2000 BMW 528i filter housing

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Fuel Tank and Fuel Pump 1
Activated carbon canister I fuel tank leak
detection unit
(LDP or DMTL), removing . . -
and installing
- Raise rear end of car and support safely.
CAUTION-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floor jack is not adequate support.
- Remove left rear wheel and inner fender panel
Remove carbon canisterlfuel tank leak detection unit
(V-8 model shown):
Disconnect electrical harness connector
(A) from fuel tank
leak detection unit.
Pinch and remove quick-disconnect fittings at intake line to
air filter housing
(5) and hose to expansion tank (C).
* Remove mounting clamp and lower canister with fuel tank
leak detection unit.
Installation is reverse of removal.
Tightening
torques
Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb)
Hose clamp
13 - 16 rnm dia 3 Nm (27 in-lb)
Running losses (312-way) valve,
removing and installing
The running losses (312-way) valve is located under the car
beneath the driver's seat, just ahead of the fuel filter. A protec-
tive covershieldsfuel system components from road hazards
and dirt.
The engine control module
(ECM) controls the operation of
the 312-way valve (pulse-width modulated). On engine start
up, the valve solenoid is energized for 20 seconds in order to
supply full fuel volume to the fuel rail.
After20 seconds, the
solenoid is deactivated and sprung closed (the bypass is
opened). This reduces the amount of fuel circulating through
the fuel rail and diverts the excess to return to the fuel tank
through the fuel pressure regulator.
The fuel injectors are supplied with pressurized fuel, but ex-
cess fuel is diverted to the fuel tank without first passing
through the fuel rail. This prevents the excess fuel from ab-
sorbing heat in the engine compartment, thus lowering the
temperature and amount of vaporization in the fuel tank.

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.. - --
Radiator and Cooling System
Tightening torques
Coolant pump to timing chain 10
Nm (89 in-lb)
cover
Coolant pump
pulley to coolant
pump
10 Nm (89 in-lb
Engine
blocic drain plug to block 25 Nm (18 ft-lb)
Radiator drain plug to radiator
2-3Nm(18-27in-lb)
Thermostat cover to coolant
pump assembly 10 Nm (89 in-lb)
Radiator, removing and installing
Removal of the radiator is similar for V-8 and 6-cylinder mod-
els.
- Raise front of car and support safely.
WARNING -
Make sure the car is stable and well supported at aN times.
Use a professional automotive liff
orjaclc stands designed for
- Remove splash shield from under engine.
- Drain radiator and engine block. See Coolant, draining and
filling
(V-8 models).
WARNING -
Allow cooling system to cool before opening or draining sys-
tem.
< Remove air filter housing:
Disconnect electrical harness connectors
(A and B).
Loosen clamps (C and D).
Remove mounting fastener (arrow) and remove air filter
housing together with mass air flow
(MAF) sensor.

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Tool for bleeding clutch hydraulics (Tool No. 21 5 030)
21 5 030 I
The clutch is hydraulically actuated by the master and slave
cylinders. With the self-adjusting clutch
(SAC), clutch disc
wear is automatically taken up through the self-adjusting
pressure plate springs, making pedal feel consistent through-
out the life of the clutch.
A soft or spongy feel to the clutch pedal, long pedal free-play,
or grinding noises
from the gears while shifting can all indi-
cate problems with the clutch hydraulics. In these circum-
stances it is best to
star? with a clutch fluid flush, followed, if
necessary, by replacement of the hydraulic parts.
NOTE-
The clutch hydraulic system shares the fluid reservoir and flu-
id with the brake hydraulic system.
Clutch hydraulic system,
bleeding and flushing
If the clutchlbralte fluid is murky or muddy, or has not been
changed within the last two years, flush the system and
change the fluid. Flushing the old fluid from the clutch lines is
done using a bralte system pressure bleeder.
- Remove brake fluid reservoir cap. Using a clean syringe, re-
move brake fluid from reservoir. Refill reservoir with clean
DOT
4 bralte fluid.
Worlting inside engine compartment, remove left
interiorven-
tilation filter housing:
Release 3 plastic taps
(A) on duct. Earlier models use a
single release latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Remove filter housing cover.
Release spring lock
(B) on interior ventilation housing and
remove housing.

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21 0-6
1 Clutch
Hydraulic system, bleeding
(using
BMW special tool 21 5 030)
4 Working underneath transmission, remove slave cylinder
mounting nuts (arrow) from clutch housing and remove
cylinder. Leave fluid line attached.
4 Use BMW special tool 21 5 030 to press slave cylinder push-
rod completely into slave cylinder.
Hold slave cylinder so that bleeder valve is at highest point.
Open bleeder valve and allow brake fluid to expel until
clean fluid comes out, free of air bubbles.
* Close bleeder valve and disconnect pressure bleeding
equipment from fluid reservoir.
Slowly unscrew and detach special tool 21
5 030 from
slave cylinder.
CAUTION-
Do not remove tool if hydraulic system is pressurized.
- Reinstall slave cylinder.
Tightening torque Slave cylinder to transmission case
22 Nm (1 6 ft-lb)
- Slowly operate clutch pedal about 10 times. Fill reservoir with
clean fluid as necessary.
Clutch master cylinder, replacing
The clutch master cylinder is mounted to the pedal assembly
directly above the clutch pedal.
Working inside engine compartment, remove left interior
ventilation filter housing:
Release 3 plastic taps
(A) on duct. Earlier models use a
single release latch.
Rotate duct inward to remove
Disconnect electrical harness to hood position switch.
Remove filter housing cover.
Release spring
loclc (B) on interior ventilation housing and
remove housing.

