners are used,
with either two holes (shown) or a single hole for the locking
pin tool.
CAUTION-
Use care when removing the cover from the cylinder head
gasket If the cover is stuck, use a sharp knife to separate
it from the head gasket.
If cylinder head gasket is damaged, remove cylinder
head and replace head gaslet. See 113 Cylinder
head and valvetrain.
- Inspect timing chain and sprocltets and guide rails for wear.
Replace worn parts.
NOTE-
I f any of the sprockets are being replaced due to wear, the
chain should also be replaced.
Tightening torques
Lower timing chain cover to block
M7 15 Nm (11 ft-lb)
ME 20 Nm (15 it-lb)
Install engine oil pan using a new gasket. See 119 Lubrica-
tion System.
NOTE-
BMW special tool 114 220 is an adjustable timing chain ten-
sioner that simulates the function of the hydraulic tensioner.
F81.,,l,ryT-iib.l>nii,:oni-Aii Ri"ilti R
-- -
Chain 1
- Install cylinder identification trigger plate to front of intake
camshaft.
Tightening torque
Intake camshaft sprocket nuts to studs
502117068
(ME) 1011 Nm (8919 In-lb)
Tightening torque
Exhaust camshaft sprocket bolls (M7)
Stage 1 5 Nrn (44 in-lb)
Stage 2 22 Nm (17 ft-lb)
< Align hub with keyway and tap into place. Insert new center
bolt with washer shoulder (arrow) facing hub.
CAUTION-
Inspect woodruff ley for damage before installing hub.
CAUTION-
Do not use flywheel locling tool to hold crankshaftstationary
to loosen or tighten cranlshaft hub center bolt. Use only the
special tools specified, or equivalent hub holding tool.
Camshaft Timing Chain
-- -- -
Tightening torque
Vibration damper hub to crankshaft 410 Nm (300 ft-lb)
Tightening torque
Vibration damper and pulley to
cranltshaft hub 22 Nm (17 ft-lb)
Tightening torque
Timing chain tensioner to tensioner sleeve 70 Nm (52 ft-ib)
Tightening torque
Cylinder head cover to cyiinder head
M6 nut 10 Nm (89 in-lb)
MB bolt 22 Nm (17 ft-lb)
Tightening torque
Upper timing chain cover to cylinder head
M6 nut 10 Nm (89 in-lb)
MB bolt 22 Nm (17 ft-lb)
VANOS oil supply pipe to VANOS control
unit banjo bolt 32 Nm (24 ft-ib)
117-34
1 Camshaft Timing Chain
DOUBLEVAMOS SYSTEM
(M52 TU AND M54 ENGINES)
Double VANOS system function
The M52TU and M54 6-cylinder engines are equipped with a
Double VANOS system that varies intake and exhaust cam-
shaft timing.
.
NOTE-
VANOS system troubleshooting and diagnostics is best
accomplished using a scan tool.
.Diagnostic Trouble Codes (DTCs) pertaining to the
VANOS system are listed in the following table. See also
OED On-Board Diagnostics.
Elevatedoil temperatures can cause VANOS to deactivate.
Oil that is too thick (high viscosity) may cause a DTC to be
set in the ECM. I f VANOS is deactivated (limp-home
mode), there will be a noticeable loss of power.
NOTE-
If the Double VANOS control unit is being replaced, camshaft
timing must be checked. This procedure requires multiple
special tools. Be sure to read the procedures through before
beginning the repair.
NOTE-
Make note of ignition coil ground strap locations.
4 Using banjo bolt from VANOS control unit oil line, install test
fitting (BMW special tool 11 3 450) to VANOS control unit.
117-39
Camshaft Timing Chain
4 Cover oil hole in VANOS control unit (arrow) with shop towel
to capture oil which will spray when compressed air line is
connected.
NOTE -
Oil will drain from pressure line. Have a container and rags
ready
NOTE-
Additional oil may drain from VANOS control unit.
NOTE-
Set screws have left hand threads. Remove with a clockwise
motion.
Camshaft Timing Chain
NOJE-
The VANOS control unit will contain residual oil. Place
shop towels beneath adjustment unit when removing.
If the VANOS control unit is replaced, or if repair operations
are completed that may change camshaft timing, the cam-
shaft timing must be checked as described in VANOS tim-
ing, checlcing and adjusting (M52 JU and M54
engines).
CAUJION-
Do not crank the engine with VANOS unit removed.
Piston/valve interference may result.
I CAUJION-
. Make sure all gaskel material is removed from lace of
cyl~nderhead. Clean sealing lace and keep lree of oil.
Checklocating dowel (A) and dowelsleeve (B) at top of
cylinder head for damage or incorrect installation.
NOJE -
- .
If the Double VANOS control unit is beino reolaced. be
sure to check and adjust camshaft timing, see VANOS
timing, checking and adjusting (M52 JU and M54 en-
gines).
* If work being carried out has no effect on camshaft timing,
it is not necessary to recheck the timing. It is recommend-
ed, however, that the VANOS operation be checked using
a compatible scan tool once the engine is running.
I Camshaft Timing Chain
- Using new gasket, install VANOS control unit to cylinde~
head.
Reinstall engine support eye.
Tightening torques
VANOS control unit to cylinder head
M6 nut 10 Nm (89 in-lb)
M7 nut 14 Nm (10 ft-ib)
CAUTIOI\C
Set screws have left hand thread Tighten counterclocltwise.
Tightening torque
Hydraulic piston to splined shaft 10 Nm (89 in-lb)
(set screw)
Tightening torque
Sealing plug to VANOS control unit 50 Nm (37 it-lb)
Fit VANOS oil line banjo bolt with new seals. Attach oil line to
VANOS control unit.
Tightening torque
-
Oil line to VANOS control unit (banjo bolt) 32 Nm (24 it-lb)
Camshaft Timing Chain
Tightening torque
Cylinder head cover to cylinder head (M6) 10 Nm (89 in-lb)
Tightening torques
Radiator fan (viscous clutch) to
coolant pump 40 Nm (30 ft-lb)
Spark plug to cylinder head 25 Nrn (18 ft-lb)
CAUTlOAC
Primary camshaft chain tensioning piston is under spring
pressure.
Camshaft Timing Chain
NOTE-
BMW special tool 11 4 220 is an adjustable primary chain
tensioner that simulates the function of the tensioner.
Tightening torque
Primary chain tensioner preload 0.7 Nm (6 in-lb)
CA UTIOPI-
Cover top of VANOS control unit with lint-free shop cloth. At-
tachment of compressed air line will force oil to spray out of
< Place BMW special tool 11 3 240 over camshafts ends and
measure clearance of tool to cylinder head surface.
NOTE-
I f the exhaust side of the tool (A) is not flush with the head,
adjust camshaft timing as described below.
Due to flexible sprocket design and VANOS control unit tol-
erances and play, the intake side of special tool 11 3 240
(B) may be up to 1 mm (0.04 in) above the surface of the
cylinder head. This is normal. Reassemble engine. Other-
wise, adjust camshaft timing as described below.
Tightening torque
Primary chain tensioner preload 0.7 Nm (6 in-lb)
CAUTION-
Male sure all gasket material is removed from face of cylin-
der head. Clean sealins face and keep free of oil.
Tightening torques
Sprocket assembly to camshaft
initial torque 5 Nm (44 in-lb)
Sprocket assembly to camshaft
M7 Torx screw (A) 20 Nm (15 fl-lb)
ivl6 mounting nut (B) 10 tdm (89 in-lb)
NOJE-
I f the exhaust side of the tool (A) is not flush with the head,
camshaft timing Is incorrect. Repeat camshaft timing pro-
cedure.
* Due to flexible sprocket design and VANOS control unit tol-
erances and play, the intake side of special tool 113 240
(6)may be up to 1 mm (0.04 in) above the sudace of the
cylinder head. This is normal. Otherwise, repeat camshaft
timing procedure.
-- - -- - --
Camshaft Timing chain1
Tightening torque
Primary chain tensioner to cylinder head 70 Nm (52 it-lb)
- Fit VANOS oil line banjo bolt with new seals. Attach oil line to
VANOS control unit.
Tightening torque
Oil line to VANOS control unit (banjo bolt) 32 Nm (24 H-lb)
Tightening torque
Radiator cooling fan (VISCOUS
clutch) to 40 Nm (30 ft-lb)
coolant pump
Cyitnder head cover to cylinder head 10 Nm (89 in-lb)
Sparlc plug to cylinder head 25 Nm (18 ft-lb)
11 7-50
/Camshaft Timing Chain
Special BMW service tools are needed for timing chain re-
moval and installation.The special tools assure proper timing
of the valvetrain. Precise marlts to set the timing on the cam:
shafts are not provided for reassembly. Read the procedures
through before beginning the job.
CA UTION-
If the camshafts are not properly timed, the pistons can con-
tact the valves.
CAUTION-
* Disconnecting the battery may erase fault code@)stored in
control module memory. Check for fault codes using spe-
cial BMW diagnostic equipment.
Prior to disconnecting the battery, read the battery dis-
connection cautfons given in 001 General Cautions
and Warninqs.
NOTE-
Mark direction of belt rotation if reusing belt.
CAUTIOIG
Primary camshaft chain tensioningpiston is under spring
pressure.
CAUTION-
Splined shafts for both intake and exhaust camshafts share
the same part numbe,: Remove and mark used splined
shafts in order to reinstallin original locations.
NOTE-
Bolt on intake camshaft side is long and extends into timing
chain cover.
CAUTION-
Do not use flywheel locking tool to hold crankshaft stationary
NOTE-
The crankshaft hub centerbolt is tightened to a torque of 410
Nm (300 ft-lb).
CAUTION-
* Use care when removing the cover from the cylinder heao
gasket. If the cover is stuck, use a sharp knife to separate
it from the headgasket.
If cylinder liead gasket Is damaged, remove cylinder
head and replace head gasket. See 113 Cylinder
head and valvetrain.
-
NOTE-
The chain cover can be removed with the coolant pump in-
stalled.
Use care when removing the cover from the coolant pipe
at rear.
CAUTIOI\C
The procedure outlined below assumes that the camshaits
are lockedin the TDC installationposition with speciallocling
tools as shown earliel:
NOTE-
If any sprockets are being replaced due to wear, the chain
should also be replaced.
-
-
To install lower timing case cover:
Clean cover and cylinder block sealing surfaces
Use new gaskets and coolant pipe O-ring.
Remove timing chain cover dowel pins from engine block.
Drive timing cover dowels in until they just protrude slightly
from sealing surface.
Apply a small bead of silicon sealer (Three Bond 1209 63
or equivalent) to corners of cylinder head where timing
cover meets cylinder head and engine block.
Tap cover into position until firmly seated.
lnstall all bolts hand tight, including two Torx bolts from
above.
Install secondary chain lower guide.
Tighten cover mounting bolts alternately and in stages.
Tightening torque
Lower timing cover to cylinder bloclc (M6) 10 Nrn (89 in-lb)
- Install oil pan with new gasket. See 119 Lubrication Sys-
tem.
Tightening torque
Oil pan to engine bloclc (M6)
8.8 grade 10 Nrn (89 in-lb)
10.9 grade 12 Nm (9 ft-lb)
- Align damper assembly with lteyway and tap into place. In-
sert new center bolt with washer.
CAUTION-
Inspect woodruff key for damage before installing hub
assembly.
CAUTION-
Do not use BMW special tool 1I 2 300 to hold crankshaft
stationary to tighten cranl(shaft hub center bolt. Use only
the special tools specified, or equivalent hub holding tool.
Have a second person hold special tool 11 8 190 while
tightening center crankshaft bolt.
Tightening torque
Crankshaft hub to crankshaft 410 Nrn (300 ft-lb)
Camshaft Timing chain/
NOTE-
BMW special tool 7 1 4 220 is an adjustable primary chain
tensioner that simulates the function of the tensioner.
Tightening torque
Exhaust camshaft locating stud 20 Nrn (15 ft-lb)
< Carefully remove chain and sprockets from tool and slide
onto camshafts. Align gap in intalte sprocket splines with cor-
responding gap in camshaft splines (arrow).
CAUTION-
Do not alterposltion ofsprocl(ets with respect to chain when
removing from specfa1tool 11 6 180.
NOTE-
If F mark is no longer visible, install spring plate as shown
Tightening torque
Primary chain tensioner preload 0.7 Nm (6 in-lb)
CAUTION--
Male sure allgasl(et material is removed from face of cylin-
der head. Clean sealing face and keep free of oil.
Cp-- Camshaft Timing Chain
Tightening torques
Sprocket assembly to camshaft
initial torque 5 Nrn (44 in-lb)
Sprocket assembly to camshaft
M7 Torx screw (A) 20 Nm ( I 5 it-lb)
M6 mounting nut ( 8 ) 10 Nm (89 in-lb)
NOTE-
* I f the exhaust side of the tool is not flush with the head (gap
A), retime the camshafts as described laler in this repair
group.
Due to flexible sprocket design and VANOS control unit tol-
erances and play, the intake side of special tool 7 1 3 240
may be up to I mm (0.04 in) above the suriace of the cyl-
inder head (gap B). This is normal. Otherwise, retime the
camshafts as described in VANOS timing, checking and
adjusting (M52 TU a n d 11154 engines).
Tightening torque
Cylinder head cover to cylinder head 10 Nm (89 in-lb)
Tightening torques
Coolant drain plug to cylinder block 25 Nm (18 ft-lb)
Radiator cooling fan (viscous clutch)
to coolant pump 40 Nm (30 ft-lb)
Radiator drain screw to radrator 2.5 Nm (22 in-lb)
Vibration damper hub to crankshaft 410 Nm (300 ft-ib)
TIMINGCHAIN
(M62 ENGINE TO 911998)
Timing chains, removing
(M62 engine to 911998)
Camshaft timing chain removal requires that the engine oil
pan be removed.
Special BMW service tools are needed for timing chain re-
moval and installation procedures. The special tools assure
propertiming of thevaivetrain. Precise marks to set the timing
on the camshafts are not provided for reassembly. Read the
procedures through before beginning the job.
CAUTION-
Special B M W service tools are needed for this procedure.
Read the procedure through before beginning the job. I f the
camshafts are notproperly timed, the pistons can contact the
valves.
Camshaft Timing chain1
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in 001 General Cautions and
Warnings.
NOTE-
Some early models use pry out trim caps and fasteners to
hold the top cover in place.
NOTE-
Make note of location of ground strap (arrow).
- Unbolt left and right side cable ducts from fuel rail
4 Remove left and right side ignition coils and spark plugs:
- Remove positive (+) terminal cable from left cylinder head
cover.
- Unbolt lefl and right side cable ducts from fuel rail,
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
CAUTION-
Crankshaft center bolt is torqued to 410 Nm (300 ft-lb) use
BMWspecialtool I I 2 450 to secure crankshaft when remov-
ing center bolt.
- Remove retaining bolt for oil dipstick tube from upper timing
chain cover on right side.
CAUTIOG
Tensioner is under spring tension. Release slowly. 1
Release fasteners (arrows) and remove cover
Camshaft Timing chain1
4 Disconnect fuel tank vent valve line and cap off line (arrow).
- Drain engine coolant and remove hoses from thermostat
housing. See 170 Radiator and Cooling System.
- Remove left side upper timing chain cover retaining bolts and
remove cover.
CAUTION-
Counter hold camshaft with a 27mm open-end wrench while
loosening sprocket bolts. Grind wrench if necessary to pre-
vent damage to head.
4 Secure right side timing chain and guide rails together with a
plastic wire ties (arrow).
