1998 BMW 528i diagnosis

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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.

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113-8
[cylinder Head Removal and Installation 1
Cylinder leak-down test
The most conclusive diagnosis of low compression symp-
toms requires a cylinder leak-down test. Using a special
tester and compressed air, each cylinder, in turn, is pressur-
ized. The rate at which the air leaks out of the cylinder, as well
as where the air leaks out, can accurately pinpoint the magni-
tude and location of the leakage.
Before attempting any repair that requires major engine dis-
assembly, use a leak-down test to confirm low compression.
~YL~NDER HEAD REMOVAL AND
~NSTALLATION (M52 ENGINE)
WARNING-
Due to rislc of personal fnjur~: be sure the engine is cold be-
fore beginning the removal procedure.
Cylinder head removal and installation is a time consuming
repair procedure requiring multiple special
service tools.
Read the entire procedure before beginning the repair.
This procedure includes the following steps:
Cylinder head, removing,
M52 engine
Cylinder head, installing,
M52 engine
Cylinder head, removing, M52 engine
- Disconnect negative (-) cable from battery in luggage com-
partment.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions in 001 General Cautions and Warnings.
-

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1 17-2
Camshaft Timing Chain
This repair group covers timing chain and VANOS repair
information for the following engines:
M52 (Single VANOS 6-cylinder engine)
M52
TU and M54 (Double VANOS engines)
M62 (Non VANOS
V-8 engine)
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.
Worn timing chains and sprocltets can lead to noisy operation
and erratic valve timing. Afaulty tensionercan also cause tim-
ing chain noises.
For specific repair procedures, refer to the appropriate repair
group:
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.
In addition, Double VANOS system diagnosis can only be
carried out by using BMW specific electronic scan tools, such
as BMW
DISplus, MoDiC or equivalent.
4 Torque wrench wl flex extension
(Tool No. BMW 00
9 250)

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Ignition System
This repair group covers component troubleshooting and re-
placement information for the ignition system.
When diagnosing engine management problems, including
on-board diagnostics (OBD
11) fault code analysis, also refer
to these repair groups:
* 130 Fuel Injection
* ELE Electrical Wiring Diagrams
OED On-Board Diagnostics
Special tools
System diagnosis and testing of the ignition system requires
special test equipment.
4 LED test light
(Tool No. Baum
1 1 15)
4 Automotive digital multimeter
4 Primary voltage test harness
(Tool No. BMW 12
7 020)
-
4 Secondary voltage test harness
(Tool No. BMW 12
7 030)

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I lgnition System
Additional information about DTCs and engine management
system electronic system diagnosis is provided in
OBD On-
Board Diagnostics.
Table a. Engine management systems
Year
l~ngine I Engine type IDME svstem I - I - . . I
Ignition system
1997-1 998
1997
1998
1999-2002
4 All engines use a distributorless ignition system with individ-
ual ignition coils for each cylinder. There is no distributor cap
or ignition rotor.
4 Each coil is controlled and monitored by the Engine Control
Module (ECM) on a cylinder-by-cylinder basis.
1999-2000
1~52 TU 16-cylinder l~iemens MS
42.0
M62
M62
M62TU
Siemens MS 41 .I M52 6-cylinder
V-8
V-8 V-8 Bosch
M 5.2
Bosch M 5.2.1
Bosch ME 7.2

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Battery, Starter, ~lternatorl
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
-I 8' C (0"
F) 8.5 V
* Measure
after applying a 200 amp load for 15 seconds.
Closed-circuit current measurement
If the vehicle battery is discharged for an unknown reason,
perform a closed-circuit current measurement as the first test.
For diagnostic purposes, it is important to not disconnect the
battery. Disconnecting the battery may reset a faulty control
unit, preventing proper diagnosis.
The following test is generally completed overnight using a
multimeterwith a closed circuitcurrent measurement adaptor
with a recording function
- Check that battery voltage is 12 volts or higher. If lower,
recharge battery.
- Switch off electrical consumers (interior lights, telephone,
aftermarket equipment, or others).
- Open luggage compartment and remove battery trim panel.
Use screwdriver to lock latch on trunk lid or hatch, simulating
closed luggage compartment. Close other doors.
- Open driver's door, then close it, simulating driver entering
vehicle.
- Switch ignition to RUN position for at least five seconds, then
turn ignition to OFF position. This simulates driving vehicle.
- Open and close driver's door, simulating driver leaving
vehicle.
- Lock car and arm alarm.
- Wait at least 16 minutes for consumer cut-off.

