1998 BMW 528i Air

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01 0-2
General
This section is intended to help the do-it-yourselfer get start-
ed. Tips on workshop practices, basic tools, and a quick refer-
ence guide to emergencies can be found here.
WARNING-
Do not use this manual unless you are familiar with basic
automotive repair procedures and safe workshop
practices.
0 This manual illustrates the worl quired for most service work; it is not a substitute for full
and up-to-date information from the vehicle manufac-
turer or for proper training as an automotive technician.
Note that it is not possible to anticipate all of the ways
or conditions under which vehicles may be serviced or
to provide cautions as to all of the possible hazards that
may result.
MOW TO USE THIS MANUAL
WARNING -
Your common sense and goodjudgement are crucial to safe
and successful service
work. Read procedures through be-
fore starting them. Think about whether the condition of your
cac your level of mechanical skill, or pour level of reading
comprehension might result in or contribute in some way to
an occurrence that might cause you injury, damage your car;
or result in an unsafe repair. If you have doubts for these or
other reasons about your ability to perform safe repair work
on your car; have the work done at an authorized
BMW deal-
er or other qualified shop.
The manual is divided into ten sections:
0 GENERAL, MAINTENANCE
0 I ENGINE
2 TRANSMISSION
3 SUSPENSION, STEERING AND BRAKES
4 BODY
5 BODY EQUIPMENT
6 ELECTRICAL SYSTEM
7 EQUIPMENT AND ACCESSORIES
- ELE ELECTRICAL WIRING DIAGRAMS
OBD ON-BOARD DIAGNOSTICS

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General
0 GENERAL, MAINTENANCE covers general vehicle infor-
mation
(010 General) as well as the recommended mainte-
nance schedules and service procedures to perform BMW
scheduled maintenance
work (020 Maintenance).
The next seven sections
(1 through 7) are repair based and
organized by three digit repair groups. Most major sections
begin with a GENERAL repair group,
e.g. 100 Engine-Gen-
eral. These "00 (double zero) groups contain descriptive the-
ory of operation and system troubleshooting information. The
remainder of the repair groups within a section contain the
service and repair information. The last two sections contain
detailed electrical wiring schematics and OBD
II scan tool and
diagnostic information.
Warnings, cautions and notes
Throughout this manual are many passages with the head-
ings WARNING, CAUTION, or NOTE. These very important
headings have different meanings.
WARNING-
The text under this heading warns of unsafe practices that
are very
likely to cause injury, either by direct threat to the per-
son(~) performing the work
orby increasedrisl( of accident or
mechanical failure while
drivinq.
CAUTION-
A CAUTION calls attention to importantprecautions to be ob-
senfed during the repair work that will help prevent acciden-
tally damaging the car or its parts.
NOTE-
A NOTE contains helpful information, tips that will help in do-
ing a betterjob and completing it more easily.
Please read every WARNING, CAUTION, AND NOTE in
001
General Warnings and Cautions and as they appear in re-
pair procedures. They are very important. Read them before
you begin any maintenance or repair job.

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

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General
Much of the necessary maintenance and minor repairthat an
automobile will need can be done with ordinary tools. Below
you'll find important information on how to work safely, a dis-
cussion of what tools will be needed and how to use them.
Safety
Although an automobile presents many hazards, common
sense and good equipment can help ensure safety. Many ac-
cidents happen because of carelessness. Pay attention and
stick to the safety rules in this manual.
Lifting the car
4 The proper jacking points should be used to raise the car
safely and avoid damage. The
jack supplied with the car can
only be used at the four side points (arrows) just behind the
front wheels or just in front of the rear wheels.
WARNING-
. Never work under a lifted car unless it is solidly supported
on
jack stands that are intended for that purpose.
When raising the car using a floorjack or hydraulic lift,
carefully position the jack pad to prevent damaging the
car body.
* Watch the jack closely. Male sure it stays stable and
does not shift or tilt.
As the car is raised, it may roll
sliahtlv and the
jack mav shift.
Raising car
- Park car on flat, level surface.
- If changing a tire, loosen lug bolts before raising car. See
Changing
a tire.
Place jack into position.
Malte sure jack is resting on flat, sol-
id surface. Use a board or other support to provide a firm sur-
face for jack, it necessary.
- Raise car slowly while constantly checking position of jack
and car.
- Once car is raised, bloclc wheel that is opposite and farthest
from jack to prevent car from unexpectedly rolling.