-
Q Remove sprocket from intake camshafts and remove timing
chain.
If necessary, remove tensioning rail (A), reversing rail (B),
and guide rail (C) to remove timing chain.
I Camshaft Timina Chain
Timing chains, installing
(M62 engine to 911998)
4 The procedure outlined below assumes that the camshafts
are locked in the TDC installation position with special lock-
ing tools as shown earlier.
/ Cylinders 5-8
NOTE-
If any sprocl(ets are being replaced due to wear, the chain
should also be replaced. If the crankshaft sprocket requires
replacement, the oil pump drive sprocket and chain must be
removed. See 119 Lubrication System for oilpump removal
information.
Tightening torque
Reversing rail to engine block 14 Nrn (10 n-lb)
NOTE-
Pressing in on rail will remove slack and reposition sprockets.
If necessarx remove sproclets and align bores centrally.
Tightening torques
Lower timing cover
M6 bolts 10 Nrn (89 in-lb)
M7 bolts 15 Nm (1 1 ft-lb)
ME bolts 22 Nm (16 ft-lb)
M10 bolts 47 Nm (35 ft-lb)
- lnstall oil pan with new gasket. See 119 Lubrication Sys-
tem.
Tightening torque
Sprocltet to camshaft flange 15 Nm (11 ft-lb)
NOTE-
BMW special tool 11 1 4 11 presses upper timing cover to cyl-
inder head to aid in proper sealing of timing chain cover to the
cylinder head gasket.
Tightenlng torque
Timing case cover to head 15 Nm (11 It-lb)
Tightenlng
- torque
Cylinder head cover to head 15 Nm (11 ft-lb)
[camshaft Timina Chain
< Remove cylinder head cover sealing gaskets from lefl cylin-
der head cover. Install BMW special tool 11 1 412 into gasket
groove of cylinder head cover.
Install lefl cylinder head cover. Fit cylinder head cover re-
taining nuts to cylinder head cover studs at cylinders 5 and
6 (first two cylinders on left side cylinder bank).
Tighten nuts uniformly in 'I2turn steps
Tightening torque
Timing case cover to head 15 Nm (11 ft-lb)
Tightening torque
Cylinder head cover to head I 5 Nm (11 ft-lb)
CAUTIOI\C
To prevent damaging engine electricalsystems, be sure to in-
stall ail ground wires previously removed.
Camshaft Timing chain/
WARNING -
Allow engine to cool before beginning this procedure. 1
- Working inside luggage compartment, disconnect negative
battery cable.
CAUTIOI\C
Prior to disconnectingbattery cable, read the battery discon-
nection cautions given in 001 General Cautions a n d
Warninss.
4 Remove left and right side ignition coils and spark plugs:
- Disconnect electrical harness connectors at ignition coils
(A).
Remove left and right side ignition coil mounting fasteners
and coils.
NOTE-
Make note of location of ground strap (arrow).
- Unbolt cable ducts from fuel rail at left and right sides.
NOTE-
Number one cylinder is at valve overlap when both the intale
and exhaust valves are starting to open.
NOTE-
When loosening bolts on camshaft sprocket, counterhold
camshaft using an 27 mm open-end wrench. I f necessary.
machine wrench accordingly to prevent damage to head.
502116429;
I Cylinders 5-8
-
BMW tool 11 2 442 and 11 2 446.
NOTE-
BMW special fool 00 9 250 is a flexible shaft torque wrench.
Camshaft Timing chain/
Tightening torque
Sprocket bolts to camshaft flange 15 Nm (11 ft-lb)
Tightening torque
Sprocket bolts to camshaft flange 15 Nm (I 1 It-lb)
NOTE-
Oil change procedure and oil filter replacement are covered
in 020 Maintenance.
CAUTIOG
V8 engines: The oil pump fasteners (including the sprocket
retaining nut) are known to vibrate loose. This can resultin oil
starvation and engine failure. Be sure to check oil bolts and
nut tightness whenever the oilpump is accessible. If any fas-
teners are found to be loose, remove them and reinstall with
Loctite B a n d torque to specifications.
Special tools
The engine needs to be properly supported while the front
suspension subframe is lowered to access the oil pan.
Engine lubrication
Oil pressure is generated by a gear-type pump bolted to the
bottom o i the engine block. The oil pump is chain driven off
the front of the crankshaft.
CAUTIOI\C
If the red oil pressure warning light comes on or flashes on
while driving, always assume that the oilpressure is low. Stop
the engine immediately and make arrangements to test oil
pressure.
-
I Lubrication System - I
Oil pressure, checking
The oil pressure warning switch is located at the base of the
oil filter housing.
Unscrew oil filter cap in order to allow engine oil to drain back
down into oil pan.
NOJE-
Thoroughly clean around the oil pressure switch before
removing it.
Be prepared to catch leaking oil with a shop towel.
NOJE-
For the most accurate test results, the engine oil and filter
should be new. The oil should be the correct grade.
Tightening torque
Oil pressure switch to oil filter housing 27 Nm (20 ft-lb)
-
-
Turn ignition switch on.
Warning light on instrument panel must light up
- Remove connector from oil pressure switch.
Warning light on instrument panel must go out.
NOTE-
I f the light does not go out, the wiring to the switch is most
likely grounded somewhere between the switch terminaland
the warning light See ELE Electrical Wiring Diagrams for
electrical schematics.
- If warning light does not light when ignition is on, remove con-
nector from oil pressure switch and use a jumper wire to
ground connector terminal to a clean metal surface. The oil
pressure warning light should come on.
NOTE-
I f there are two wires to the oil pressure switch, ground the
brown/green wire that carries the signal to the warning light.
CAUTION-
Keep in mind that low oil pressure may be preventing the
switch from turning the light out If the light remains on while
the engine is running, check the oil pressure as described
earlier. Do not drive the car untilthe problemis corrected. The
engine may be severely damaged.
4 Remove seal carrier bolts from oil pan (arrows). Loosen all
oil pan bolts.
Lubrication stern/
Remove remaining seal carrier bolts (arrows) and carefully
remove seal carrier without damaging the oil pan gasltet.
CAUTION-
After removingseal carrier, checlc oilpan gasket for damage.
If gasket is damaged during removal, remove oil pan (as de-
scribed later) and replace gasket.
< Remove old seal and install new seal into seal carrier using
BMW special tools 11 1 260 and 00 5 500.
NOTE-
A new radial seal is used from 4/98 production, and is the
only version available from BMW as a replacement. The
new sealno longer uses a spring to support the sealing lip.
Do not lcinlc or damage the sealing lip. Do not touch with
fingers.
* BMW offers the rear main seal carrier and seal in a lit A
plastic support bushing, required for sliding the seal over
the crankshaft, is included with the lcit.
I CAUTION- 1
Do not use BMW special tool 1 I 2 213 (mstallation guide)
with the new style seal. Use only the special tool supphed
with the seal lcit.
Use plastic support bushing (A) that comes with seal ltit as
an installation - - seal over end of crankshaft. Use
quide, fittina
care to push seal carrier and support bushing on straight,
without tilting sideways. Remove support bushing.
Tightening torques
Oil drain plug fo oil pan (MI21 25 Nm (18 ft-lb)
Oil pan to engine block
M6 (8.8 grade) 10 Nm (89 in-ib)
M6 (10.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 it-lb)
Rear main seal carrier to crankcase
M6 10 Nm (89 in-lb)
ME 22 Nm (16 ft-lb)
CAUTION-
Do not damage oil pan gasket.
< Remove old seal and reinstall new seal into seal carrier using
) BMW special tools 11 1 230 and 00 5 500.
- When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace gasitet between rear main seal carrier and cranlt-
case.
Apply thin coat of 3 Bond 8 1209 or equivalent sealant to
oil pan gasltet sealing surfaces.
* Lubricate crankshaft and seal contact surfaces.
Tightening torques
Flywheel to crankshaft (use new bolts) 120 Nm (89 ft-lb)
dra~nplug to 011pan (M12)
011 25 Nm (18 ft-lb)
Oil pan to eng~neblock
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (10 9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Rear main seal carrier to crankcase
M6 10 Nrn (89 in-lb)
ME 22 Nm (16 ft-lb)
11 9-10
Lubrication System
Make sure the car is stable and well supported at all times.
Use a professionalautomotive lift orjackstands designed for
NOTE-
* If necessary, remove air filter assembly for better access to
dipsticlc tube.
The dipstick guide tube is sealed in the block using an O-
ring. Check that the O-ring comes out with the tube.
WARNING-
Be sure to support hood while disconnecting support struts.
Lubrication system/
NOTE-
For better access to power steering assembly, unbolt fluid
reservoir and suspend with wire.
< Remove right and left lower engine mount nuts (arrow)
NOTE-
I f oil pan will not slide backwards, disconnect stabilizer bar
links and lower front axle support further.
If the oil pan does not separate easily from the engine cylin-
der block, a few taps with a rubber malletshould breakit free.
Do not pry the oil pan loose.
Tightening torques
Oil drain plug to oil pan (M12) 25 Nm (18 ft-lb)
Oil pan to engine block
MG (8.8 grade) 10 Nm (89 In-lb)
MG (10.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nrn (16 R-lb)
-- -
. .
. . - Lubrication system]
NOTE-
BMW does not specify a front end alignment following this
procedure.
Tightening torques
Front subfrarne to body rail
(M12, use new bolts)
8.8 grade 77 Nrn (57 ft-lb)
10.9 grade 105 Nrn (77 ft-lb)
12.9 grade 110 Nrn (81 ft-lb)
Stabilizer bar link to stabilizer bar 65 Nrn (48 ft-lb)
Steering shaft universaljoint clamping bolt
(use new bolt) 19 Nrn (14 it-lb)
CAUTION-
It is recommended that the oil pump retaining bolts and oil
pump drive sprocket retaining nut tightening torque be
checkedany time the oilpan is removed.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotivelift orjack stands designedfor
[LubricationSystem
CAUTIOI\C
If the lowerpan does not separate easily from upperpan, a
few taps with a rubber mallet should break it free. Do notpry
the oil pan loose.
-
prevent damage to sealing lip.
Install new oil pan mounting bolts (threads coated with
sealer).
Remove guide studs and install remainder of oil pan bolts.
- Remainder of reassembly 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-lb)
M6 (10.9 grade) 12 Nm (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
4
-
Remove engine top cover:
Early version: Pry off caps (arrows) and remove fasteners.
Late version: Depress fasteners (arrows) and lift cover.
4 Remove upper nuts (arrow) from left and right motor mounts.
NOTE-
Replace dipstick O-ring seal.
< Working at right side of engine, remove oil return line from
upper section of oil pan.
< Working through lower oil pan opening, remove pump mount-
ing bolts (arrows).
Remove oil pump. See Oil pump, removing and install-
ing (V-8).
r-
Lubr~cat~on
System -
- 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
AIC drive belt tensloner
M6 10 Nm (7.5 it-lb)
M8 24 Nm (18 ft-lb)
Front axle subframe to chassis
(Use new fasteners) 77 Nm (57 ft-lb)
Oil drain line to upper oil pan 30 Nm (22 ft-lb)
Oil pump to crankcase 34 Nm (25 ft-lb)
Oil pan fasteners (upperllower)
M6 8.8 10 Nm (7.5 ft-lb)
M6 10.9 (replace) I 2 Nm (9 ft-lb)
M8 8.8 22 Nm (16 ft-lb)
Steering column universal joint to
steering box (replace) 19 Nm (14 ft-lb)
NOTE-
Any time the oilpressure warning switch is removed, be sure
to replace the sealing washer.
Tightening torque
Oil ~ressureswitch to oil filter housins 27 Nrn (20 ft-lb)
NOTE-
Any time the oil level warning switch is removed, be sure to
replace the sealing O-ring between switch and oil pan.
/Lubrication System
CAUTIOI\C
Oil pump sproclcet nut has left-handthreads. Turn clockwise
to loosen.
NOTE-
Record location of any spacers between pump and engine
bloclc Note positions of locating dowels.
- Remove cover from oil pump and check for wear or scoring.
Spin oil pump shaft and check that gears turn smoothly. Re-
place pump if gears spin with difficulty orany wear is present.
Tightening torques
Oil drain plug to oil pan 25 Nm (18 ft-lb)
Oil pan to engine bloclc
M6 (8.8 grade) 10 Nm (89 in-lb)
M6 (10.9 grade) 12 Nrn (9 ft-lb)
M8 (8.8 grade) 22 Nm (16 ft-lb)
Oil pump sprocket to oil pump shait
(M10 x 1) (left hand thread) 25 Nm (18 it-lb)
Oil pump to crankcase (ME) 22 Nm (16 it-lb)
Oil pump pickup tube to cranltcase (M6) 10 Nm (89 in-lb)
119-24
Lubrication System
CAUTION-
V8 engines: The oil pump fasteners (including the sprocket
retaining nut) are known to vibrate loose. This can resultin oil
starvation and engine failure. Be sure to checlc oil bolts and
nut tighness whenever the oil pump is accessible. If any fas-
teners are found to be loose, remove them and reinstall with
Loctite 8 and torque to specifications.
CAUTIO&
During reinstallation, do not damage O-rings on sharp edges
of engine blocl<.
Tightening torques
Oil pump cover to oil pump (M6) 10 Nm (89 in-lb)
Oil pump sprocket to shaft (M10) 45 Nm (33 ft-lb)
Oil pump to engine block
M8 (8.8 grade) 22 Nm (16 ft-lb)
119-26
/Lubrication System
< Use Allen wrench to adjust chain slaclc (B) by turning thread-
ed spacer (A).
- Coat remaining oil pump mounting fastener with Loctite 03. In-
stall and tighten.
- 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 (16 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)
< Inspect oil pump relief valve components and bore for scor-
/ ,- -.-~.
Oil pressure relief valve assembly
t o -...,
!~. - ~-
- ~ ! ~ ~ - %
c y ~ ~ n oengrnej
er
h.
.- .,, ing or other damage.
1. Control plunger
2. Spring
3. Sealing O-ring
4. Sleeve
5. Circlip
CAUTION--
There is high spring pressure in the relief valve.
4 Inspect oil pump relief valve components and bore lor scor-
ing or other damage.
1. Control plunger
2. Spring
3. Sleeve
4. Circlip
Special tools
System diagnosis and testing of the ignition system requires
special test equipment.
-
4 Secondary voltage test harness
(Tool No. BMW 12 7 030)
120-3
Ignition System
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
CAU 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.
Ignition system
4 All engines use a distributorless ignition system with individ-
ual ignition coils for each cylinder. There is no distributor cap
or ignition rotor.
NOTE-
Schematic diagrams shown are for illustrative purposes only.
See ELE Electrical Wiring Diagrams for engine manage-
ment specific wiring information.
WARNING-
Do not touch or disconnectany 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 the 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.
NOTE-
BMWmodels covered in this manual were equipped with one
of three versions of MIL warning lights (as shown).
Misfire detection
Engine m~sfirein one or more cylinders, may be caused by a
var~etyof malfunctions in various subsystems. The OBD II
system ~ncorporated into the engine management systems is
des~gnedto detect and warn of misfire faults during englne
operat~on.See OED On Board Diagnostics.
WARNING -
lgnition misfires can cause high hydrocarbon exhaust emis-
sions andcatalytic converter damage. For this reason, if a se-
vere misfire is detected, the fuel injector will be turned off to
the specific cylinder and the MIL will be illuminated. A misfire
may also produce an overheated catalytic converter, which
can be a fire hazard.
