2000 BMW 528i rear main seal

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.- .
Fuel Tank and Fuel Pump
- 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 (26 lb-ft)
Fuel level sender (left side),
removing and installing
The procedure for removing and replacing the left side fuel
level sender is
simllar to that used for the r~ght side. There is
no fuel pump on the left side.
- Remove rear seat lower cushion by lifting off catches at front.
- 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.

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- 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 designed for
the
ournose. A floor jack is not adeouate suooort.
- If necessary, remove transmission splash shield.
- Disconnect fluid line from slave cylinder on lefl side of trans-
mission. Place pan under hose to catch dripping fluid.
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder.
- Installation is reverse of removal, noting the following:
Check for wear on slave cylinder. Any wear except on tip is
caused by misalignment of clutch components.
Lightly coat
pushrod tip with molybdenum disulfide grease
(MolyltoteIB Longterm or equivalent).
. During installation be sure pushrod tip engages recess in
clutch release lever.
Fill fluid reservoir with clean fluid.
. Bleed clutch hydraulics as described earlier.
Tightening
toraues - -.
Clutch slave cylinder to transmission 22 Nm (16 R-lb)
Fluid line to slave cylinder 17 Nm (13 ft-lb)
The transmission must be removed from the engine to access
the clutch mechanical components. It is recommended that
the clutch disc, pressure plate and release bearing be re-
placed during a clutch overhaul.
Besure tocheck the bottom of the bellhousing foroil. If engine
oil is found, check for a faulty rear crankshaft main oil seal.
See
119 Lubrication for rear main seal replacement.
Clutch variations
Two versions of the clutch are used:
1997 528i (6 cylinder) uses traditional clutch components.
All
540i (V-8) and 1998 and later 6 cylinder models from
use a self-adjusting clutch (SAC).

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260-1 0
/ Driveshaft
Driveshaft, installing
- Prepare CV joint for reinstallation:
Extend joint to limit.
Clean off old grease and fill with fresh grease
Install new seal.
- Bend driveshaft slightly at center universal joint to install
CAUTION-
Do not allow CVjoint seal to become displaced.
- Align matchmarlts on driveshaft to matchmarks on final drive
and transmission flanges.
- Fit constant velocity joint to final drive input flange. Alternate-
ly tighten two opposite nuts to draw constant velocity joint
evenly into the final drive input flange. Once seated, tighten
down remaining nuts.
I CAUTION-
I Do not reuse self-locking nuts. These nuts are designed to be /
I used onlv once. 1
- Insert bolts in front of driveshafl to transmission output
flange. Counterhold each bolt while tightening nut.
CAUTION-
. Do not reuse self-locking nuts. These nuts are designed to
be used only once.
Avoid stressing the flex-disc when torquing the bolts.
Do this by counterholding the bolts and turning the nuts
on the flange side.
- Position center support bearing and install mounting nuts.
Use new self-locking nuts.
- Install heat shields.
- Install rear transmission support crossmember.
- Install exhaust system. See 180 Exhaust System.
Reconnect oxygen sensor wiring harnesses and reattach
wiring harness retainers to rear transmission support
crossrnernber.

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Steering and Wheel Alignment
Power assist is provided by a belt-driven pump at the lower
left front of the engine. The power steering fluid reservoir is lo-
cated at the left side of the engine compartment.
Power steering pump, removing and
installing
When working with power steering components, absolute
cleanliness is needed to ensure proper operation of the hy-
- Empty power steering fluid reservoir using clean syringe. Do
not reuse fluid.
- Raise front of car. Remove splash shield from under engine.
WARNING-
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
Darts.
Remove drive belt from power steering pump. See
020 Main-
tenance.
Remove alternator cooling duct
Remove fluid hoses from pump. Plug openings in pump and
hose ends.
Remove pump front mounting bolts
(A).
Remove fluid line support bracket (B)
Remove pump rear mounting bolt (arrow)
- Installation is reverse of removal, noting the following:
Make sure all thread bores, bolts, nuts, fluid couplings and
mating
surfaces are clean, and inside surface of multi-
ribbed-belt is free of grease and dirt.
Use new sealing washers when reattaching power steer-
ing pressure lines.
Make sure hoses have adequate clearance from chassis.
Install front pump fasteners.

