1998 BMW 528i fan clutch

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11 7-66
I Camshaft Timing Chain
4 install cylinder head cover:
Check for correct seating of half-moon seals
(A) in back of
cylinder head cover.
Use a small amount of Three Bond
1209 8 or equivalent
sealant at corners
(B) of half-moon cutouts. Seal corners
in front of cylinder head at VANOS control unit.
Tightening torque
Cylinder head cover to cylinder head
10 Nm (89 in-lb)
- Remainder of reassembly is reverse of removal, noting the
following:
Secure all coolant hoses, thermostat housing, engine cool-
ant drains.
Install new engine oil filter and oil. See
119 Lubrication
System.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling system.
Use scan tool to check VANOS operation with engine
idling.
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 41 0 Nm
(300 ft-ib)
TIMING CHAIN
(M62 ENGINE TO 911998)
Timing chains, removing
(M62 engine to 911 998)
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 BMW service tools are needed for this procedure.
Read the procedure through before beginning the job. If the
camshafts are notproperly timed, the pistons can contact the
valves.

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121-16
Battery, Starter, Alternator
- installation is reverse of removal.
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
11 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)
Alternator, removing and installing
(M62 engine, air cooled)
A replacement alternator should have the same rating as the
original. Alternator manufacturer and ampere rating are nor-
mally
marked on the alternator housing.
- Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions
001 General Warnings and 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.
Disconnect positive
(+) lead from jump start post (arrow).
Raise car and support in a safe manner.
WARNING-
Make sure the car is stable and well supported at aN times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floorjack is not adequate support.

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121-17
Bauery, Starter, Alternator
- Remove engine splash shield from underneath car.
Working underneath car at rear of alternator, loosen alterna-
tor air cooling duct clamp
(arrow) and remove duct.
Remove three alternator mounting fasteners
(arrows)
Pull alternator forward and disconnect wiring from rear of
alternator.
Release clip retaining wiring harness to alternator.
Rotate alternator forward and then up and out of engine com-
partment, using care to not damage radiator.
CAUTIOe
Protect radiator with heavy cardboard or sheet metal.
Installation is reverse of removal,
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

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Battery, Starter, Alternator
- Installation is reverse of removal, noting the following:
Replace alternator rubber sealing O-ring.
* Fill and bleed cooling system as described in 170 Radiator
and Cooling System.
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.
If starter turns engine slowly when ignition is in start position:
Check battery state of charge.
Inspect starter wires, terminals, and ground
connectlons
for good contact. In particular, make sure ground connec-
tions between battery, body and
englne are completely
clean and tight.
If no faults are found, starter may be faulty and should be
replaced.
- If starter fails to operate, check EWS (drive-away protection
system). Try another ignition key.
If no faults can be found,
have the EWS system checked using
BMW scan tool equip-
ment.
Checkclutch pedal operated
starter lock-out switch or gear
position switch (automatic).
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.

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176 Radiator and Cooling System
General ........................... .I7 0.2
Special tools
........................ .I7 0.2
Cooling system overview
(M52 TU shown. others similar) ......... .I7 0.3
Coolant pump
....................... .I7 0.3
Thermostat
......................... .I7 0.3
Mechanical thermostat (M52 engine)
..... .I7 0.4
Electrically heated thermostat
.......... .I7 0.4
Radiator and expansion tank
........... .I7 0.4
Mechanical cooling fan with viscous clutch
.I7 0.4
Electric (auxiliary) cooling fan ........... .I7 0.4
Transmission fluid heat exchanger
....... .I7 0.5
Warnings and cautions
................ .I7 0.7
Troubleshooting ................... .I7 0.7
Cooling system inspection
............. .I7 0.8
Cooling system pressure test
........... .I7 0.9
Combustion chamber leak test
......... .I7 0.10
Thermostat
........................ .I7 0.1 0
Cooling System Service ........... 170-10
Coolant. draining and filling
(6-cylinder models)
.................. 170-1 0
Coolant. draining and filling (V-8 models)
. 170-12
Cooling system. bleeding
............. 170-14
Mechanical (viscous clutch) cooling fan.
removing and installing
............... 170-14
Electric cooling fan.
removing and installing
............... 170-15
Thermostat. removing and installing
(M52engine) ....................... 170-16
Thermostat. removing and installing
(M52 TU or M54 engine) .............. 170-17
Thermostat. removing and installing (V-8 models)
....................... 170-1 8
Coolant pump. replacing (6-cylinder models)
.................. 170-1 9
Coolant pump. replacing (V-8 models) ... 170-20
Radiator. removing and installing
....... 170-22
Expansion tank. removing and
installing . . 170-24