~i,+i!,~,i~tiii~iit~~,t1!lc,',l~~4~l~,~,l,~+~{+',,l
1W W Sl @, 10 :o 9 20 21 10 0
15. 15
4Normal oscilloscope pattern for ignition system at idle.
(r+~+~+~(.~i+~/.~~itlt~~(tit~lii~~jt~~~i~ittiii~l
IW 10 ED 10 (0 ID U 10 11 sa,ma,
70 0
2
.
15 - 30
< Defective ignition coil.
. 1. Normal combustion period.
.
. 2. Absence of spark voltage line (arrow).
20
.
-
5 I0
--
--
0 0
iiiCi;kiW*huiMwiritil~tiii
110 10 00 ro w M A, 30 2"
m
:*,: u
-,
Normal secondary voltage patterns
:I
i
1- (4-cylinder pattern shown).
:<O
!I
1 iI,...>....
F1...,,,,.h ,,,.!,.,.
- .,.,ti.,,, ,.,.$,.,!
i
,:,, .,xt J
* ", *, ,
{ 8
>* m2>2n,,,,
Firing order
M52 - M52 TU - M54 6-cylinder 1-5-3-6-2-4
M62 - M62 TU V-8 1-5-4-8-6-3-7-2
.-
ignition System
CAUTION-
Relay locations may vary. Use care when identifying relays.
See 610 Electrical Component Locations.
CAUTION-
If a spark test is done incorrecth damage to the Engine Con-
trol Module (ECM) or the ignition coils may result.
NOTE-
Spark plug replacement is covered in 020 Maintenance.
black and sooty, but not always. If a coil is not operating, the
engine management system will electrically disable the fuel
injector to that cylinder. The key is to look for differences be-
tween cylinders.
C4 UTION-
Use a digital multimeter for the following tests. I
- Remove plastic engine cover from top of valve cover by pry-
ing off bolt covers and removing cover mounting bolts.
NOTE-
A leaky coil may indicate a faulty Engine Control Module
(ECM). Check ECM before installing a new coil.
CAUTION-
Note location of coilground straps before coil removal; rein-
stall in the same location.
NOTE-
When replacing ignition coils, ensure that the replacements
are from the same manufacturer with the same partlcode
numbers. I f individual coils with the correct specifications are
not available. all coils should be re~laced.
120-12
ignition System
Crankshaftspeedsensor
Crankshaft speed sensor, replacing (M52, M52 TU and
M54 engines)
- If the- OBD
-
~~ II svstem misfire detection ~rotocoldetects 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-
I f the crankshaft speed sensor pulse wheel is damaged, the
engine will have to be disassembled down to the crankshaft
to reolace the wheel.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professionalautomotive lift orjacltstands designed for
the ouroose. A floor iaclc is not adequate support.
Tightening
- torques
Intake camshaft sensor to cylinder head 10 Nrn (7 ft-lb)
VANOS solenoid to VANOS control unit 30 Nm (22 ft-lb)
120-15
Ignition system1
Tightening torque
Exhaust camshaft sensor to cylinder head 10 Nm (7 ft-lb)
Tightening torque
Intake camshaft sensor to timing chain 5 Nm (3.5 ft-lb)
cover
Knock sensors
Knock sensors, replacing (M52, M52 TU and M54
engines)
The knock sensors are bolted to the left side of the cylinder
block under the intake manifold.
Tightening torque
Knock sensor to head 20 Nm (15 ft-lb)
- Use scan tool to read out and clear ECM fault memory.
The knock sensors are bolted to the side of the cylinder block
under the intake manifold.
Ignition System
I CAUTION- I
Note the installedangle of the knock sensors on the bloclt be-
fore removalit. Reinstallthe sensors in the same position. Be
sure to use a torque wrench when tightening the sensor
mounting bolts.
Tightening torque
Knock sensor to engine bloclc 20 Nm (15 ft-lb)
- Use scan tool to read out and clear ECM fault memory.
Special tools
point
002125~1
WARNING -
Wear goggles, rubber gloves, and a rubber apron when
working around the battery or battery acid (electrolyte).
Battery acid contains sulfuric acid and can cause skin
irritation and burning. If acid is spilled on your skin or
clothing, flush the area at once with large quantities of
water. If electrolyte gets into your eyes, flush them with
large quantities of clean water for several minutes and
call a physician.
Batteries that are being charged or are fully charged
give off explosive hydrogen gas. Keep sparks and open
flames away. Do not smoke.
CAUTIOI\C
Only use a digital multimeter when testing automotive elec-
trical components.
. If a repair procedure specifies disconnecting the bat-
tery, follow the instruction for safety reasons.
Prior to disconnecting the battery, read the battery dis-
connection cautions in 001 General Cautions and
Warnings.
Models with MS43 engine management: Allow at least
3 minutes to elapse after turning ignition ley to OFFpo-
sition before disconnecting battery. This willallow sum-
cient tinie to complete the DMJL (fuel tank pressure)
test
* Disconnecting the battery cables may erase fault codes
stored in ECM memory.
Always disconnect the negative (-) battery cable first
and reconnect it last. Cover the battery post with an in-
sulating material whenever the cable is removed.
Do not disconnect battery, alternator or starter wires
while the engine is running.
0 Never reverse the battery cables. Even a momentary
wrong connection can damage the alternator or other
electrical components.
Do not depend on the color of insulation to tell battery
positive and negative cables apart. Label cables before
removing.
The slide-tilt sunroof may fail to function properly after
disconnecting and reconnecting the battery. Reinitial-
ize sunroof as described in 540 Sunroof.
Battery, Starter, ~iternatorl
Battery testing
Battery testing determines the state of battery charge. On
conventional or low-maintenance batteries. the most com-
mon method of testing the battery is that ofchecking the spe-
cific gravity of the electrolyte using a hydrometer. Before
testing- the battery, check that the cables are tight and free of
corrosion.
Hydrometer testing
Before hydrometertesting, load the battery with 15 amperes
for one minute. If the battery is installed in the vehicle, this can
be done by turning on the headlights without the engine run-
ning. The state of battery charge based on specific gravity
values are given in Table b. Specific gravity of battery elec-
trolyte at 27" C (80°F).
NOTE-
Electrolyte temperature affects hydrometer reading. Checlc
the electrolyte temperature with a thermometer. Add 0.004 to
the hydrometerreading forevery 6°C (10°F) that the electro-
lyte is above 27°C (80°F). Subtract 0.004 from the reading
forevery 6°C (10°F) that the electrolyte is below27"C
(80°F).
.
WARNING-
Always wear protective goggles and clothing when perform-
ing a load test.
-
Table d. Battery load test minimum voltage
Ambient temperature Voltage*
27 " C (80" F) 9.6 V
NOTE-
Automatic transmission cars: ambershifier LED willgo out at
consumer cut-off.
NOTE-
Green LED will light up to indicate correct installation of
closed-circuit current measurement adaotor.
NOTE-
Any electrical overloading will be indicated at this point by
lighting the red LED.If the red LED lights up, check the adap-
tor connections.
NOTE -
Set multimeter to record average readings.
Ifpossible, turn offpowersaving features of multimeter
which prevent a long term (overnight) test by automatically
powering down meter.
Battery charging
Discharged batteries can be recharged using a batterycharg-
er. Remove the battery from the trunk during charging.
WARNING -
Hydrogen gas given off by the battery during charging is ex-
plosive. Do not smoke. Keep open flames away from the top
ofthe b a t t e ~and prevent electrical sparks by turning off the
battery charger before connecting or disconnecting it.
Alternator, basic
Alternator
-
1997 98 5281
1997 540i On 1997-1 998 6-cylinderand 1997 V-8 models, the charging
system indicator light is supplied voltage (+) to one side of the
/-- -----, -----------: light bulb, and the other side of the bulb is connected to the
F15 /
.&
.
30
I ,'
7.5A/
....
1Xi0015
voltage regulator.
Battery With the engine off and the key in the run position, voltage
from the ignition switch flows through the regulator to ground,
completing the circuit and illuminating the charge indicator
bulb.
lBL
and stsrt
light is turned off.
1.
.--------,charge
,
I , indicator
I
i
xGoli
I
<"9,7,a,T
Alternator with
4 On cars with multi-function control alternator, the charge in-
multi-function control (MFR) dicator lamp is activated by means of an electronic switch in-
tegrated in the alternator controller. This switch receives its
voltage supply from terminal 15 on the 3-pin connector at the
rear of the alternator. The controller measures internally the
voltage difference between terminal 30 and terminal 15 and
signals the DME ECM to turn the charge indicator lamp on.
Water-cooled alternator
The water-cooled alternator, used on 1999 and later M62 TU
engines, is a sealed unit housed inside the engine block wa-
ter jacket. It is cooled via the engine cooling system. It is a
"brushless" sealed unit that cannot be serviced. Maintaining
consistent alternator temperatures increases the life span of
the alternator, and elimination of the alternator cooling fan re-
duces alternator noise significantly.
NOTE-
Some model require up to 15 second to reacli full alternator
output.
CA U T I O G
If the charge indicator light in the instrument cluster remains
on, the charge warning circuit in the instrument cluster may
be faulty. Check that the ground lead is securely affachedto
the grounding stud on the cylinder head (A). Replacing the
instrument cluster before repairing the ground lead will both
damage the instrumentcluster and cause the failure to
reoccur.
Battery, Starter, ~lternatorl
NOTE-
The regulated voltage (engine running) should be between
13.2 and 14.5, depending on temperature andoperating con-
ditions. If the voltage is higher than 14.8, the voltage regula-
tor or mulitfunction controller is most likely faulty
Check for clean and tight battery cables. Check ground cable
running from negative (-) battery terminal to chassis and
ground cable running from engine to chassis. Check alterna-
tor drive belt condition and tension.
CAUTIOI\C
* Do not disconnect the battery while the engine is running.
Damage to the alternator and/or engine electronicsystems
may result.
Only use a digital multimeter when testing charging
system components.
--7
4 Turn ignition key on. Check that battery warning light comes
on.
NOTE-
If the warning light does not come on, repair bulb or wiring
faults before continuing to checlc the charging system.
/
Charge indicator
502820805
NOTE-
On V-8 engines, access to the rear of the alternator is limited.
Check for battery voltage between the jump start post on the
left cylinder head and ground.
- Making sure all test equipment and tools are clear, start en-
gine. Voltage should increase to 8.0 VDC or higher. The
charge indicator light should go out.
If voltage does not increase and system is not charging,
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in 001 General Warnings and Cau-
I tions.
- Remove radiator cooling fan and fan shroud. See 170 Radi-
ator and Cooling System.
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
'4 Remove upper and lower mounting bolts (arrows)and lift out
alternator.
Tightening torques
Belt tensloner to engine block
M8 (8.8 grade) 22 Nm (16 ft-ib)
Fan clutch to coolant pump
with BMW special tool 11 5 040 30 Nm (22 ft-lb)
without BMW special tool 1 1 5 040 40 Nm (29 ft-ib)
Pulley to alternator 70 Nm (44 ft-lb)
Terminal 30 (B+) wire to alternator (M8) 13 Nm (10 ft-ib)
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions 001 General Warnings a n d Cautions.
- Remove cooling fan and alternator drive belt. See 020 Main-
tenance.
- Pry out trim caps and remove fasteners from plastic cover on
left head. Lift off cover.
WARNING-
Make sure the car is stable and well supported at aN times.
Use a professionalautomotive lift orjack stands designed for
the purpose. A floorjack is not adequate support.
121-17
Bauery, Starter, Alternator
CAUTIOe
Protect radiator with heavy cardboard or sheet metal.
Tightening torques
Fan clutch to coolant pump
with BMW special tool 11 5 040 30 Nm (22 ft-lb)
without BMW special tool 11 5 040 40 Nm (29 ft-lb)
Pullev to alternator 70 Nm 144 it-lb)
-,
Terminal 30 (Bt)wire to alternator (ME) 13 Nm 110 ft-lb\
121-18
I Battery, Starter, Alternator
CAUTION-
Allow engine to cool before removing alternator as coolant
will escape from the alternator water jacket.
CAUTION-
Prior to disconnecting the battew read the battery discon-
nection cautions given in 001 General Warnings and Cau-
tions.
- Remove radiator cooling fan and fan shroud. See 170 Radi-
ator and Cooling System.
NOTE-
If necessary, raise car and remove engine compartment
splash shield to access lower alternator mounting bolts.
The upper coolant hose can also be removed to assist al-
ternator removal.
aling
ring
Battery, Starter, Alternator
Tightening torques
Fan clutch to coolant pump
with BMW special tool 11 5 040 30 Nm (22 ft-lb)
without BMW special tool 11 5 040 40 Nm (29 ft-lb)
Terminal 30 (Bc) wire to alternator (ME) 13 Nm (10 ft-lb)
STARTER
Starter troubleshooting
Typical starter wiring terminal identification is shown. Large
wire at terminal 30 (not shown in photo) is direct battery volt-
age. Smaller wire at terminal 50 operates starter solenoid via
ignition switch.
NOTE-
* A factory-installed drive-away protection system, also re-
ferred to as EWS, is used on E39 cars. This system pre-
vents operation of the starter if a specially coded ignition
key is not used.
On cars with automatic transmission, the transmission
gear position switch signals EWS to prevent the engine
from starting in gear positions other than PARK or NEU-
TRAL.
On cars with manual transmissions, a starter immobiliza-
tion switch at the clutch pedal is used to prevent the starter
from operating unless the clutch pedal is pushed fully to
the floor.
I Battery, Starter, Alternator
- Check for battery voltage at terminal 50 of starter motor with
key in start position. If voltage is not present, check wiring be-
tween ignition switch and starter terminal. Check the EWS
system and other inputs that disrupt terminal 56 to the start-
er. See ELE Electrical Wiring Diagrams. If voltage is
present and no other visible wiring faults can be found, prob-
lem is most likely in starter motor.
NOTE-
Access to the starter wiring is very limited. Forbetteraccess,
it may be necessary to remove the intake manifold.
CAUTIOI\C
Prior to disconnecting the battern read the baltery discon-
nection cautions in OOlGeneral Cautions and Warnings.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professionalautomotive lift orjack stands designed for
the purpose. A floorjaclc is not adequate support
Tightening torques
Starter to engine 47 Nrn (35 It-lb)
Starter sipport bracket to starter 5 Nrn (44 in-lb)
Starter support bracket to engine 47 Nrn (35 ft-lb)
Wlre terminals to slarter
M5 5 Nrn (44 in-lb)
M6 7 Nrn (62 in-lb)
M8 13 Nrn (10 ft-lb)
CA UTIOW-
Prior to disconnecting the battery, read the battev discon-
nection cautions in OOlGeneral Cautions and Warnings.
-
/ WARNING-
~ ~~ ~~ ~~~ ~ 1
Make sure the car is stable and well supported at all times.
Use a professionalautomotive lift orjacltstands designed for
I the purpose. A floor jack is not adequate support I
-
Battery, Starter, Alternator
Tightening torques
Starter to engine 47 Nrn (35 ft-lb)
Wire terminals to starter
M5 5 Nrn (44 in-ib)
M6 7 Nm (62 in-ib)
ME 13 Nrn (10 ft-lb)
121-23
Battery, Starter, ~lternatorl
NOTE-
I f the field winding strap is damaged or burned, a new or
rebuilt starter motor is needed.
CAUTION-
When installingfield winding strap to starter, position itso that
it does not contact the starter body.