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21 0-8
Clutch
4 Remove hydraulic line locking clip (1) and pull line (2) off
master cylinder.
CAUTION-
. To prevent brake fluidspill, wrap clutch master cylinder with
shop rags when removing hydraulic fluid lines from master
cylinder.
* Brake fluid damages paint andstains carpets. Clean off
any brake fluid on or
in the car immediately.
- Remove master cylinder with supply hose
4 Remove switch module from master cylinder.
Press locking button
(A) to release harness connector.
Pull harness connector
(8) off switch module.
Use screwdriver to lever
off switch module (C).
- Installation is reverse of removal.
CA UTlON-
Switch module must snap firmly into place on the master cyl-
inder during installation.
Tightening torques
Clutch master cylinder to pedal cluster
10 Nm (89 in-lb)
Fluid line
to master cylinder or slave cylinder 17 Nm (13 ft-lb)
- Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as
described earlier.
Clutch slave cylinder, replacing
4 Working inside engine compartment, remove left interiorven-
tilation filter housing:
Release
3 plastic taps (A) on duct. Early models: release
latch.
Rotate duct inward to remove.
Disconnect electrical harness to hood position switch.
Release spring lock (B) on interior ventilation housing and
remove housing.
- Pinch off brake fluid supply hose to clutch master cylinder us-
ing BMW special tool
13 3 01 0 or equivalent hose clamping
tool.

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Automatic Transmission
- Raise and safely support vehicle.
CA U JIOG
Male sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A floorjack is not adequate support
4 With engine running and selector lever in PARK, remove filler
plug (arrow)
(A5S 360R transmission shown, refer to other
illustrations for location of filler and drain plugs on other
transmissions).
If a small stream of fluid runs out of the filler hole the level
is correct.
If no fluid
leaks out when plug is removed, fluid level is to
low. Add ATF fluid until it starts to overflow.
Install filler plug using a new sealing ring.
Hot ATF can scald. Wear eye protection and protective cloth-
ing andgloves during
the check. If the tmnsmission was over-
filled, hot ATF will spill from the filler hole when the
fill plug is
removed.
ATF, draining and filling
The procedure given here includes removal and installation of
the fluid strainer (filter). Refer to illustrations in Automatic
transmission fluid
pan and strainer.
Remove ATF drain plug
(1) and drain fluid into container.
WARNING-
ATFshould be warm when draining. Hot ATFcan scald. Wear
eye protection, protective clothing and gloves.
Remove transmission pan mounting bolts and remove pan.
Remove pan gasket and clean
gasket sealing surface.
- Pull ATF strainer from transmission pump housing. If strainer
sealing ring remains in pump housing remove using a seal
puller.
- Installation is reverse of removal.
Always replace seal for drain plug and all
gasket(s)
and O-rings.
Clean sump and sump
magnet(s) using a lint-free cloth.
Tighten transmission pan bolts in sequential order.
Using filler plug
(2), fill transmission with approved ATF.
Check fluid level as described earlier.

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Brakes
Brakes, bleeding
The procedure below requires a BMW Service Tester (DIS-
pluslGTl/MoDiC).
- Determine type of traction control (ASC, DSC with precharge
pump, DSC without precharge pump). Be sure to use correct
specification brake fluid, according to application table below.
Brake fluid applications
ABS I ASC and ABS / DSC models DOT 4 brake fluid
with precharge pump (to 911998)
ABS I DSC models without precharge DOT 4 low viscosity
pump (911998 and later) brake
fluid
< Remove left side interior ventilation microfilter housing:
Remove upper cover and microfilter loclting clip
(A).
Release locking clamp (B), and rotate air tube in direction
of arrow to remove.
Disconnect wiring harness from hood switch
(C).
Release filter body mounting clamp (D) and remove lower
microfilter housing.
- Top off bralte fluid in reservoir and connect BMW Service
Tester to
20 pin Data Link Connector (DLC) under hood or 16
pin
DLCIOBD I1 connector under dash.
- Call up service function Bleeding ABS / ASC or service func-
tion Bleeding ABS
/ DSC, depending on installed system.
- Fill pressure bleeding device with the correct brake fluid and
connect to brake fluid reservoir and apply pressurize.
Do not exceed a pressure of
2 bar (29 psi) when pressure
bleeding the
brake system. Excessive pressure will damage
4 Starting at right rear wheel, connect bleed hose and fluid re-
ceptacle to bleeder screw (arrow).
CA UTlON-
Bleeder hose must always remain submersed in clean brake
fluid whenever the bleeder valve is open.

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Brakes
Master cylinder, removing and installing
CAUTlOI\C
Brake fluid is highly corrosive and dangerous to the environ-
ment. Dispose of it properly.
4 Remove left side interior ventilation microfilter housing:
Remove upper cover and microfilter locking clip
(A).
- Release locking clamp (B), and rotate air tube in direction
of arrow to remove.
Disconnect wiring harness from hood switch
(C).
Release filter body mounting clamp (D) and remove lower
microfilter housing.
4 Remove side trim panel from left rear of engine compartment
by releasing clips
(arrows).
4 Disconnect bralte fluid level sensor connector (A) from fluid
reservoir. Remove reservoir cap.
. Using a clean syringe, empty bralte fluid reservoir.
Where applicable, disconnect hydraulic clutch system sup-
ply line from fluid reservoir duct
(5). Keep supply line sup-
ported and above clutch master cylinder to prevent air
bubbles from reaching clutch hydraulic system.
Where applicable, disconnect DSC system precharge
pump supply line from fluid reservoir duct
(C). Secure sup-
ply line in vertical position to prevent fluid loss.
Plug open brake fluid lines and ducts to prevent fluid leak-
age or contamination.
- Remove brake fluid reservoir by tilting sideways.