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330-1 3
Rear Suspension
1 1 4 Check roll fold of air spring (arrows). Reinstall only if roll fold
is undamaged and formed correctly.
- To install air spring:
Check sealing O-rings at air spring inlet. Replace
if dam-
aged. Do not grease O-rings. Reinstall protective plug.
* Install spring above suspension subframe. Make sure ec-
centric lug at bottom of air spring fits in recess of
subframe
spring seat.
Reattach top spring mounting clips.
- Reattach air line connections.
- Remainder of installation is reverse of removal.
Tightening torques
Air line connection
2 Nm (1 8 in-lb)
Air spring
to wheel bearing carrier 20 Nm (1 5 ft-lb)
Road
wheel to hub 120 510 Nm (89-F-7 ft-lb)
REAR SUSPENSION ARMS,
SUBFRAME AND BUSHINGS
A damaged suspension arm orworn bushings will change the
rear wheel alignment and may adversely affect handling and
stability.
WARNING-
Do not attempt to straighten a damaged suspension arm.
Bending or heating may
weaken the original part. Always re-
olace a damaoed susoension arm.
Rear suspension arm
components
1. Eccentric washer
(for rear toe adjustment)
2. Upper front control arm
(guide link or traction strut)
3. Outer swing arm bushing and
integral link
4. Swing arm (lower control arm)
5. Upper rear control arm
(wishbone)
6. Wheel bearing carrier
7. Circlip
8. Swing arm ball joint
9. Eccentric washer
(rear camber adjustment)

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WARNING
Your common sense, good
judgement, and general alertness are
crucial lo sale and
successlul service
work. Belore attempling any work on
your BMW, be sure to read 001
General Warnings and Cautions
and lhe copyright page
a1 llle Iron1 01
the manual. Review lliese warnings
and cautions each time you prepare
lo work on your
BMW Please also
read any warnings and
caulions lhal
accompany the procedures In !he
manual.
Component locations
see Electrical system
Compression test
113-5
Compressor see
AlC
Condenser see
AlC
Constant velocity (CV) joint
see Maintenance
see also
Driveshall
see also Drive axles
Consumer cutoff
600-10
Control arm see Front suspension
see also Rear suspension,
suspension arms
Coolant (antifreeze) see Maintenance
see also Cooling system
Coolant pump
see Cooling system Cooling system
coolant bleeding
170-14 6-cylinder engine, draininglfilling
170-10
V-8 engine, draininglfilling 170-12
coolant pump 170-3
6-cyiinder engine, replacing 170-1 9
V-8 engine, replacing 170-20 cooling fan 170-4
viscous ciutch fan, removingi
installing 170-14
electric fan, removlngiinstailing 170-1 5
expansion tank, removinglinstalling
170-22
electrically heated (ciiaracterislic
map) therrnostat 170-4
radiator, removinglinstaliing 170-22
service
see Maintenance
therrnostat 170-16
transmission fluid heat exchanger
170-5 troubleshooting 170-7
combuslion leal( test 170-10
pressure test
170-9
Crankshaft oil seals
iront
117-6
rear 11 9-6
Crankshaft speed sensor
see Ignition syslem
Crash sensor
see
Airbag system (SRS), side-impact
airbag crasii sensor
Cruise control clutch switch 612-9
CV joint
see Maintenance
see also Driveshalt
see also Drive axles
CV joint boot
see Maintenance
see also Drive axles
Cylinder head removinglinslaliing
M52 engine 113-8
M52 TU / M54 engine 113-22
M62 engine 113-56
Cylinder head and valvetrain
hydraulic lifters, checking and
replacing
116-7 leak test 116-5 valves 11 6-56
see
alsocylinder head Dashboard
513-7
Deck
lid
seeTrunk lid
Diagnostic monitors
OED-4
Diagnostic trouble codes
(DTCs)
080-7
Digital multimetel
010-17
Differential see Final drive
DLC (data
link connector) 020-4, OED-4
DME (digital motor electronics)
see
130 under appropriate fuel
injection system
see also ignition system
DM-TL (detection module-tank leak)
see
Fuel lank, leak deteclion unit
Drive
belts
see Maintenance
Dome light
seeLighls, interior lights
Door
door
check, replacing 411-4
hinge adjustment 41 1-5
loci(
see Door lock see also Central locking
removinglinslaliing 41
1-2
panel, removinglinstaliing 41 1-7 window
see Door window
Door
check
see Door
Door
handle
see Door lock
Door glass
see Door window
Door
lock
handles and loci(s 515-16
see also Central locking
Door
molding
510-13
Door panel see Door