Tightening torque
Field strap to starter 13 Nm (10 ff-lb)
130-1
This repair group covers service and repair of the Bosch and
Siemens engine management systems used on 1997
through 2002 E39 models. Additional engine management
service and repair information may also be found in the fol-
lowing repair groups:
0 020 Maintenance
120 Ignition System
160 Fuel Tank and Fuel Pump
610 Electrical Component Locations
OBD O n Board Diagnostics
NOTE-
Camshaft position sensor, crankshaft speed sensor and
knoclc sensors are covered in 120 Ignition System.
- management
Table a. Engine - system applications
~ ~
1 ~odellmodelyear /I Engine -
IDME
I
system
5281, 1997-1998 IM52. 2.8 liter ISiemens MS 41 .I
I 1
528i. 1999ZO00 1 ~ 5 TU,
2 2.8 liter ]siemens MS 42.0
I I
5251, 2001-2002 1 ~ 5 42.5
I
, liter 1 Siemens MS 43.0
I
NOTE-
* Professional diagnostic scan tools available at the time of
this printing include the BMW factory tools and a small
number of aftermarket BMW-specific tools. The CS2000
from Baum Tools Unlimited, the Retriever from Assenma-
chef Specialty Tools, and the MT2500 from Snap-on are
three examples.
In addition to the BMW-specific professional line of scan
tools, there are inexpensive generic OBD I1 scan tool soft-
ware programs and handheld units available. Although
these tools have limited capabilities as compared to the
dedicated tools, they are powerful diagnostic tools.
For the DIY owner, simple aftermarltet DTC readeris avail-
able through http://www.pealteresearch.com. This tool is
capable of checlting for DTCs as well as turning off the il-
luminated MIL and resetting the service indicator lights.
WARNING-
Gasoline is highly flammable and its vapors are explosive.
Do not smoke or work on a car near heaters or other fire
hazards when diagnosing and repairing fuel system prob-
lems. Have a fire extinguisher available in case of an emer-
gency
Renew fuel system hoses, clamps and O-rings any
time they are removed.
When working on an open fuel system, wear suitable
hand protection, as prolonged contact with fuel can
cause illnesses and skin disorders.
* 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.
-
CAUTION-
Disconnecting the battery may erase fault code($ storedin
memory Check for fault codes prior to disconnecting the
battery cables. Read the battery disconnection cautions in
001 General Warnings and Cautions.
a Connect and disconnect the DME system wiring and
1 test equipment leads only when the ignition is switched
off.
Wait at least 1 minute after turning off the ignition be-
fore removing the engine control module (ECM) con-
nector. If the connector is removed before this time,
residualpower in the system relay may damage the
control module.
Fuel system cleaners and other chemical additives oth-
er than those specifically recommended by BMW may
damage the catalytic converter, the oxygen sensor or
other fuel supply components.
* Do not connect any test equipment that delivers a 12-
volt power supply to terminal 15 (+) of the ignition coil.
The current flow may damage the ECM. In general,
connect test equipment only as specified by BMW or
the equipment maker.
Only use a digital multirneter for electrical tests. Only
use an LED test light for quiclc tests.
130-6
Fuel Injection
NOTE-
* Fuel delivery volume and fuel pressure are critical to prop-
er operation. Fuelpressure direcfly influences fuel deliv-
ery
Fuel pump relay, fuel pressure and fuel volume tests are
given in 160 Fuel Tank and Fuel Pump.
-
CAUTION-
The tests in this section may set fault codes (DTCs) in the
ECM and illuminate the MIL. Affer all testing is completed,
access and clear DJC fault memory using an OED I1 or
BMW compatible scan tool. See OBD On-Board Diag-
nostics.
Only use a digital multimeter for electrical tests.
.
0
NOTE-
The ECM relay is also referred to as the DME main relay.
Gmund from
Ern
SOZI~O~~I~Y
- Reinstall relay and turn ignition on. Gain access to back side
of relay socket and check for ground on terminal 4 (85).
If ground is present continue testing.
If ground is not present, signal from ECM is missing. Check
wire between ECM and relay.
NOTE-
I f no faults are found during testing but power is not reaching
the ECM or other components, check the fuses in the fuse
carrier X8680 in the E-box.
Fuel Injection I
Mass air flow (MAF) sensor,
checking and replacing
4 The hot film mass air flow (MAF) sensor (arrow) sends a
varying voltage (approx. 0.5 - 4.5 vdc) to the ECM represent-
ing the measured intake air. The air mass input signal is pro-
duced electronically by the MAFsensorusing a heated metal
film in the air flow stream.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using throttle position and engine rpm in-
puts. A faulty MAF sensor illuminates the MIL.
NOTE-
Visually inspect the sensor for damage, missing or blocked
screens. The screens affect air flow calibration. Also inspect
the sealing O-rings where the sensor inserts into the air filter
housing and intake boot. Ensure the pin connections are
clean and tight.
r
1
CAUTIOI\C
Be sure ignition is OFFbefore disconnecting or reconnecting
DME svstem components. 1
130-10
Fuel Injection
R
1 -4 The ECT sensor is located below cylinder 1 intake port
The ECT sensor is a dual temperature sensor. One circuit
provides coolant temperature information to the ECM while
the other circuit provides coolant temperature information to
the instrument cluster.
NOTE-
The ECT sensor is an NTC (negative temperature coeffi-
cient) type sensor. in other words, as the temperature rises,
resistance through the sensor decreases.
WARNING -
Due to risk of personal injury, be sure the engine is cold be-
fore disconnecting or reconnectingECT sensor.
Fuel Injection
CAUTION-
Be sure ignition is OFF before disconnectingor reconnecting
DME system components.
Tightening torque
Temperature sensor to cylinder head 13 Nm (10 it-lb)
NOJE-
The IATsensor is an NTC (negative temperature coefficient)
type sensor. In other words, as the temperature rises, resis-
tance through the sensor decreases.
CAUTION--
Be sure ignition is OFFbefore disconnecting or reconnecting
DME system components.
130-12
Fuel Injection
-
Throttle ~ o s i t i o nsensor testina values
Terminals Test values
1 and ground in harness 5 vdc (approx.)
connector, ltey on
1 and 3 at sensor 4.0 itR(appr0x.)
1 and 2 at sensor Throttle plate rotated from idle to
lull throttle, continuously variable
from 1.0 - 4.0 1tR
rCAUTION-
Be sure ignition is OFFbefore disconnecting or reconnecting
DME svstem components.
130-13
Fuel Injection I
CAUTION-
Be sure ignition is OFFbefore disconnectingor reconnecting
DME system components.
NOTE-
Do not confuse the throttle position sensor on the main Nirot-
tle body with the throttle position switch on the secondary
throttle body, where applicable.
NOTE-
Poor idle quality may be noticeable for a period i f the adapta-
tion settings are not cleared after installing new TPS.
Afaulty ldle speed control valve sets afault code and the MIL
is illuminated when OED II fault criteria are exceeded.
Before checking the idle speed control valve, confirm that the
throttle position sensor is working correctly.
CAUTION-
Be sure ignition is OFFbefore disconnectingor reconnecting
DMEsystem components.
< Disconnect intake air boot from throttle housing. Unbolt throt-
tle body and lay aside. Do not disconnect throttle cable or
electrical harness connectors to throttle body.
NOTE-
For additional worlcing room, unfasten and lift out the com.
plete air filter housing.
connector - Working under intake manifold, disconnect electrical harness
connector from idle speed control valve.
The injectors receive voltage from the ECM relay. The ECM
controls the opening by activating the ground circuit forthe in-
jector valve solenoids. The ECM varies the duration (in milli-
seconds) of "opening" time to regulate the airlfuel ratio.
For a quick check of the injectors, run the engine and touch
each injector with a screwdriver or stethoscope. You should
feel a vibration or hear a buzzing
CAUJ I O G
Be sure ignition is OFFbefore disconnectingor reconnecting
DME system components.
l ~ u einjector
l coil resistance 16R at 20" C (68"F)
CAUTIOG
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in 001 General Warnings and Cau-
tions.
Clamp off fuel supply line and fuel return line at end of fuel
rail. Disconnect fuel supply fuel return lines from fuel rail.
WARNING -
Clamp off the fuel lines and then wrap a clean shop towel
around the lines before removing them. Residual fuelpres-
sure is present in the lines.
Fuel is discharged. Do not disconnect any wires that
could cause electrical sparks. Do not smoke or work
near heaters or other fire hazards. Keep an approved
I fire extinguisher handy. I
- Remove fuel rail mounting fasteners
Tightening torque
Fuel rail to intake manifold 10 Nm (89 in-lb)
Evaporative emissions
1. ECM
2. Purge valve
3. Leak detection pump (LDP) (in
lefl rear wheel housing)
4. Filter
5. Liquid vapor separator
6. Purge canister
7. Fuel tank
NOTE-
Consult an authorized BMW dealer before replacing the
ECM.
CAUTION-
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
-
DISplus, MoDiC, GTI or equivalent:
Code replacement ECM with application information (i.e.
engine code, transmission type, etc.).
Align ECM to EWS (electronic immobilizer).
CAUTION-
a Always wait at least one minute after turning off the ignition
before removing the connector from the ECM. If the con-
nector is removed before this time, residual power in the
system relay may damage the ECM.
Always connect or disconnect the control module con-
nector and meter probes with the ignition off
25 ground Oxygen sensor heater (no. 1 in front of catalytic Oxygen sensor heater ground
converter)
26 input Power supply (terminal 30) Battery voltage (E+) at all times
27 output Idle speed control valve Pulsed ground-open signal (See pin 53)
28 ground Ground Ground
29 output Ignition coil control, cyl. 1 Primary signal, ignition coil 1
30 output Ignition coil control, cyl. 3 Primary signal, ignition coil 3
31 output Ignition coil control, cyl. 5 Primary signal, ignition coil 5
32 ground Ground Ground
33 output Fuel injector control, cyl. 5 Pulsed ground (pulse width in ms), cyl 5
I- I I
35 loutput /Secondary air injection ISecondary air inj. pump relay control
36 /output I Engine speed output IEngine speed signal
37 1- /Not used I
Fuel lniection 1
Table b. Siemens MS 41.1 ECM pin assignments (continued)
Pin lSiqnal
I - 1I Componentlfunction /INotes
40 1I ground
-
/Crankshaft position sensor
I
/crankshaft position sensor control
I
41 1I ground
-
/Camshaft position sensor (CMP)
I
/shielding for CMP sensor
I
42 1 ground I~hrottieposition sensor (TPS) /TPS ground
43 ground Camshaft position sensor (CMP) Camshaft positionlrpm sensor control
44 output Throttle position sensor (TPS) Voltage supply to TPS (5 vdc)
45 output Throttle position sensor (traction control) ABSIASC module
46 output Instrument cluster Instrument cluster, fuel reserve signal
47 Not used
48 outout Crankshaft position sensor (Hall effect) Crankshaft position sensor control
49 input Power supply (terminal 15) Battery voltage with key on or engine running
50 Not used
51 Not used
I I I
52 I ~ oused
t
53 output Idle speed control valve Pulsed ground-close signal (see pin 26)
54 input Power supply Battery voltage from main relay (terminal 87)
55 ground Oxygen sensor heater (no. 2 in front catalytic Oxygen sensor heater ground
converter)
56 ground Ignition circuit Ignition circuit monitoring signal
57 output Knock sensor (cyl. 1-3) Knock sensor
58 input Knock sensor (cyl. 1-3) Knock sensor signal
59 output Knock sensor (cyl4-6) Knock sensor
60 inputloutput Data linic connector (TxD) Diagnostic TxD (transmit) signal to pin 18 in data link
connector
61 ground Oxygen sensor heater (no. 2 behind catalytic Oxygen sensor heater ground
converter)
62 output Secondary air injection Secondary air injection control valve
63 input Knock sensor (cyl. 4-6) Knocic sensor signal
64 input Camshaft positionlrpm sensor Camshaft positionlrpm sensor control
65 input Camshaft positionlrpm sensor Camshaft positionlrpm sensor control
66 Not used
I I I
67 ground Oxygen sensor (no. 1 in front of catalytic Oxygen sensor signal ground
converter)
I I
68 output Evaporative purge valve control Pulse ground with engine at normal temperature with
varying engine load
Fuel pump relay control
/Fuel injection
Fuel Injection
CAUTION-
* The tests in this section may set fault codes (DTCs) in tlie
ECM and illuminate the MIL. After all testing is completed,
access and clear DTC fault memory using an OBD I/ or
BMW compatible scan tool. See OBD On-Board Diag-
nostics.
Only use a dgital multimeter for electrical tests.
Relay positions can vary. Be sure to confirm relayposi-
tion by identifying the wiring in the socket using the wir-
ing diagrams found in ELE Electrical Wiring
Diagrams.
-
NOTE-
OBD I1 fault memory. (including an illuminated MIL! can
only be reset using the special scan tool. Removing the
connector from the ECM or disconnecting the battery will
not erase the fault memory.
The BMW-dedicated 20-pin diagnostic linlc connector
(DLC) is in the right rear of the engine compartment The
20-pin DLC is discontinued on models after 6/2000.
The 1&pin OBD I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.
- Air:
Idle speed valve
Electronic throttle
Hot film mass air flow (MAF) sensor
Resonance-turbulence intake control
- Fuel:
* Fuel supply
Running losseslnon return
Fuel injection
Fuel Injection
- Ignition:
Direct ignition
Knock control
4 Primary1secondary ignition monitoring
- Emissions:
OBD II compliance
Secondary air injection
Pre- and post-catalyst oxygen sensors
0 Electrically heated DME-mapped thermostat
Misfire detection
Evaporative emission control and leak detection
Malfunction indicator light (MIL)
Performance controls:
CONTROL
RESONANCE.
TURBULENCE
----,
VALVE
CRANUSHAFT
SECONDARY AIR
MULTI-FUNCTION
ROLLING CODE
130-26
Fuel Injection
Resonance- turbulence
0021664
-
Fuel Injection
NOTE-
The ECM relay is also referred to as the DME main relay
ECM
Ignition coils
* Fuel injection
Evaporative leak detection pump
NOTE-
Relay locations can vary Confirm relay identification by
matching wiring colors and terminal numbers.
130-28
Fuel Injection
- Reinstall relay and turn ignition on. Gain access to back side
of reiay socket and check for ground at terminal 4.
If ground is present continue testing.
If ground is not present, signal from ECM is missing. Check
wire between ECM and relay.
NOTE-
I f no faults are found during testing but power is not reaching
the ECM or other components, check the fuses in the fuse
carrier X8680 in the E-box.
ECM Relay
4 The hot f ~ l mmass air flow (MAF) sensor sends a varying volt-
age (approx. 0.5 - 4.5 vdc) to the ECM representing the mea-
sured Intake air. The alr mass input signal is produced
electron~cailyuslng an electrically heated metal fllm in the air
flow stream.
If there is no output signal from the MAF sensor, the ECM op-
erates the engine using the throttle position and engine rpm
inputs. A faulty MAF sensor illuminates the MIL.
Fuel Injection
- 3.
If any faults are found, checlc for wiring breaks between
MAF sensor and ECM and between MAF sensor and main
DME relay.
NOTE-
Visually inspect the sensor for damage, missing or blocked
screens. The screens affect air flow calibration. Also inspect
- -
the sealina 0-rinas where the sensor inserts into the air filter
housing and intake boot. Ensure the pin connections are
clean and tight.
CAUTION-
Be sure ignition is OFFbefore disconnectingor reconnecting
DME system components.
NOTE-
The ECT sensor is an NTC (negative temperature coeffi-
cient) type sensor. In other words, as the temperature rises,
resistance through the sensor decreases.