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Battery, Starter, Alternator
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.
The M62 TU water-cooled alternator incorporates load start
reduction. This function is intended to shorten the duration of
engine starting, particularly at low ambienttemperatures. The
current load is limited to
20 amps during starting in order to re-
duce alternator braking torque on the engine. Following the
current limiting phase, full power output is then progressively
reached.
Charging system diagnostics requires special test equip-
ment. If the test equipment is not available, charging system
fault diagnosis can be performed by an authorized
BMW
dealer or other qualified repair shop. See Table a. Battery,
alternator and starter troubleshooting for general electri-
cal component troubleshooting.
Before checking the alternator, make sure the battery is fully
charged and capable of holding a charge. Check that the bat-
tery terminals are clean and tight and the alternator drive belt
is properly tensioned and not severely worn.
NOTE-
Some model require up to 15 second to reacli full alternator
output.
CA UTIOG
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
affached to
the grounding stud on the cylinder head
(A). Replacing the
instrument cluster before repairing the ground lead will both
damage the instrument cluster and cause the failure to
reoccur.

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130-1
130 Fuel injection
General ........................... .I3 0.2
Tools and test equipment .............. .I3 0.3
Warnings and cautions ................ .I3 0.5
Fuel Supply ....................... .I3 0.6
Relieving system fuel pressure .......... .I3 0.6
Siemens MS 41 . 1. ................... 1 30-7
ECM relay. testing .................... .I3 0.7
Mass air flow (MAF) sensor.
checking and replacing
................ .I3 0.9
Engine coolant temperature (ECT) sensor.
testing and replacing
.................. 130-10
Intake air temperature (IAT) sensor.
testing and replacing
................. .I3 0.1 1
Throttle position sensor (TPS).
testing and replacing
.................. 130-1 2
ldle speed control valve.
checking and replacing
............... .I3 0.1 3
Fuel injectors. checking and replacing .... 130-15
Evaporative emissions. overview ....... .I3 0.1 6
Secondary air injection. overview ....... .I3 0-17
Engine control module (ECM).
removing and installing
................ 130-18
Siemens MS 41.1 ECM pin assignments . .I3 0.19
Siemens MS 42.0 and MS 43.0. ..... .I3 0.23
ECM relay. testing ................... .I3 0.27
Mass air flow (MAF) sensor.
checking and replacing
............... .I3 0.28
Engine coolant temperature (ECT) sensor.
testing and replacing
................. .I3 0.30
Intake air temperature (IAT) sensor.
testing and replacing
................. .I3 0.31
MS 42.0 throttle valve assembly. replacing . 130-32
MS 43.0 throttle valve assembly. replacing . 130-35
Throttle cable. adjusting (MS 42.0) ...... .I3 0.38
ldle speed control valve. checking
and replacing
....................... .I3 0.38
Evaporative emissions control diagrams . . 130- 39
Evaporative emissions control.
(MS
42.0 and MS 43.0). .............. .I3 0.39
Engine control module (ECM).
removing and installing
................ 130-40
Siemens MS 42.0 and MS 43.0
ECM pin assignments ................. 130-41
Bosch M5.2 (M62 up to 911997)
BOSC~ M5.2.1 (M62 911997 to 911998) 130-46
M5.2 system features ................. 130-47
M5.2.1 system features ............... 130-47
ECM relay. testing ................... 130-49
Oxygen sensors. checking ............. 130-51
Fuel injectors. checking and replacing .... 130-52
Mass air flow (MAF) sensor. replacing .... 130-53
ldle speed control valve. testing
and replacing
....................... 130-54
Throttle position sensor (TPS).
testing and replacing
................. 130-55
Engine coolant temperature (ECT) sensor.
testing and replacing
................. 130-55
Intake air temperature (IAT) sensor.
testing and replacing
................. 130-57
Auxiliary throttle valve (ADS) (M62 and
M62 TU engine). replacing ..... 130-57
Evaporative system pressure
leak diagnosis. overview
(5.2.1 only) ..... 130-58
Bosch 5.2 ECM pin assignments
(M62 UP to 911 997) ................... 130-59
~osch 5.2.1 ECM pin assignments
(M62 911 997 to 911 998) ............... 130-62
BOSC~ ME 7.2 ..................... 1 30-66
ME 7.2 system overview ............... 130-67
EDK adaptation ..................... 130-69
ECM relay. checking .................. 130-69
Engine coolant temperature
(ECT) sensor. testing
................. 130-71
Engine coolant temperature
(ECT) sensor. replacing
............... 130-71
Oxygen sensors. replacing ............. 130-72
Fuel injectors. removing and installing .... 130-72
Mass air flow (MAF) sensor.
removing and installing
................ 130-73
Evaporative system pressure
leak diagnosis. overview
............... 130-74
Secondary air injection. overview ........ 130-75
Bosch ME 7.2 ECM pin assignments .... 130-76