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Gaskets and seals 01
0-9
Gearshift automatic transmission
adjusting
250-7
shift interiock. checkino function " 250-9
shiftloclc. checicino function 250-8 - manual transmission
gearshift lever, removingiinstalling
250-5
steptronic 250-7
General module (GM Ill)
600-8
see also Central locking
Generator see Battery, starter, alternator
Glass see Door window
Glove compartment
513-16
see also
Global positioning system
(GPS)
620-9
Grill
see Exterior trim
Grounds
100-5
Guide link
see Rear suspension, suspension
arms
Halogen headlight
630-5
Hand brake
see Brakes, pariring brake
Handle, door
see Door
locks
Hatch seeTailgate
Hazard warning switch
see Switches Headlight
housing trim
see Exterior trim
washer611-17 see also Lights
Headlight spray
nozzle
611-17
Headlight switch
see Switches
Heater core
see Heating
Heater valve
see Heating
Heating lieater core, replacing
640-18
lheater core temperature sensor,
removingiinstalling
640-12 heater valve, replacing 640-17
IHKA housing, removinglinstallin~
640-21
see also NC
Hood
410-6
Hood latch and release
410-10
Hydraulic valve lifters
see Cylinder head and valvetrain
IAT
(lntalce air temperature) sensor
see 130
under appropriate fuel
injection system
idle speed control valve
see 130
under appropriate fuel injection system
Idle stabilizer
see 130
under appropriate fuel
injection system, idie speed controi
valve
idler arm
320-30
lgnition coll
see lgnition system
lgnition interlock
320-13
lgnition lock cylinder
removingiinstalling
320-1 1. 612-4
lgnition switch
seeSwifches
Ignition system
diagnosis checking for
spark 120-10
disabling ignition system 120-10 misfire detection 120-6
oscilioscope diagrams 120.6
troubleshooting 120-6
camshaft position sensors 120-14 coils 120.10
crankshaft speed sensor 120-12 firing order 120-9
knoclc sensors 120-16
IHKA
see NC
IHKR see NC
Injector
see 130 under appropriate
fuel
injection system, luel injector
Input shaft
oil seal
see Manual transmission, oil seals
Inspection
see Maintenance
Instruments GPS see Global positioning system
(GPSI layout 6202
removingiinstalling 620-8 self-testing 620-6
Intake air temperature sensor (IAT)
see 130 under appropriate fuel
injection system
Intake manifold
removingiinstalling
6-cvlinder enoine 110-10. 113-8. 113-22 -
V-8 engine (M62) 113-56
Integral link
see Rear suspension, suspension
arms
lnterior lights
see Lights
lnterior protection
(FISIUIS) 515-25
lnterior trim
513-13
lnterior ventilation microfilter see
NC, ventilation microfiller

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Manual transmission
applications 200-2. 230-5
back-up light switch, replacing 230-6
gear ratios 230-6
gearshift
see Gearshiit
ID tag 200-2
fluid 020-1 0. 200-4 fluid service 230-6
oil seals
input shaft seal, replacing
230-17
output shalt seal, replacing 230-1 1
selector
shaft seal, replacing 230-8 pilot bearing 210-16
removallinstallation 230-19
see also Maintenance
Map light
see Lights, interior
Mass air flow
(MAF) sensor
see 130 under appropriate fuel
injection syslem
Master cylinder
see Brakes
see also Clutch, hydraulics
MDK
130-42
Microfilter see
NC, ventilation microfilter
see also Maintenance
Mirror see Exterior trim
Misfire see Ignition syslem, diagnosis
Motor mount
see Engine,
mounl
MRS (multiple restraint system)
see Airbag system (SRS)
Muffler
see Exhaust syslem
Neutral safety switch
see Automatic transmission, range
switch
OED II (on-board diagnostics)
OED-l
Oil change equipment 010-16
Oil level sensor
see Lubrication system
Oil pan
see Lubrication system
OH pressure
see Lubrication system
Oil pump
see Lubrication system
Oil service 020-1 1
On-Board Monitor
640-12
On-board diagnostics OED-1
Outside air temperature sensor
610-14
Outside door handle
see Door
loclc
Outside mirror switch
see Switches
Output
shaft oil seal
see Manual transmission, oil seals
Overheating
see Cooling system, troubleshooting
Overload protection
600-11
Oxygen sensors
130-72, 180-8
P codes OED-10
Panic mode operation
515-11
Parking brake
see Brakes
see also Maintenance
Parts, buying
010-11
Pedal cluster switches
see Switches
Pedal position sensor (PWG)
6-cvlinder
enqine
V-8 engine (M62 TU) 130-68
Pitman arm
see Steering
Power steering
see Steering
Power steering
fluid
see Maintenance
Power window switch
512-3 see also Switches
PWG see Pedal position sensor
(PWG)
Racic and pinion steering
see Steering
Radiator see Cooling system
Radiator cooling fan seeCooling system, cooling fan
see also Cooling system, electric fan
Radiator grill
see Exterior
trim
Radio
650-2 see also Antenna
see also Speakers
Rain sensor
611-6
Raising car safely
010-5
Readiness codes
OED-6
Rear door window
see Door window
Rear main seal
see Crankshalt oil seals
Rear parcel
sheif
513-16