WARNING -
Due to rislc of personal injury, be sure the engine is cold be-
fore removing ECT sensor connector.
CAUTIOI\C
Be sure ignition is OFFbefore disconnectingor reconnecting
DME svstem components.
Tightening torque
Temperature sensor to cylinder head 13 Nm (10 ft-lb)
CAUTION-
Be sure the ignition switch is in the off position before repiac-
ins the intake temperature sensor.
-
- Depress loclting clip on side of temperature sensor and pull
straight out of intake manifold.
NO TE -
The MDIC unit is non-adjustable and must be replaced as
a complete unit if found to be faulty.
i f replacing the MDK unit, the adaptation values stored in
the ECM must be clearedand the new unit initialized using
BMW special service tools.
CAUTION-
If the adaptation process is not completedcorrect& the en-
gine wiii not start.
CAUTION-
Prior to disconnecting the battern read the battely discon-
nection cautions in 001 General Warnings and Cautions.
Fuel lniection I
NOTE-
The EDK unit is non-adjustable and must be replaced as a
complete unit if found to be faulty
I f replacing the EDK unit, the adaptation values stored in
the ECMmust be cleared and the new unit initialized using
BMW special service tools.
CAUTIOIG
I f the adaptation process is not completedcorrectk the en-
qine will not start
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in 001 General Warnings and Cau-
tions.
<
-
Remove complete air filter housing:
Disconnect electrical harness connector on mass air flow
sensor (A).
Disconnect vacuum line at intake boot ( 6 ) .
Loosen intaite air duct clamp (C).
Remove filter housing mounting screws.
Disconnect air duct and lift complete air filter housing and
MAF sensor out of engine compartment, pulling it forward
away from throttle housing.
130-36
[ ~ u eInjection
l
Fuel Injection 1
4 If necessary, disconnect electrical harness connector at fuel
tank venting valve (A). Disconnect hose at quick disconnect
fitting (arrow).
Basic adjustment:
Ensure that at idle (accelerator pedal in rest position) throt-
tle cable has detectable play at throttle lever attaching
point. Play must not exceed maximum allowable.
Adjust by turning knurled adjuster (arrow) on end of throt-
tle cable sheath at throttle housing.
NOTE-
Faulty throttle adjustment values must be reset using the
BMW service tester DISplus, MoDiC, GTI or equivalent.
A faulty idle speed control valve sets a fault code and the MIL
is illuminated when OED II fault criteria are exceeded.
Before checking the idle speed control valve, confirm that the
throttle position sensor is working correctly.
Fuel Injection
CAUTIOIG
Be sure ignition is OFFbefore disconnectingor reconnecting
DME system components.
NOTE-
When installing idle speed control valve, remove intake boot
sealing ring from valve and install into intake air boot. Then
install valve info sealing ring.
MS 42.0 (LDP)
,-a"-
NOTE-
Consult an authorized BMW dealer before replacing the
ECM.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions in 001 General Warnings and Cautions.
Fuel Injection I
Working inside E-box, disconnect ECM harness connector
(arrow) by releasing fastener and pivoting connector up and
off ECM.
CAU T I O W
Be sure ignition is OFF before disconnecting or reconnecting
DME system components.
/ CAUTIOW I
A l ~ a y swait at least one mfnule after turning off the ignition
before remov;ng [he connecror irom rhe ECM. If the con-
nector is removed before this time, residual power in the
system relay may damage the ECM.
Always connect or disconnect the control module con-
nector and meter probes with the ignition off.
I I I
18 llnout IHeater, post-catalyst oxygen
-~
sensor 2 ]Heated oxygen sensor 2 behind cat. conv.
19 input Heater, post-catalyst oxygen sensor 2 Heated oxygen sensor 2 behind cat. conv.
20 Ground Ground, precatalyst oxygen sensor 1 Heated oxygen sensor 1 in front of cat. conv.
21 Ground Ground, precatalyst oxygen sensor 2 Heated oxygen sensor 2 in front of cat. conv.
22 Ground Ground, post catalyst oxygen sensor 1 Heated oxygen sensor 1 behind cat. conv.
23 Input ECM (DME main) relay signal activation ECM
24 Ground Ground, post catalyst oxygen sensor 2 Heated oxygen sensor 2 behind cat. conv.
Connector X60003 52-pin
1 Input Signal, mass air flow sensor Hot film mass air flow sensor
2 Input Signal, exhaust camshaft sensor Camshaft position sensor
3 Not used
I I I
4 loutput l~hrottlevalve supply (MS 42.0) I~hrottlevalve (MS 42)
I I I
5 1 lnput ISignal, intake camshaft position sensor /camshaft position sensor 1
130-43
Fuel Injection ]
Table c. Siemens MS 42.0 and MS 43.0 ECM pin assignments (continued)
Pin Signal Component/function Notes
6 Not used
7 Output Throttle valve supply potentiometer 2 Throttle valve
8 Input Signal, crankshaft position sensor Crankshaft position sensor
9 Input Signal, pedal position sensor 2 (MS 42.0) Throttle valve (MS 42.0)
10 Input Signal, throttle position sensor 1 Throttle valve
11 Not used
I I I
12 llnput IFeedback signal,
- engine start /Starter
I I I
/I13 Input Alternator (generator)
14 Ground Ground, throttle position sensor (MS 42.0) Throttle valve (MS 42.0)
15 Ground Ground, exhaust camshaftsensor I Camshaft position sensor I
16 Input Signal, pedal position sensor 1 (MS 42.0) Throttle valve (MS 42.0)
17 Ground Ground, mass air flow sensor Hot film mass air flow sensor
18 Ground Ground, intake camshaft sensor 1 Camshaft position sensor i
19 Input Signal, throttle potentiometer 1 Throttle valve
20 Ground Ground, throttle position sensor Throttle valve
I I I
21 Ground Ground, crankshaft position sensor Cranltshaft position sensor
22 loutput I ~ i g n a lintake
, air temperature Ilntake air temperature sensor
I 1 - I
23 l~round I ~ r o u n dintaite
, air temperature sensor /Intake air temperature sensor
24 Output Signal, coolant temperature sensor Coolant temperature sensor
25 Ground Ground, coolant temperature sensor Coolant temperature sensor
26 Input Signal, oil pressure Oil pressure switch
27 Output Signal, engine oil temperature sensor Oil temperature sensor
28 Ground Ground, engine oil temperature sensor Oil temperature sensor
29 Output Signal, knock sensor Knoclt sensor
30 Out~ut Signal, knock sensor I<noclt sensor
I I - I
31 Output Signal, knock sensor Knoclt sensor
32 loutput ISignal, ltnock sensor l ~ n o c ksensor
I 1 - I
33 1 input ISignal, cylinder 1 fuel injector /cylinder 1 fuel injector
34 Input Signal, cylinder 2 fuel injector Cylinder 2 fuel injector
35 input Signal, cylinder 3 fuel injector Cylinder 3 fuel injector
36 Input Signal, cylinder 4 fuel injector Cylinder 4 fuel injector
37 Input Signal, cylinder 5 fuel injector Cylinder 5 fuel injector
38 Input Signal, cylinder 6 fuel injector Cylinder 6 fuel injector
39 Inout -
Sianai, oil level sensor Oil level sensor
40 Input Signal. VANOS inlet valve VANOS inlet valve
41 Input Signal. VANOS outlet valve VANOS outlet valve
Fuel Injection
40 Not used
Connector X60005 9-pin
1 Input Signal, ignition coil 3 Ignition coil 3
2 Input Signal, ignition coil 2 Ignition coil 2
3 Input Signal, ignition coil 1 Ignition coil 1
4 Not used
5 Ground Ground Ground connector
6 Ground Ground Ground connector
7 Input Signal, ignition coil 6 Ignition coil 6
8 Input Signal, ignition
. coil 5 lqnition coil 5
I I - I -
9 llnput /signal, ignition coil 4 I Ignition coil 4
130-46
Fuel Injection
CAUTIOiU-
The tests in this section may set fault codes (DTCs) in the
ECM and illuminate the MIL. After ail testing is completed,
access and clear DTC fault memory using an OED I/ or
BMW compatible scan tool. See OBD On-Board Diag-
nostics.
Only use a digital multimeter for electrical tests.
NOTE-
OED I1 fault memory (including an illuminated MIL) can
only be reset using~thespecial scan tool. Removing the
connector from the ECM or disconnecting the battery will
not erase the fault memory.
The BMW-dedicated 20-pin diagnostic link connector
(DLC) is in the right rear of the engine compartment.
The 16-pin OBD I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.
Fuel Injection
CAUTIOI\C
Relay positions can vary. Be sure to confirm relayposition by
identifying the wiring in the socket using the wiring diagrams
in ELE Electrical Wiring Diagrams.
NOTE-
The ECM relay is also referred to as the DME main relay.
* ECM
Ignition coils
Fuel injection
Evaporative leak detection pump (5.2.1 only)
Idle air actuator
Camshaft sensors
Evaporative emissions valve
Hot film mass air flow sensor
Fuel pump relay
Oxygen sensor heaters
NOTE-
Relay locations can vary. C o n h relay identification by
matcliing wiring colors and terminal numbers.
Bosch M5.2 4 Check for voltage at terminal 6 of main relay socket (30-red
wire). On M5.2 cars also check for battery voltage at terminal
ECM relay
8.
1 HoL al ail iirnel XOL a1 ail limes
i--[-----iF109 (BOA) If battery voltage is present, continue testing
electronics :.IL.$. .I:
If battery voltage is not present, check large red wire(s) in
relay socltet. See ELE Electrical Wiring Diagrams.
,
/;is? /control ! ! . ! .L
I lij :module
i
f
....1.: ......
.,A . ; Fuse carrier
!.::..! :engine
electronics
~ ~6 1 ~ ~ ~ ~ . ~ ~ ~ ~ : .
If battery voltage is present, relay has energized and is
. ... . ....... .-,
~ ~ ~ ~ . Engine control
ii~~-~.~~..~
........ module relay functioning correctly.
I;- If battery voltage is not present and all earlier tests are OK,
relay is faulty and should be replaced.
130-51
Fuel Injection
NO JE -
The test given below is not a conclusive test of oxygen sen-
sor efficiency and does not test how the oxygen sensor re-
acts to changing conditions. Pin numbers and wire colors
can vary Always check the wiring diagrams to confirm wire
color and pin assignment.
0 The oxygen sensorconnectorplugs are locatednext to the
catalytic converters.
WARNING -
Exhaust manifolds andpipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
NOJE-
Connector style may vary depending on system application.
Consult wiring diagram for system-specific wiring. See ELE
Electrical Wiring Diagrams.
NOJE-
To check sensor response to lean and rich mixtures, create
an air leak.
NOJE-
The oxygen sensor heater is powered via fusedpositive (+)
battery voltage and a switchedground from the ECM. See
ELE Electrical Wiring Diagrams for specific circuit informa-
tion.
/Fuel lnjeciion
NOJE-
With engine oft disconnect harness connector and checlc
heating element resistance between white wires on the sen-
sor side of harness. If the element is electrically open (no
continuity), replace sensor.
NOJE-
If not already applied, coat oxygen sensor threads w ~ t hanti-
seize compound before installat~on.Do not get the com-
pound on the sensor tip.
Tightening torque
Oxygen sensor to exhaust system 55 Nm (41 ft-lb)
CAU J I O G
Use only a digital multimeter or an LED injector tester when
testing injectors or wiring. Use of an analog VOM or incan-
descent test light may damaqe the engine controlmodule.
4 Remove fuel rail cover. See 110 Engine Removal and in-
stallation.
-
Injector electrical loom removal:
Loosen mounting nuts A.
Remove ground wire C.
Disconnect ignition coil harness D
Fuel Injection I
4 Release spring clips (arrows) from fuel injectors and pull in-
jector electrical loom straight up to remove.
NOTE-
The test given below is an electrical check only. It does not
check the mechanical operation of the valve. I f the valve is
sticking, hanging up or is sluggish in operation, substituting a
Inown good valve is the best way to check it.
Turn on AIC or shift car into drive. ldle should remain steady
or increase slightly.
NOTE-
I f you suspect an intermittent fault, lightly tap the valve while
testing resistance.
NOTE-
The idle speed control valve receivespositive (+) battery volt-
-
age from the ECM (DME main) relay
Fuel Injection
NOTE-
Do not confuse the TPS on the primary throttle housing with
the throttle switch on the ASC secondary throttle housing.
NOTE-
The ECT sensor is an NTC (negative temperature coeff-
cient) type sensor. In other words, as the temperature rises,
resistance through the sensor decreases.
- Unscrew ECT sensor from cylinder head and install new sen-
sor.
Use new copper sealing washers when installing sensor.
Replace any lost coolant.
Tightening torque
ECT sensor to coolant flange 13 Nm ( I 0 it-lb)
Fuel Injection
Vacuum chamber.
Pneumatic pump chamber.
DME activated vacuum solenoid
Reed switch (provides switched voltage feedback signal to
ECM).
The vacuum supply line is in the wiring harness from the en-
gine compartment and runs down the driver's side of the vehi-
cle.
38
I output AIC comuressor relav
Not used
Not used
-
. sianal Heatinq and AIC control module (ground - compressor OFF)
39 1 I Not used
40 input Knock sensor signal Knoclc sensor
41 1I inuut
'
II Knock sensor signal
. I Knock sensor
I
42 input Fuel reserve signal Instrument cluster
43 1I I Not used
I
II
44 input Throttle position sensor signal (0.4-4.2 V) Throttle position sensor
45 1I outout
'
II Hot film mass air flow sensor signal
- .(0-5 V) II Hot film mass air flow sensor
46 1 ground I Heated oxygen sensor signal (voltage 0.1-1.0 V) I Oxygen sensors
47 Not used
48 Not used
49 output Cyl. 1 ignition signal (primary signal) Cyl. 1 ignition coil (RZV adapter)
50 output Cyl. 5 ignition signal (primary signal) Cyi. 5 ignition coil (RZV adapter)
51 output Cyl. 4 ignition signal (primary signal) Cyi. 4ignition coil (RZV adapter)
52 output Cyl. 8 ignition signal (primary signal) Cyl. 8 ignition coil (RZV adapter)
53 output Throttle position sensor (c5 V voltage supply) Throttle position sensor
54 inout Terminal 87 f > 10 V) Fuse F1
I ' I I
55 1I ground
-
I Ignition ground
I
I Ground point
56 input Terminal 15 (> 10 V) ignition switch
-.-
Fuel Injection
20 Not used
21 Not used
22 Not used
23 Output Terminal 85 control Engine control module relay
Fuel lnjection
Fuel Injection
14 1 1 Not used I
15 Not used
16 Not used
17 Output Engine speed signal output (TD) Cruise control module (Tempomat)
18 Not used
19 Not used
20 loutput ICARB signal /Data link connector
I I I
21 Oulput Washer fluid level, brake fluid level Light module
22 llnput I Right rear wheel speed signal /ABS/ASC or ABSIDSC control module
Fuel Injection
CA UTIOI\C
The tests in this section may set fault codes (DTCs) in the
ECM and illuminate the MIL. After all testing is completed,
access and clear DTC fault memory using an OBD I1 or
BMW compatible scan tool. See OBD On-Board Diag-
nostics.
. Only use a digital multimeter for electrical tests.
Relay positions can vary. Be sure to confirm relay posi-
tion by identifying the wiring in the socket using the wir-
ing diagrams found in ELE Electrical Wiring
Diaqrams.