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I Radiator and Cooling System
This section covers component repair information for the en-
gine cooling system.
Heater core replacement is covered in
640 Heating and Air
Conditioning.
Special tools
Special tools are necessaryfor belt-driven fan clutch removal
and also for pressure testing the cooling system.
4 Cooling fan counterhold wrench
(Tool No. BMW
11 5 030)
4 Cooling fan wrench
(Tool No. BMW
11 5 040)
< Expansion tank cap test adaptor
(Tool No.
BMW 17 0 007)
17 0 002 4 Cooling system pressure tester set
1 17 o 005 (Tool No. BMW 17 0 OOZi17 0 005)

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-
I Radiator and Cooling System
Mechanical thermostat
(M52 engine)
4 The mechanical thermostat relies on coolant temperature to
operate. While coolant is cold, it remains closed, and circu-
lating coolant bypasses the radiator for rapid engine warm
up. At higher coolant temperature, the thermostat progres-
sively opens to allow coolant flow through the radiator, thus
controlling engine temperature. Port
A restricts coolant flow
from radiator, and port
B restricts coolant flow to radiator.
Electrically heated thermostat
4 The electrically heated thermostat is DME map-controlled.
The engine control module (ECM) activates the thermostat to
maintain engine coolant temperature within a narrow range.
In case of failure of the electronics, the mechanical function of
the thermostat acts as a fail-safe.
Radiator and expansion tank
The radiator is a crossflow design. An expansion tank pro-
vides for coolant expansion at higher temperatures and easy
monitoring of the coolant level.
On cars with automatic transmission, ATF is circulated
through an additional heat exchanger (ATF cooler).
Mechanical cooling fan with viscous clutch
The mechanical cooling fan is belt-driven via a viscous fluid
coupling (clutch) attached to the front of the coolant pump.
The fan clutch controls the speed of the fan based on the tem-
perature of the air flowing through the radiator core.
Electric (auxiliary) cooling fan
The electric cooling fan is mounted on the bumper side of the
radiator.
In models manufactured up to
911 998 (M52 or 1997 M62 en-
gine), the electric cooling fan is controlled by a dual tempera-
ture fan switch mounted in the side of the radiator.

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170-8
I Radiator and Cooling System
Common cooling system faults can be grouped into one of 4
categories:
Cooling system
lealts
Poor coolant circulation
Radiator cooling fan faults
Electrical/electronic faults
Cooling system inspection
- Check that coolant pump drive belt tensioner is functioning
properly and that belt tension is correct. Belt tensioner sys-
tems for the different models are shown in
020 Maintenance.
- Check condition of coolant pump drive belt.
- Checlc coolant hoses for cracks or softness. Checlc clamps
for looseness. Check coolant level and check for evidence of
coolant
lealts from engine.
- 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.
- To check coolant pump:
Remove mechanical cooling fan. See Mechanical
(vis.
cous clutch) cooling fan, removing and installing.
Remove drive belt from coolant pump pulley. See
020
Maintenance.
Firmly grasp opposite sides of pulley and check for play in
all directions.
Spin pulley and check that shaft runs smoothly without
play.
NOTE-
The coolant provides lubrication for the pump shaft, so an oc-
casional drop of coolant
lealing from the pump is acceptable.
If coolant drips steadily from the vent hole, replace the pump.
- At normal engine operating temperature, cooling system is
pressurized. This raises boiling point of coolant.
Leaks may
prevent system from becoming pressurized. If visual evi-
dence is inconclusive, pressure test cooling system as de-
scribed later to help pinpoint hard-to-find leaks.
- 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.