2000 BMW 528i ABS

Downloaded from www.Manualslib.com manuals search engine
Fuel Tank and Fuel Pump
Fuel pressure gauge, installing
(V-8 models)
Remove engine cover by pressing down on pins (arrows) to
release cover locks.
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.
< Install inline fuel pressure gauge.
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 (0 to 75 psi).

Downloaded from www.Manualslib.com manuals search engine
Fuel Tank and Fuel Pump
4 Relieve system pressure and attach a fuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
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.
- Operate fuel pump as described in Operating fuel pump for
tests. Compare fuel pressure to specifications in accompa-
nying table.
Fuel pressure specification
All E39 vehicles 3.5 +0.2 bar (50.76 i2.9 psi)
- If pressure is low, repeat test while gradually pinching off re-
turn hose to fuel tank. Pressure should rise rapidly. If not, fuel
pump is most likely faulty. If pressure rises, the fuel pressure
regulator is most
likely faulty.
- If pressure is too high, checlc return line from pressure regu-
lator to tank. Check for
ltinks in hose. If no faults can be
found, pressure regulator is most likely faulty.
CAUTION-
The fuel pump is capable of developing a higher pressure
than that regulated by 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.
- Reassemble engine, noting the following:
Remove fuel pressure gauge and fittings.
Replace schraeder valve, if removed
Replace fuel pump relay.
Replace fuel filler cap.
Residual pressure, testing
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.

Downloaded from www.Manualslib.com manuals search engine
. .
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-8 models).
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
- Start engine allow it to run for approximately one minute.
Note fuel pressure reading.
- Observe fuel pressure reading after approximately 20 mln-
utes. The pressure should not drop more than 0.5 bar from
system pressure listed in fuel pressure specifications in ac-
companying table.
Fuel pressure specification
Ail
E39 vehicles 3.5 i-0.2 bar (50.76 i2.9 psi)
- When finished, disconnect pressure gauge and fitting, and
replace schraeder valve, if removed.
- If fuel system does not maintain pressure:
Visually check for leaks in fuel lines and unions,
Check for leaking
injector(s).
Check for faulty fuel pump check valve.
- To test fuel pump check valve:
Repeat residual pressure test.
Immediately aftershutting off engine, pinch off fuel delivery
line using a fuel hose pinch clamp (BMW
13 3 010 or
equivalent).
If pressure is now maintained, fault is most likely at fuel
pump check valve.
If pressure again drops below specifications, fault is most
likely in fuel pressure regulator.

Downloaded from www.Manualslib.com manuals search engine
.-
I Fuel Tank and Fuel Pump
- Expose right side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover insu-
lation.
Peel back insulation at
perforations to expose fuel tank ac-
cess cover.
Remove right side cover to expose electrical harness con-
nector.
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.
Remove
tank sending unit:
Release electrical harness by sliding lock back, then lifting
off connector.
a Disconnect hose (arrow).
Unscrew threaded collar from fuel
pumpifuel level sender.
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.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CAUTION-
Do not bend fuel level sender arm.
To remove fuel pump, press locking tabs (arrows) towards
pump body.
Lifl out pump, using care not to damage hoses.

Downloaded from www.Manualslib.com manuals search engine
/ ~uel Tank and Fuel Pump
4 Remove tank sending unit:
Disconnect electrical harness connector.
Disconnect hose (arrow).
- Unscrew threaded collar from fuel level sender.
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.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CA UTIOW-
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).
- Installation is reverse of removal
Attach tank siphon hose to sender unit firmly.
Use new sealing ring at tank collar.
. Be sure that fuel sender float points in same direction as
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) -

Downloaded from www.Manualslib.com manuals search engine
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.
- Drain fuel tank as described later,
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).
- The tank lobe siphon pump is held to baffle in bottom of right
tank lobe. Release retainer and lift out pump.
- Installation is reverse of removal.
Attach siphon pump to right side baffle.
Attach tank siphon hose to left sender unit firmly.
Use new sealing ring at tank collars
Be sure that fuel sender floats point in same direction as
during removal.
Reconnect harness connectors.
. Before starting engine, fill fuel tank with at least 5 liters
(1.5 gallons) of fuel.
Check for
leaks by running engine.
Afler finishing repairs but before starting engine, be sure

Downloaded from www.Manualslib.com manuals search engine
Radiator and Cooling System
Cooling system, bleeding
Trapped air in the cooling system can prevent proper coolant
circulation and overheating. Wheneverthe coolant is drained
and filled, bleed the cooling system to remove trapped air.
4 Loosen bleed screw (arrow) on radiator expansion tank.
- Set temperature controls in passenger compartment to full
warm, set blower to low setting and turn ignition to
ON posi-
tion (do not start engine).
CAUTIOIG
On late model cars with latent heat pump, do not turn ignition
to ON position.
- Slowly add coolanUdistilled water mixture to expansion tank
until it spills from bleed screw. When coolant spilling from
bleed screws is free of air bubbles, tighten screw and replace
cap on expansion tank.
Run engine until it reaches operating temperature,
- After engine has cooled, recheck coolant level.
Top up so that coolant level indicator is at MAX.
- If trapped air cannot be bled manually, pressure-bleed sys-
tem using cooling system pressure tester.
CA UTlON--
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)
Mechanical (viscous clutch) cooling fan,
removing and installing
The procedure given here describes the removal of the me-
chanical fan and fan shroud. It is possible to remove the fan
without the shroud.
< Working at top of fan shroud:
Remove expansion tank bleed screw (arrow) and expan-
sion tank locking tabs.
Push top of expansion
tank toward engine and lift to free
from lower mounts.
- Remove two expansion rivets in upper corners of fan shroud.
Unclip expansion tank bleed hose located under shroud.

Downloaded from www.Manualslib.com manuals search engine
Anach pressure brake bleeder to fluid reservoir and pump
bleeder a few times to pressurize hydraulic fluid 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.
- Raise and safely support vehicle.
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.
- If necessary, remove transmission splash shield.
Hydraulic system, bleeding
Worlting underneath transmission, connect a hose from
clutch slave cylinder bleeder valve
(arrow) to a container.
Open bleeder valve and allow bralte fluid to expel until
clean fluid comes out, free of air bubbles.
Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly operate clutch pedal about
10 times. Fill reservoir
with clean fluid as necessary.
CR* .,,, .rP,ll,h.:I,,~,~mn.lI","i,,i"