NOTE-
= OBD I1 fault memory (including an illuminated MIL) can
only be reset using the special scan tool. Removing the
connector from the ECM or disconnecting the battery will
not erase the fault memory.
0 The BMW-dedicated 20-pin diagnostic link connector
(DLC) is in the right rear of the engine compartment. The
20-pin DLC was eliminated on models after 6/2000.
The 16-pin OBD I1 diagnostic connector (arrow) is located
inside the car on the lower left dash panel.
130-67
Fuel Injection /
ME 7.2 system overview
The Bosch ME 7.2 system is used on 1999 - 2002 540i mod-
els.
4 The ME 7.2 uses a non-return fuel rail. The fuel pressure reg-
0 ulator is integrated into the fuel filter.
NOTE-
The fuel filter is available as a replacement part without the
fuel pressure regulator. When replacing the fuel filter, trans-
fer the fuel pressure regulator from the old filter to the new fil-
ter.
I iY.,lii,in
Mmn
< The M62 TU engine uses an electrically controlled throttle
valve called EDK. The throttle plate is positioned by a DC
CON,ROL
gear reduction motor based on inputs signals to the ECM
from the pedal position sensor (PWG).
Fuel Injection I
The PWG potentiometers provide DC voltage signals as in-
put to the ME 7.2 control module for throttle and idle control
functions. Potentiometersignal 1 is the primary signal, poten-
tiometer 2 is used for a plausibility cross-check.
1. Potentiometer 1 ground
2. Potentiometer 1 power
3. Potentiometer 2 ground
4. Potentiometer 2 power
5. Potentiometer 1 signal to ECM
6. Potentiometer 2 signal to ECM
If errors are detected between potentiometer 1 and 2, the
ECM calculates the engine intake air mass (from MAFsensor
signal) and only utilizes the potentiometer signal that closely
matches the detected intake air mass. The ECM control mod-
ule uses the air mass signal for a comparative source to pro-
vide fail-safe operation. If the ECM cannot calculate a
plausible conclusion from the monitored potentiometerthe
EDK motor is switched off and fuel injection cut-out is activat-
ed (no fail-safe operation possible).
EDK is continuously monitored during all phases of engine
operation. If faults are detected, the EDK motor is switched off
and fuel injection cut off is activated. The engine continues to
run extremely roughly at idle speed.
EDK adaptation
When the EDK throttle assembly is replaced, the adaptation
values of the previous EDK must be cleared from the ME 7.2
ECM using the BMW service testeroran equivalentscan tool.
Once the old adaptation values have been cleared, the new
EDK assembly should be installed and adapted as follows:
0 Switch ignition OFF for 10 seconds.
* Switch ignition ON. Afler approximately 30 seconds, the
EDK is briefly activated indicating that the replacement unit
is now adapted to the ME 7.2 system.
NOTE-
This EDK adaptation procedure is also necessary after re-
placing the ME 7.2 engine control module. However, the ad-
aptation values do not require clearing since they have not
yet been established.
NOTE-
The ECM relay is also referred to as the DME main relay
130-70
Fuel Injection
--
CAUTION-
Relay positions can vary Be sure to confirm relayposition by
identifying the wiring in the socl(et using the wiring diagrams
in ELE Electrical Wiring Diagrams.
NOTE-
Relay locations can vary Confirm relay identification by
matching wiring colors and terminal numbers.
NOTE-
The ECT sensor is an NTC (negative temperature coeffi-
cient) type sensor. In other words, as the temperature rises,
resistance through the sensor decreases.
I WARNING-
/ Due to risk ofpersonal injury, be sure the engine
- is cold be- I
I fore r e p l a c i n ~ ~ ~ ~ s e n- s o r . I
- Disconnect ECT sensor harness.
- Unscrew ECT sensor from cylinder head and install new sen-
sor.
Use new copper sealing washers when installing sensor.
Replace any lost coolant.
Tightening torque
ECT sensor to coolant flange 13 Nm (10 it-lb)
130-72
Fuel Injection
WARNING-
Exhaustmanifolds and pipes can be hot enough to cause se-
rious burns. Wear suitable heavy gloves and other appropri-
ate protection.
Tightening torque
Oxygen sensor to exhaust system 50 Nm (37 ft-lb)
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.
WARNING -
Fuelmay be expelled underpressure. Do not srnol(e or work
near heaters or other fire hazards. Keep a fire extinguisher
handy. Before disconnectingfuel hoses, wrap a cloth around
fuel hose to absorb anv leakinq fuel. Plug all open fuel lines.
Vacuum chamber.
Pneumatic pump chamber
DME activated vacuum solenoid
Reed switch (provides switched voltage feedback signal to
DME).
The vacuum supply line is in the wiring harness from the en-
gine compartment and runs down the driver's side of the vehi-
cle.
Connector X60003
Pin Type Descriptionlfunction Notes
1 Output Injection signal Cylinder 2 fuel injector valve
2 Output Injection signal Cylinder 3 fuel injector valve
3 Output Signal evaporative emission valve Evaporative emission valve
I 1 - I
4 /output l ~ e m ~ e r a t usignal.
re E-box fan I E-box fan
5 Not used
6 Ground Ground for electronic components Ground connector X6460
7 Output Voltage supply for hot film mass air flow sensor Hot film mass air flow sensor
8 Input Signal EDK (electric throttle actuator) Electric throttle actuator
9 Ground Hot film mass air flow sensor, ground Hot film mass air flow sensor
10 Output Electric throttle actuator Electric throttle actuator, voltage supply
11 Not used
12 Input Voltage signal, terminal 30h Starter
13 Input Alternator D+ (terminal 61) signal Alternator (generator)
14 Output Injection signal Cylinder 7 fuel injection valve
15 Output Injection signal Cylinder 6 fuel injection valve
16 Input VANOS valve, signal VANOS valve, cylinder 5-8
I Fuel Injection
Connector X60003 (continued)
25 Input Ground, electric throttle actuator Electric throttle actuator
26
-
1 Not used
27 Output injection signal Cylinder 8 fuel injection valve
28 Output Injection signal Cylinder 5 fuel injection valve
29 input VANOS valve, signal VANOS valve, cylinders 1-4
30 Not used
31 Output Thermostat characteristic map, signal Characteristic map
32 Input Crankshaft position sensor, signal Crankshaft positionlrpm sensor
33 Not used
I I I
34 input Hot film mass air flow sensor, signal Hot film mass air flow sensor
35 l~round
I
I ~ n o c sensor,
I
k shield 1 ~ n o c sensor
I
k
36
-
jlnput I Knoclc sensor 2, signal 1 Knock sensor
37 input Knock sensor 4, signal Knock sensor
38 Ground Knock sensor, shield Knocic sensor
39 Input Oil level (thermal) Oil level sensor
40 Output Injection, signal Cylinder 4 fuel injection valve
41 Output Injection, signal Cylinder 1 fuel injection valve
42 Innut Electric throttle actuator, signal
. Electric throttle actuator
I ' I I
43 1ln~ut
I
' IElectric throttle actuator, signal (Electric throttle actuator
44 Not used
45 Ground Ground Crankshaft sensor shield
46 Input Crankshaft position sensor, signal Crankshaft positionlrprn sensor
47 Not used
48 Ground Knoclc sensor, shield Knock sensor
49 input Knock sensor 1, signal Knock sensor
50 Input Knock sensor 3, signal Knock sensor
51 Ground Knock sensor, shield Knock sensor
52 Input Secondary air injection pump valve, signal Secondary air injection pump valve
Connector )(GO004
Pin Type Descriptionlsignal type Notes
1 Output Charge indicator signal (terminal 61) Instrument cluster
2 Output Voltage signal, terminal 30h Integrated instrument cluster control
3 Outout Secondam. air .pump
. relay, activation Secondary air injection pump
. relay
I ' I I
~
4 Input Signal, electric (auxiliary) cooling fan, signal Electric (auxiliary) cooling fan
5 I ~ oused
t
Fuel Injection I
Connector X60004 (continued)
8 Input Pedal position sensor (PWG), signal Pedal position sensor
0
9 Output
10 Output Fuel pump relay, activation Fuel pump relay
11 Output Oil pressure indicator Instrument cluster
12 Ground Pedal position sensor (PWG), ground Pedal position sensor
13 Input Pedal position sensor (PWG), signal Pedal position sensor
14 Output Pedal position sensor (PWG), power supply Pedal position sensor
15 Not used
16 Not used
17 Output Engine speed signal output (TD) OED II plug
18 Not used
19 Signal back-up light Integrated instrument cluster control module (IKE)
20 Input DM-TL (diagnostic module, tank leakage)
21 Output Signal oil level sensor Light module
22 input Right rear wheel speed, signal ABSIDSC control module
23 Input Clutch pedal position switch, signal Clutch pedal position switch
24 Input Brake light switch, signal Brake light switch
25 Not used
26 Input Voltage supply, terminal 15 Fuse F14
27 Input Data link, MFL (multi-function steering wheel) Airbag contact coil spring
28 Input Brake light test signal Brake light switch
29 input AJC compressor signal Heating and A/C control module
30 Input DM-TL (diagnostic module, tank leakage)
31 Not used
32 Output Diagnosis signal TxD OBD II plug
33 Input/-output Communication link (EWS) Electronic immobilizer (EWS)
34 Not used
35 Not used
36 Input/-output CAN-BUShiqh
- CAN-Bus link
I I I
37 Input/-output CAN-Bus low CAN-Bus link
38 1 Ground l~round I Coolant outlet temperature sensor
39 llnput lsignal l ~ o o l a noutlet
t temperature sensor
40 /output Istart signal Istarter relay
Connector X60003
Fuel Injection
NOTE-
Fuel filter replacement is covered in 020 Maintenance,
Special tools
Some of the procedures in this group require the use of
special tools.
13 3 010
I( Fuel line clamp
(Tool No. BMW 13 3 010)
Fuel pump
The electric fuel pump is mounted in the fuel tank in tandem
with the right side fuel level sender. The fuel pump delivers
pressurized fuel to the fuel injection system. A pressure regu-
lator maintains system pressure. The quantity of fuel supplied
exceeds demand, so excess fuel returns to the fuel tank via a
return line. See 130 Fuel Injection for more information.
NOTE-
Fuel pump removal procedures are given under Fuel level
sender (right side) and fuel pump, removing and install-
ing.
NOTE-
1997 V-8 models (540i) with Bosch DME M5.2 are not
equipped with an OBD I1 running losses monitoring system.
NOTE -
"3/2-way valve", 'tunning losses valve" and "fuel changeover
valve" are used interchangeably in BMW technical literature.
Fuel Tank and Fuel Pump
WARNING-
* The fuel system is designed to retain pressure even when
the ignition is off. When working with the fuelsystem, loos-
en the fuel lines slowly to allow residual fuel pressure to
dissipate. Avoid spraying fuel. Use shop rags to capture
leaking fuel.
Before beginning any work on the fuel system, place a
fire extinguisher in the vicinity of the work area.
Fuel is highly flammable. When working around fuel, do
not disconnect any wires that could cause electrical
sparks. Do not smoke or worknearheaters or other fire
hazards.
* Always unscrew the fuel tank cap to release pressure
in the tanlc before working on the tank or lines.
When disconnecting a fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
Do not use a work light with an incandescent bulb near
any fuel. Fuel may spray on the hot bulb causing a fire.
0 Make sure the worlc area is properly ventilated.
-
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in 001 General Cautions an4
Warnings.
Before making any electrical tests with the ignition
turned on, disable the ignition system as described in
120 Ignition System. Be sure the battery is discon-
nected when replacing components.
To prevent damage to the ignition system or other DME
components, including the engine control module
(ECM), always connect and disconnect wires and test
equipment with the ignition off.
Cleanlinessis essential when worl~ingwith the fuel sys-
tem. Thoroughly clean the fuel line unions before dis-
connecting any of the lines.
Use only clean tools. Keep removed parts clean and
sealed or covered with a clean, lint-free cloth, especial-
ly if completion of the repair is delayed.
Do not move the car while the fuel system is open.
Avoid using high pressure compressed air to blow out
lines and components. High pressure can rupture inter-
nal seals and gaskets.
Always replace seals, O-rings and hose clamps.
.-- -
/ Fuel Tank and Fuel Pump - .
. -. -- 1
rk-;
I
I
1
I ECM
I
I,._--___.I
31 8
-
gage compartment fuse panel)
CAU T I O G
Relay locations may vary Use care when identifying relays
and making electrical checks at the fuse/relay panel. See
610 Electrical Component Locations for additional re-
lay information.
The fuel pump relay has a 1.5 m d red/violet wire at
terminal 6 in the relay socket. Terminal2 has a 2 . 5 m d
white/blue wire. See ELE Electrical Wiring Diagrams
for additional wiring information.
NOTE-
* The fuel pump will run as soon as the jumper wire Is at-
tached.
Thejumper wire should be 1.5 m d (14 ga.) and include
an in-line fuse holder with a 15A fuse. To avoid fuse/relay
panel damage from repeated connecting and disconnect-
ing, also include a toggle switch in the jumper harness.
- Remove rear seat lower cushion by lifting front edge off left
and right catches.
160-8
I Fuel Tank and Fuel Pump
4Disconnect harness connector from tank sending unit by
sliding connection lock to release connector.
NOTE-
Fuelpump power (+) is supplied through the white/blue wire
Ground (-)is supplied by the brown wire.
CAUTION-
Do not allow the test leads to short to ground.
NOTE-
See 600 Electrical Systern-General for information on elec-
trical tests using a digital multirneter.
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or 45 -
75psi) andmay be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from coming loose underpressure.
CAUTION-
When using the BMWspecial tool, use care when turning the
T-handlein to open the schraeder valve. Screw the handle in
just until the schraeder valve opens. Turning the handle in too
far will damage the schraeder valve.
NOTE-
* The schraeder valve must be opened to the fuel pressure
gauge connection. Either remove the valve using a stan-
dard tire valve removal tool or use the BMW special tool
15 5 220.
* The fuel pressure gauge should have a minimum range of
0 to 5 bar (0to 75 psi).
- For vehicles without the schraeder valve on the fuel rail, at-
tach the fuel pressure gauge in line with the fuel supply line
to the fuel rail.
Fuel Tank and Fuel Pump
4 Disconnect and remove fuel supply line from lefl side of fuel
rail by sliding loclting collar in (arrows) and pulling lines
apart.
NOTE-
* ME2 TU and MS43 vehicles (1999 and later models) use a
non-return fuel line with only one line to the fuel rafl.
BMW uses three styles of fuellfne connections; a one-use
clamp, a locking fitting that uses BMWspeclal tool 16 1 050
to release, and a quick release sleeve (above) that discon-
nects the line when depressed.
WARNING -
-
* Fuel In fuel line is under pressure (approx. 3 5 bar or 45 -
75psi) and may be expelled underpressure.Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any lealiing fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before workina on the tank or lines.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from coming loose underpressure.
NOTE-
The fuel pressure gauge should have a minimum range of 0
to 5 bar (0to 75 psi).
Fuel Tank and Fuel Pump
WARNING-
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or worlc near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines.
CAUTION-
The fuel pump is capable of developing a higherpressure
than that regulatedby the pressure regulator. In the event the
fuel pump checlc valve is faulty (stuck closed), male sure the
I
fuel pressure does not rise above 6.0 bar (87psi). Damage
to the fuel lines or fuel system components could result.
For quick restarts and to avoid vapor lock when the engine is
hot, the fuel injection system retains fuel pressure after the
engine is shut off. This residual pressure is primarily rnain-
tained by the fuel pressure regulator and a checlc valve at the
fuel pump outlet.