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

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General Tightening fasteners
When tightening the bolts ornuts on acomponent, it is always
good practice to tighten the bolts gradually and evenly to
avoid misalignment or over-stressing any one portion of the
component. For components sealed with gaskets, this meth-
od helps to ensure that the
gasket will seal properly.
WARNING
-
Table a: General bolt tightening torques in Nm (max.
permissible) is
a general reference only The values listedin
the table are not intended to be usedas a substitute for tor-
ques specifically called out in the text or in manufacturer's in-
formation.
4 Where there are several fasteners, tighten them in a se-
NOTE-
* Metric bolt classes or grades are rnarlced on the bolt head.
* Do not confuse wrench size with bolt diameter. Fora listing
of the common wrenches used on various bolt
diameters,
see Basic tool requirements.
2 BOO~FNG
quence alternating between opposite sides of the compo-
nent. Repeat the sequence until all the bolts are evenly
tightened to the proper specification.
For some repairs a specific tightening sequence is
neces-
sary, or particular order of assembly is required. Such special
conditions are noted in the text, and the necessary sequence
is described or illustrated. Where no specific torque is listed,
Table
a: General bolt tightening torques in Nm (max. per-
missible) can be used as a general guide for tightening fas-
teners.

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01 0-1 0
General
Electrical testing
Many electrical problems can be understood and solved with
only a little fundamental knowledge of how electrical circuits
function.
Electrical current
only flows in a complete circuit. To operate.
every electrical device in the car requires a complete circuit
including a voltage source and a path to ground. The positive
(+) side of the battery is the original voltage source, and
ground is any return path to the negative
(-) side of the bat-
tery, whether through the wiring harness or the car body. Ex-
cept for portions of the charging system, all electrical current
in the car is direct current (DC) and flows from positive
(+) to
negative
(-).
4 Switches are used to turn components on or off by complet-
ing or interrupting the circuit.
A switch is "open" when the cir-
cuit is interrupted, and "closed" when the circuit is completed.
See
600 Electrical System-General for electrical trouble-
(LW, 1 shooting
Wire repairs
Light bulb
(consumer) ' - Repairs to a wiring harness require special care to make the
repair permanent. The wire ends must be clean.
if frayed or
Car body otherwise damaged, cut off the end and remove enough insu- (ground) i Battery lation to complete the repair. if the wire is too short, splice in a BOZLiEL new piece of wire of the same size and make two connec-
tions.
Use connectors that are designed for the purpose. Crimped
on orsoldered-on connectors are best. Crimp connectors and
special crimping pliers are widely available. If soldering, use
needle nose pliers to hold the wire near the solder joint and
create a "heat dam". This keeps the heat and the solder from
traveling up the wire. Always use a solder made specifically
for electrical
work (rosin core).
NOJE-
Twisting wires together to make a repair is not recommend-
ed. Corrosion and vibration will eventually spoil the connec-
tion and may lead to irreparable damage to sensitive
electronic components.
Insulate the finished connection. Electronics stores can sup-
ply heat-shrinkable insulating tubing that can be placed on to
the wire before connecting, slid over the finished joint, and
shrunic to a tight fit with a heat gun or hair dryer. The next best
alternative is electrical tape. Make sure the wire is clean and
free of
solder flux or other contamination. Wrap the joint tight-
ly to seal out moisture. See
600 Electrical System-General
for more information.

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- - ..
General
Many of the maintenance and repair tasks in this manual call
forthe installation of new parts, orthe use of new gaskets and
other materials when reinstalling parts. Most often, the parts
that will be needed should be on hand before beginning the
job. Read the introductorytext and the complete procedure
to
determine which parts will be needed.
NOTE-
For some biggerjobs, partial disassembly and inspection is
required to determine a complete parts list. Read the proce-
dure carefully and, if necessary, male other arrangements to
get the necessary parts while your car is disassembled.
Genuine BMW parts
Genuine BMW replacement parts from an authorized BMW
dealer are designed and manufactured to the same high stan-
dards as the original parts. They will be the correct material.
manufactured to same specifications, and guaranteed to fit
and work as intended. Most genuine BMW parts carry a limit-
ed warranty.
Many independent repair shops make a point of using genu-
ine
BMW parts, even though they may at times be more ex-
pensive than parts from other sources. They know the value
of doing the job right with ihe right parts. Parts from other
sources can be as good as BMW parts, particularly if manu-
factured by one of
BMW's or~ginal equipment suppliers, but it
is often difficult to know.
BMW is constantly updating and improving their cars, often
malting improvements during a given model year. BMW may
recommend a newer, improved part as a replacement, and
your authorized dealer's parts department will know about it
and provide it. The BMW parts organization is best equipped
to deal with your BMW parts needs.
Non returnable parts
Some parts cannot be returned, even for credit. The best ex-
ample is electrical parts, which are almost universally consid-
ered non returnable. Buy electrical parts carefully, and be as
sure as possible that a replacement is needed, especially for
expensive parts such as electronic control units. It may be
wise to let an authorized BMW dealer or other qualified shop
confirm your diagnosis before replacing an expensive non re-
turnable
Dart.