..
I Fuel Tank and Fuel Pump I
4 Relieve system pressure and attach afuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing (V-8models).
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines
FUELPUMP
AND FUELLEVELSENDER
E39 models use a two-lobed fuel tank. Each lobe of the tank
has its own fuel level sending unit. Each sender has a float
connected to a variable resistance wipercontact. To equalize
fuel level between the two tank lobes, a siphon pump is in-
stalled in the left lobe.
WARNING-
When removing the fuel level sender or the fuel pump, the
fuel tank should be drained to 1/4 capacity or below as de-
scribed later in this repair group.
NOTE-
The compensating siphon pump maintains the fuel level be-
tween the right and left tank lobes. If fuel level sender resis-
tances are not approximately the same on left and right,
remove the senders and visually inspect the level in each
lobe. If the levels are different, check the siphon pump.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in 001 General Cautions and
Warnings.
WARNING-
Fuel may be spilled. Do not smolce or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may re-
sult if the special tool is not used.
CAUTION-
Do not bend fuel level sender arm.
- To reinstall:
Use new sealing ring at tank collar.
* Align tab of sending unit with matching recess in opening
of tank.
Be sure that fuel line connections point in same direction
as they came out.
Reconnect harness connector and hose.
Fill tank and check for leaks by running engine.
Install access cover and its mounting fasteners.
CAUTIOI\C
After finishing repairs but before starting engine, be sure
there is at least 5 liters (1.5 gallons) of fuel in the tank. The
NOTE-
It is common practice to replace the fuel filter when the fuel
pump unit is replaced. See 020 Maintenance.
Tightening torque
Tank collar locking ring to tank 35 Nm (26lb-ft)
-
-
Expose left side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover
insulation.
Peel back insulation at perforations to expose fuel tank
access cover.
Remove cover to expose electrical harness connector.
WARNING-
Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
/ ~ u eTank
l and Fuel Pump
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may
result if the special tool is not used.
CAUTIOW-
Do not bend fuel level sender arm.
4 Once level sensor unit has been lifted partially out of tank,
disconnect tank siphon hose by pressing tabs (arrows).
- during removal.
Reconnect harness connector.
Fill tank and check for leaks by running engine.
CAUTION-
After finishing repairs but before starting engine, be sure
there is at least 5 liters (1.5gallons) of fuel in tan/(. The fuel
pump will be damaged if run without fuel.
Tightening torque
Tank collar loclting rlng to tanlt 35 Nm (26 lb-ft) -
7
.- A Fuel Tank and Fuel Pump
Siphon pump, removing and installing
The fuel compensating siphon pump equalizes fuel level
between the two fuel tank lobes.
WARNING -
Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.
- Remove left and right fuel level sensors and fuel pump as
described earlier.
4 Once left side level sensor unit has been lifted partially out
of tank, disconnect tank siphon hose by pressing tabs
(arrows).
WARNING-
#Before removing tank, be sure that all hot components,
such as the exhaust system, are completely cooled down.
Fuel may be spilled. Do not smoke or work near heat-
ers or other fire hazards.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in 001 General Warnings a n d Cau-
tions.
- Slide suction hose into filler neck about 130 cm (51 in.), twist-
ing as necessary. Withdraw fuel into storage unit.
-
-
Monitor fuel level reduction in both lobes:
Remove rear seat cushion and access both fuel tank send-
er harness connectors.
Use multimeter to measure resistance at both senders,
Resistance should drop as fuel level drops.
- If siphoning mechanism is faulty, drain left tank lobe sepa-
rately by removing sender cover and pumping fuel directly
out of left lobe.
Fuel Tank and Fuel pump/
CAUTION-
After finishing repairs but before starling engine, be sure
there is at least 5 liters (1.5 gallons) of fuel in tanlc. The fuel
pump will be damagedif run without fuel.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given in 001 General Cautions and
Warnings.
Make sure the car is stable and we/ supported at all times.
Use a professionalautomotive lift orjack stands designedfor
the purpose. A floorjaclc is not adequate support.
4 Working underneath car, pinch off supply and return fuel hos-
es (arrows), then disconnect hoses from rigid metal lines.
CAUTlOI+
The fuelpump will be damaged if run without fuel.
* I f the filler neck has been removed from the body, be
sure to reattach the neck grounding screw (where ap-
plicable). Check electrical resistance between the
ground tab and wheel hub. The resistance should be
no hiaher than 0.6f2
Tightening torques
Fuel tank to body 23 Nm (17 ft-lb)
Hose clamp 8 -13 mm dia. 2 Nm (18 in-lb)
Hose clamp 13 - 16 mm dia. 3 Nm (27 in-lb)
Hose clamp 42 - 48 mm dia. 4 Nm (36 in-lb)
.-
Fuel Tank and Fuel pump(
-
CAU T I O G
Make sure the car is stable and well supported at all times.
Use a professionalautomotive lift orjack stands designedfor
the ouroose. A floor iack is not adequate support
4 Tilt vent tank down and loosen or cut off hose clamps
(arrows). Pull hoses off fittings.
- Release vacuum line loclting clips and remove tank
Tightening torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp 13 - 16 mm dia. 3 Nm (27 in-lb)
Hose clamp 42 - 48 mm dia. 4 Nm (36 in-lb)
Fuel Tank and Fuel Pump 1
Activated carbon canister I fuel tank leak
detection unit (LDP or DMTL),.. removing-
and installing
- Raise rear end of car and support safely.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjack stands designed for
the purpose. A floor jack is not adequate support.
Tightening torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp 13 - 16 rnm dia 3 Nm (27 in-lb)
The fuel injectors are supplied with pressurized fuel, but ex-
cess fuel is diverted to the fuel tank without first passing
through the fuel rail. This prevents the excess fuel from ab-
sorbing heat in the engine compartment, thus lowering the
temperature and amount of vaporization in the fuel tank.
160-25
Fuel Tank and Fuel pump1
CAU T I O W
Male sure the car is stable and well suppodedat all times.
Use a professional automotive lift orjack stands designedfor
the purpose. A floor jack is not adequate support.
WARNING-
Fuel will be spilled. Use shop rags to capture fuelas fuellines
are disconnected. Do not smoke or work near heaters or oth-
er fire hazards.
NOTE-
Install protective cover and seals correctly to keep moisture
and road dirt out of underbody fuel system components.
Tightening torques
Hose clamps 8 - 13 mm dia. 2 Nm (18 in-lb)
Hose clamps 10 - 16 mm dia. 2 Nm (18 in-lb)
Hose clamps 18 mm dia. 3 Nm (27 in-lb)
Hose clamps 42 - 48 mm dia. 4 Nm 136 in-ib)
176 Radiator and Cooling System
Special tools
Special tools are necessaryfor belt-driven fan clutch removal
and also for pressure testing the cooling system.
Coolant pump
A centrifugal coolant pump is mounted to the front of the en-
gine. The belt-driven pump circulates coolant through the
system whenever the engine is running.
Thermostat
Two types of thermostats are used in the cars covered by this
manual. 6-cylinder models built up to 911 998 (M52 engine)
use a conventional mechanical thermostat. All V-8 models
and 6-cylinder models from 911998 use an electrically heated
thermostat.
-
When the vehicle is first started, the ECM activates the elec-
tric fan briefly at 20% of its maximum speed, then switches
off. This is for diagnostic monitoring. The voltage generated
by the fan when it slows down (acting as a generator) must
match the stored rpm values in the fan output stage toconfirm
that the fan is operating correctly.
NOTE-
If the ECMfault memory indicates a cooling fan fault, check
that the fan is not seized and that it spins freely.
When A/C is switched ON, the electric fan is not immedi-
ately turned on.
After the engine is switched OFF the fan may continue to
run at varying speeds for up to 10 minutes, based on cal-
culated catalyst temperature.
.
WARNING -
At normal operating temperature the cooling system is
pressurized. Allow the system to cool as long as possible
before opening (a minimum of one hour), then release the
cap slowly to allow safe release ofpressure.
a Releasing the coolant system pressure lowers the cool-
ant boilingpoint and the coolant may boil suddenly. Use
1 heavy and wear eye and face protection to
guard against scalding.
Use extreme care when draining and disposing of en-
gine coolant. Coolant is poisonous and lethal to hu-
mans andpets. Pets are attracted to coolant because
of its sweet smell and taste. Seek medical attention im-
mediately if coolant is ingested.
CAUTIOG
Avoid adding cold water to the coolant while the engine is
hot or overheated. If it is necessary to add coolant to a hol
system, do so only with the engine running and coolanl
pump turning.
To avoid excess silicate gel precipitation in the cooling
system and loss of cooling capacity, use BMW coolant
or equivalent low silicate antifreeze.
a If oil enters the cooling system, the radiator, expansion
tank and heating circuit must be flushed with cleaning
agent. BMW recommends removal of the radiator and
expansion tank to flush.
When worlcing on the cooling system, cover the alter-
nator to protect it against coolant drips.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in 001 General Warnings
and Cautions.
- Check that radiator fins are not blocked with dirt or debris.
Clean radiator using low-pressure water or compressed air.
Blow outward, from engine side out.
-
-
If cooling system is full of coolant and holds pressure:
Use an appropriate scan tool to interrogate engine control
module (ECM) for radiator fan or DME control circuit faults.
Checlc for loose or worn drive belt.
0 Test for failed thermostat or coolant pump impeller. Some
pumps may be fitted with plastic impellers.
Radiator and Cooling System
WARNING-
At normal operating temperature the cooling system is pres-
surized. Allow the system to cool before opening. Release
the cap slowly to allow safe release ofpressure.
I
0021663
Table a. Cooling system test pressures
Component l ~ e spressure
t
CAUTION-
Exceeding the specified test pressure could damage the ra-
diator or other svstem com~onents.
170-10
I Radiator and Cooling System
Combustion chamber leak test
- If you suspect that combustion chamber pressure is leaking
into the cooling system past the cylinder head gasket, use an
exhaust gas analyzer to test the vapors rising from the cool-
ant at the expansion tank.
CAUTIO&
Use an extension tube above the reservoir neclc to main-
tain distance between the top of the coolant and the gas
analyzer nozzle. The gas analyzer is easily damaged if it is
allowed to inhale liquid coolant.
* While running engine to checlc for causes of overheat-
ing, observe coolant temperature carefully in order to
avoid engine damage.
Thermostat
If the engine overheats or runs too cool and no other cooling
system tests indicate trouble, the thermostat may be faulty.
WARNING -
Allow the cooling system to cool before opening or draining
the cooling system.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjack stands designed for
the purpose. A floor jack is not adequate support.
NOTE-
Be sure radiator bleed screw is loose when filling cooling
system.
Tap water may cause corrosion of radiator, engine and
coolant hoses.
Coolant can be reusedprovided it is clean and less than
two years old. Do not reuse coolant when replacing dam-
aged engine parts.
WARNING -
Allow the cooling system to cool before opening or draining
the cooling system.
I WARNING- 1
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjack stands designed for
I the purpose. A floorjack is not adequate support 1
- Remove splash shield from under engine.
NOTE-
For radiators without drain plug, remove lower hose to drain
radiator.
WARNING -
Coolant is poisonous. It is especially lethal to pets. Clean up
spills immediately and rinse the area with water. If coolant is
ingested, immediately seek medical attention.
170-13
Radiator and Cooling ~ v s t e m l
< V-8 engine bloclc drain plugs (one shown at arrow) are locat-
ed on each side of engine block (exhaust manifold removed
for photo).
NOTE-
Be sure radiator bleed screw is loose when filling cooling
system.
Tap water may cause corrosion of radiator, engine and
coolant hoses.
Coolant can often be reused provided it is clean and less
than two years old. Do not reuse coolant when replacing
damaged engine parts.
Tightening torques
Block drain plug 25 Nm (18 ft-lb)
Radiator drain plug 2 - 3 Nm (18 - 27 in-lb)
Radiator and Cooling System
CAUTIOIG
On late model cars with latent heat pump, do not turn ignition
to ON position.
CAUTlON--
Always use genuine BMW coolant or its equivalent to avoid
the formation of harmful, clogging deposits in the cooling sys-
tem.
Tightening torque
Radiator bleed screw to radiator 2.5 Nm (22 in-lb)
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
Tightening torques
Clutch nut to pump
Without BMW tool 11 5 040 40 Nm (29 ft-lb)
With BMW tool 11 5 040 30 Nm (22 ft-lb)
- Pry out expansion rivets holding air duct. Slide air duct down-
ward to remove.
170-16
I Radiator and Cooling System
- Remove fan and fan shroud mounting fasteners. Slide fan
and fan shroud downward to remove.
WARNING -
Allow the cooling system to cool before opening or draining
the system.
-
-
Installation is reverse of removal, noting the following:
Use new O-ring and gasket(s) when installing thermostat
and housing.
NOTE-
Some thermostats have a direction arrow or vent hole near
the edge. Install the thermostat so that either the arrow or
hole are at the top.
CAUTION-
Be sure to reconnect ground wire@) at thermostat housing
mounting bolt, where applicable.
Radiator and Cooling systeml
Tightening torques
Block drain plug to block 25 Nm (18 it-lb)
Coolant hose clamp (32 - 48 2. 5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator 2-3Nm(l8-27in-lb)
Thermostat housing to cylinder 10 Nm (89 in-lb)
head
I Coolant thermostat housing assmbly- - I 4 The electric map-controlled thermostat is part of the thermo-
stat housing at the front of the cylinder head.
1. Bolts (M6)
2 Bolt (ME)
3. Housing with thermostat
4. Gasket
CAUTION-
Allow cooling system to cool before opening or draining the
system.
4 Lever out retaining clips (arrows) and pull hose fittings off
thermostat housing.
WARNING -
Allow cooling system to cool before opening or draining the
system.
NOTE-
M62 engine: Hose is clamped on.
M62 TU engine: Hose is attached with quick-disconnect fit.
ting. Remove clip to disconnect hose.
170-19
Radiator and Cooling System
-
Installation is reverse of removal, noting the following:
Keep sealing faces clean and free of oil.
Use new sealing gasket.
Fill system with coolant. See Coolant, draining and fill-
i n g (V-8models).
Tightening torques
Block drain plug to block 25 Nm (18 it-lb)
Coolant hose clamp (32 - 48 2. 5 Nm (22 in-lb)
mm hose diameter)
Radiator drain plug to radiator 2 - 3 Nm (18 - 27 In-lb)
Thermostat cover to 10 Nm (89 in-lb)
coolant pump
Coolant pump < The engine coolant pump is mounted in the front of the en-
gine in the timing chain cover.
WARNING-
Allow cooling system to cool before opening or draining sys-
tem.
NOTE-
The coolant pump is mounted on studs and retained by nuts.
.," --
Radiator and Cooling System --- 1
insert two M6 screws (arrows) in tapped bores and tighten
uniformly until pump is free from timing chain cover (thermo-
stat and hoses have been removed for purposes of visual
clarity).
Tightening torques -
Coolant pump to timing chain 10 Nm (89in-lb)
cover
Coolant pump pulley to coolant 10 Nm (89 in-lb
pump
Engine block drain plug to block 25 Nm (18 It-lb)
1. Thermostat housing
2. Thermostat
3. Thermostat sealing O-ring
4. Water pump
5. Water pump gasket
NOTE-
Mark direction of drive belt rotation i f reusing belt,
NOTE-
* The coolant pump is retained to the block using different
length bolts.
0 Bolts A: M6 X 105 mm
0 Bolts 8: M6 X 35 mm
Tightening torques
Coolant pump to timing chain 10 Nm (89 in-lb)
cover
Coolant pump pulley to coolant 10 Nm (89 in-lb
pump
Engine blocic drain plug to block 25 Nm (18 ft-lb)
Radiator drain plug to radiator 2-3Nm(18-27in-lb)
Thermostat cover to coolant 10 Nm (89 in-lb)
pump assembly
WARNING -
Make sure the car is stable and well supported at aN times.
Use a professional automotive liff orjaclc stands designed for
WARNING -
Allow cooling system to cool before opening or draining sys-
tem.
4 Pry out expansion rivets (A) on left and right side of fan
shroud. Loosen hose clamp (6) and remove hose from ex-
pansion tank.
NOTE-
The radiator cooling fan nut (32 mrn wrench) has left-hand
threads.
NOTE -
Later models use retaining clips to fasten coolant hoses to
expansion tank and radiator.
- Slide right side of radiator back toward engine and pull radi-
ator up to remove.
Tightening torques
Engine block drain plug to block 25 Nm (18 it-lb)
Radiator drain plug to radiator 2 - 3 Nm (18 - 27 in-ib)
WARNING-
Make sure the car is stable and well supportedat all times.
Use a professionalautomotive /iff orjacltstands designed for
the purpose. A floorjacl~is not adequate support.
I WARNING-
I Allow cooling system to cool before opening or draining sys-
tem.
170-25
Radiator and Cooling system]
WARNING -
The exhaust system and catalytic converter operate at
very high temperatures. Allow components to cool before
servicing. Wear protective clothing to prevent burns.
Do not use flammable chemicals near a hot cataiyiic
converter.
Corroded exhaust system components crumble easily
and often have exposed sharp edges. To avoid injury,
wear eye protection and heavy gloves when working
WARNING-
Exhaust gases are colorless, odorless, and very toxic. Run
the engine only in a well-ventilatedarea. Immediately repair
any leaks in the exhaust system or structural damage to the
car body that might allow exhaust gases to enter the passen-
ger compartment.
CAUTION-
Use care not to drag or bang oxygen sensors. Oxygen sen-
sors can be easily ruined.
... .
Exhaust System
- With exhaust system fully cold, raise and support car for ac-
cess to exhaust system.
WARNING-
Do not worlc under a lifted car unless it is solidly supportedon
jack stands designed for that purpose. Never work under a
car that is supported solely by a jack.
NOTE-
I f the catalytic converterlfront exhaust pipe assembly is to be
replaced, transfer the oxygen sensors to the new pipe(s).
Tightening torque
Oxygen sensor 55 Nm (41 ft-lb)
NOTE-
Where applicable, tighten front pipe with semi-flexible com-
pensator last when installing front pipe to manifolds.
Tightening torques
Exhaust manifoldsto cylinder head 22 Nm (17 It-lb)
Front exhaust pipe to manifolds 30 Nm (22 ft-lb)
Muffler, replacing
BMW offers individual mufflers as replacement parts for the
original one-piece assembly. Replacement of a rear muffler
may be possible with the system installed on the car. Re-
placement of the front or middle muffler should only be done
with the exhaust removed from the car.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work under a lined car unless it is solidly supported on
jack stands designed for that purpose. Never work under a
car that is supported solely by a jack.
NOTE-
On cars with oxygen sensors mounted in the exhaust mani-
folds, use care when removing manifolds. To be safe, remove
the sensors from the manifolds before removing manifolds.
Tightening torque
Exhaust manifolds to cylinder head 20 Nm (15 ft-lb)
180-6
Exhaust System
I Exhaust manifolds with converters I 4 The exhaust manifolds incorporate the catalytic converters.
Two precatalyst and two post-catalyst oxygen sensors are
mounted in the exhaust manifold assembly.
With exhaust system cold, raise and support car for access
to exhaust system.
WARNING-
Do not worlc undera liftedcar unless it is solidly supported on
jack stands designed for that purpose. Never worlc under a
car that is supported solely by a jaclc.
-
in order to avoid damaging oxygen sensors:
Detach oxygen sensor harness connectors,
Remove oxygen sensors from exhaust manifolds as de-
scribed later in this group.
CAU T I O G -
Take care tliat the front and rear oxygen sensor connectors
are not mixed up.
NOTE-
The front exhaust manifold must be removed before the rear
manifold.
Tightening torques
Exhaust manifold to cylinder head 20 Nm (15 ft-lb)
Front exhaust pipe to manifold 30 Nm (22 ft-lb)
Oxygen sensor to manifold 50 Nrn (37 ft-lb)
NOTE-
Access to manifolds is extremely limited. I f removing exhaust
manifolds as part of additional engine worlc (such as cylinder
head removal), it may be easier to first remove engine.
- With exhaust system cold, raise and support car for access
to exhaust system.
WARNING -
Do not work undera lifted car unless it is solidly supported on
jaclt stands designedfor the purpose. Never worlc undera car
that is supportedsolely by a jack.
NOTE-
The supports on special tool 00 0 208 must rest on the
screws on the fenders.
Exhaust System
WARNING-
Allow components to cool before servicing.
NOTE-
In photo, secondary air pump has been removed for clarity.
Tightening
- - torque
.
WARNING-
Allow components to cool before servicing
CAUTlOI\C
Label connectors so that front and rear connectors are not
mixed up.
Tightening torque
Oxygen sensor to manifold 50 Nm (37 ft-lb)
I WARNING- I
I Allow components to cool before servicing. I
Using BMW scan tool DlSplus or equivalent, read out and
clear ECM fault codes.
Tightening torque
Oxvaen sensor to manifold 50 Nm (37 it-lb)
Exhaust System
M52 engine
(5281 1997-1 998)
1. Exhaust manifolds
2. Sealing washer
3. Plug
4. Gasket (manifold to cylinder
head)
5. Clamping sleeve
6. Post-catalytic converter oxygen
sensor
7. Pre-catalytic converter oxygen
sensor
8. Hanger
9. Rear muffler
10. Vibration dampener
11. Center support bracket
12. Clamping sleeve
13. Front pipe with catalytic
converters
14. Hanger
15. Center muffler
16. Gasket (front pipe to manifold)
I Exhaust System
M52 TU and M54 engines
(528i 1999-2000
and 525i 2001-2003)
1. Transmission bracket
2. Center support bracket
3. Front muffler
4. Clamping sleeve
5. Vibration dampener
6. Hanger
7. Rear muffler
8. Hanger
9. Center muffler
10. Oxygen sensors, post-catalytic
converter
11. Oxygen sensors, pre-catalytic
converter
12. Exhaust manifoldlcatalytic
converter assemblies
Exhaust systeml
M54 engine
(5301 2001-2003)
Clamping sleeve
Front muffler
Rear muffler
Hanger
Vibration dampener
Clamping sleeve
Center muffler
Hanger
Gasket (front pipe to manifold)
10. Exhaust manifold/catalytic
converter assemblies
11. Oxygen sensors, post-catalytic
converter
12. Oxygen sensors, pre-catalytic
converter
I Exhaust System
M62 engine
(540i 1997-1 998)
1. Right side catalytic converters
2. Support bracket
3. Support bracket
4. Center muffler
5. Hanger
6. Rear muffler
7. Clamping sleeve
8. Oxygen sensors, post-catalytic
converter
9. Oxygen sensors, pre-catalytic
converter
10. Left side catalytic converter
11. Sealing rings
12. Left front exhaust manifold
13. Left rear exhaust manifold
14. Gasket
15. Exhaust manifold, right front
16. Exhaust manifold, right rear
Exhaust systeml
M62 TU engine
(540i 1999-2003)
1. Oxygen sensors, pre-catalytic
converter (2)
2. Oxygen sensors, post-catalytic
converter (2)
3. Hanger
4. Rear muffler
5. Clamping sleeve
6. Hanger
7 . Center muffler
8. Clamping sleeve
9. Catalytic converter, left side
10. Catalytic converter, right side
11. Exhaust manifoldlcatalytic
converter, left side
12. Gasket (2)
13. Gasket (2)
14. Exhaust manifoldlcatalytic
converter, right side
200 Transmission-Genera!
Drivetrain
BMW E39 models are equipped with a longitudinal drivetrain.
The transmission is bolted directly to the rear of the engine. A
driveshaft connects the output shaft of the transmission to the
rear final drive. Individual drive axles with integrated constant
velocity joints transfer rotational power from the final drive
unit to the rear wheels.
CAUTION--
If in doubt as to the type of fluid installedin a particular trans-
mission, consult an authorizedBMW dealer service depari-
ment for the latest in operating fluids.
210 Clutch
NOTE-
See 200 Transmission-General for transmission applica-
tion information.
Special tools
Some special tools and techniques are required for clutch re-
pairs. Be sure to read a procedure through before beginning a
job.
1 1 11 2350
< pilot bearing instaation tool
(Tool No. 11 2 350)
4 Tom T60 socket for V-8 flywheel bolt removal
(Tool No. 11 4 180)
NOTE-
The clutch hydraulic system shares the fluid reservoir and flu-
id with the brake hydraulic system.
CAUTION-
* Do not exceed 2 bar (29 psi) pressure at the fluid resenfoil
when bleeding or flushing the hydraulic system.
Brake fluid is poisonous, highly corrosive and danger-
ous to the environment. Wear safety glasses and rub-
bergloves when working with brake fluid. Do not siphon
brale fluid with your mouth. Immediately clean away
any fluid spilled on painted surfaces and wash with wa-
ter, as brale fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container. Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the clutch and
brake hydraulic systems, ;nd will also lower the brake
fluid boiling point. Dispose of brale fluid properly.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjackstands designed for
the purpose. A floor iack is not adequate support.
CR* .,,,
.rP,ll,h.:I,,~,~mn.lI","i,,i"
210-6
1 Clutch
Hydraulic system, bleeding
(using BMW special tool 21 5 030)
CAUTION-
Do not remove tool i f hydraulic system is pressurized.
Tightening torque
Slave cylinder to transmission case 22 Nm (16 ft-lb)
4 Remove hydraulic line locking clip (1) and pull line (2) off
master cylinder.
.
CAUTION-
To prevent brake fluidspill, wrap clutch master cylinder with
shop rags when removing hydraulic fluid lines from master
cylinder.
* Brake fluid damages paint andstains carpets. Clean off
any brake fluid on or in the car immediately.
CAUTlON-
Switch module must snap firmly into place on the master cyl-
inder during installation.
Tightening torques
Clutch master cylinder to pedal cluster 10 Nm (89in-lb)
Fluid line to master cylinder or slave cylinder 17 Nm (13 ft-lb)
- Pinch off brake fluid supply hose to clutch master cylinder us-
ing BMW special tool 13 3 010 or equivalent hose clamping
tool.
- Raise and safely support vehicle
WARNING-
Make sure the car is stable and well supporied at all times.
Use a professional automotive /iff orjack stands designedfor
the ournose. A floor jack is not adeouate suooort.
-
Tightening- toraues
.
Clutch slave cylinder to transmission 22 Nm (16 R-lb)
Fluid line to slave cylinder 17 Nm (13 ft-lb)
Clutch variations
Two versions of the clutch are used:
WARNING-
The clutch disc contains asbestos. Inhaling or ingesting as-
bestos dust can cause severe health problems. Always wear
an approvedrespiratorandprotective clothing when handling
components containing asbestos. Do not use compressed
air to clean components. Do not grind, heat, weld, or sand on
or near anv asbestos materials.
CAUTION--
On S6S 420G transmission, always replace release bearing
ball stud and retainer spring.
Tightening torque
Flywheel to cranltshaft
(use new self-locking bolts) 120 Nm (89 ft-lb)
- Use BMW special tool 11 4 180 (Ton. T60)to loosen and re-
move flywheel mounting bolts. Remove flywheel.
Dowel sleeve I < When installing dual-rnass flywheel, position dowel sleeve
next to two locating notches (arrows).
Tightening torque
Flywheel to crankshaft 105 Nm (77 ft-lb)
CAUTIOI\C
Do not reinstall flywheel bolls with LoctiteCTJor similar thread
locl~ing
compound.
CAUTIOG
Avoidcontaminating clutch friction surfaces with oilorgrease.
Do not touch these surfaces.
CAUTIOG
Be sure clutch disc is facing the correct way The disc should
Dual mass
flywheel - be marked 'kngine side" or "transmission side':
Tightening torques
Clutch to flywheel
. M8 (8.8 grade) 24 Nrn (18 ft-lb)
- M8 (10.9 grade) 34 Nrn (25 ft-lb)
CAUTION-
Do not grease release bearingguide sleeve. If guide sleeve
is greased, release bearing may stick to it.
Transmission to engine
MB (Torx) 22 Nm (16 fl-lb)
MlO(Torx) 43 Nm (32 fl-lb)
CAUTION-
Avoidcontaminating clutch friction surfaces with oilorgrease.
Do not touch these surfaces.
CAUTION-
Be sure clutch disc is facing the correct way The disc should
be marked "engine side" or "transmission side':
The large bolt in the clutch disc centering tool is used to in-
stalland remove the tool only. Once the disc is in place on the
eel, remove the bolt to male room for tlie SACpressure
210-18
Clutch
Tightening torques
Clutch to flywheel
- M8 (8.8 grade) 24 Nm (18 it-lb)
MB 110.9 orade) 34 Nm (25 ft-lb)
NOTE-
The spring lockplate may make snapping noises while being
unscrewed.
CAUTIOG
Do not grease guide sleeve. Ifguide sleeve is greased, re-
lease bearing may stick to it.
Tightening torques -
Transmlsslon to engine
-
-
. MB (Torx) 22 Nm (16 it-lb)
MI0 (Torx) 43 Nm (32 it-lb)
* M12 (Torx) 72 Nm (53 it-lb)
.-
Clutch
CAUTIOI\C
Avoidcontaminating clutch friction suifaces with oilorgrease.
Do not touch these suifaces.
CAUTION--
Be sure clutch disc is lacing the correct way The disc should
be marked 'kngine side" or 'Transmission side':
NOTE-
The large bolt in the clutch disc centering tool is used to in-
stalland remove the tool only Once the disc is in place on tlie
flywheel, remove the bolt to male room for the SACpressure
plate.
1 Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or 11 2 070 (V-8 model).
Tightening torques
Clutch to flywheel
- M8 (8.8 grade) 24 Nm (18 ft-ib)
M8 (10.9 grade) 34 Nm (25 ft-lb)
CAU T I O G
Do not grease guide sleeve. If guide sleeve is greased, re-
lease bearing may stick to it.
Tightening torques
Transmission to engine
- ME (Torx) 22 Nm (16 ft-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
. M12 (Torx) 72 Nm (53 it-lb)
Self-adjusting clutch (SAC), breaking in
With normal driving, 800 to 1000 gearshifts are required to
break in the clutch.
Tightening torques
Clutch slave cylinder to transmission case 22 Nm (16 It-lb)
Clutch master cylinder to pedal cluster 10 Nm (89 in-lb)
Bralte fluid line to clutch master or slave cylinder 17 Nm (13 ft-lb)
Transmission to engine
M8 (Torx) 22 Nm (16 fl-lb)
. M1O (Torx) 43 Nm (32 ft-lb)
MI2 (Torx) 72 Nm (53 it-lb)
Flywheel to crankshaft
6 cylinder engine (use new self-loclting bolts) 105 Nm (77 ft-lb)
V-8 engine 105 Nm (77 ft-lb)
Clutch to flywheel
M8 (8.8 grade) 24 Nm (18 ft-lb)
M8 (10.9 grade) 34 Nm (25 ft-lb)