170-19

Radiator and Cooling System

Remove thermostat housing fasteners (arrows) and remove thermostat housing.

– Installation is reverse of removal, noting the following:

• Keep sealing faces clean and free of oil.

• Use new sealing gasket.

• Fill system with coolant. See Coolant, draining and fill-ing (V-8 models).

Valley pan cover, replacing (M62 V8 engine)

The valley pan is located in the center (valley) area of the en-gine block and seals off a long coolant chamber in the block. When the valley pan seal fails, coolant can be seen dripping off the rear of the engine, above the transmission bellhousing.

To access the pan, the intake manifold and the water pump assembly need to be removed. Prior to valley pan replace-ment, be sure to read the fuel system warnings in Warnings and Cautions in 130 Fuel Injection.

– This job will require new seals and gaskets. A minimum list includes:

• Valley pan with integral seal/gasket.

• Intake manifold gaskets (4)

• Coolant pump gasket

• O-rings for coolant pipes (qty. 4 - 2 per pipe)

• Recommended: throttle body and rear breather plate pro-file gaskets.

New valley pan from BMW comes with sealing gasket in place.

– Disconnect negative (-) battery cable.

– With engine fully cold, drain engine coolant. Remove engine drive belt and coolant pump. See 170 Radiator and Cooling System.

Tightening torques

Block drain plug to block 25 Nm (18 ft-lb)

Coolant hose clamp (32 — 48 mm hose diameter)

2. 5 Nm (22 in-lb)

Radiator drain plug to radiator 2 - 3 Nm (18 - 27 in-lb)

Thermostat cover to coolant pump

10 Nm (89 in-lb)

WARNING —Prior to disconnecting the battery, read the battery discon-nection cautions in 001 Warnings and Cautions.

art # here

529

Radiator and Cooling System

170-20

Remove intake manifold. 130 Fuel Injection.

• Carefully lift off intake manifold with fuel rail while checking that no hoses or harnesses become snagged. Cap all fuel lines.

• Note that breather tube (arrow) gets unclipped at rear of intake manifold, slid forward, and remains on engine dur-ing intake manifold removal.

NOTE —Stuff lint free rags into cylinder head port openings to prevent debris from entering engine.

Pull cooling pipes from rear coolant manifold (arrows). Turn pipe while pulling to assist with removal.

Pick out old O-rings at rear coolant manifold and discard (arrows).

530

170-21

Radiator and Cooling System

Remove bolts from valley pan (arrows) and remove pan. It may be necessary to pry up on front of pan to loosen.

Unclip plastic cover from old valley pan. The cover is retained by 3 tabs on either side of the cover. Clip cover onto new pan.

– Install new cover. Install all bolts finger tight. Tighten bolts in two stages working outward from the center in a diagonal pattern.

– The remainder of installation is reverse of removal, noting the following:

• Install knock sensor before installing coolant pipes / cool-ant pump.

• Install new O-rings in coolant pump housing and use a new pump gasket. Install new gaskets on intake manifold.

NOTE —• It is recommended that new gaskets for the throttle body

and rear breather plate be installed while the manifold is removed.

• Fill and bleed cooling system as described in 170 Radiator and Cooling System and check for leaks.

• Check that all electrical connectors and hoses have been correctly installed.

Tightening torques

Valley pan to cylinder block 10 Nm (89 in-lb)

531

established 1950Automotive Reference™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

BMW 5 Series (E39)Service Manual: 1997–2003525i, 528i, 530i, 540i, Sedan, Sport Wagon Price: $169.95Bentley Stock Number: B503Publication Date: 2011.feb.18ISBN: 978-0-8376-1672-82 volume hardcover set, 8 3/8 in. x 11 in.Case quantity: 12072 pages, 2667 photos, illustrations and diagrams Includes color 14 page BMW 5 Series Product Familiarization section

The BMW 5 Series (E39) Service Manual: 1997-2003 contains in-depth maintenance, service and repair information for the BMW 5 Series from 1997 through 2003. The aim throughout has been simplicity and clarity, with practical explanations, step-by-step procedures and accurate specifications. Whether you’re a professional or a do-it-yourself BMW owner, this manual helps you understand, care for and repair your BMW.

Technical features:

• Procedures from the basic oil change service to interpreting the Malfunction Indicator Light (MIL). This manual tells you what to do and how and when to do it.

• Engine and cylinder head service, including camshaft timing chain setup and adjustment.

• Information for specific driveability problems, including explanation of engine management systems and BMW OBD II Diagnostic Trouble Codes (DTCs).

• Theory of operation and repair information for the Siemens and Bosch engine management systems.

• Drivetrain maintenance, troubleshooting, adjustment and repair of self-adjusting clutch (SAC), gearshift linkage, driveshaft, and drive axles.

• Manual and automatic transmission removal, installation, seal replacement and external service.

• System description and repair information for Antilock Brakes (ABS), Automatic Stability Control (ASC) and Dynamic Stability Control (DSC).

• Heating and air conditioning repair (IHKA and IHKR), including component replacement.

• Body adjustments and repairs, including sunroof and tailgate.

• Wiring schematics and extensive electrical component section specifying relay, control module and ground locations with detailed illustrations and photos.

Engines covered6-cylinder engines: M52, M52 TU, M54V-8 engines: M62, M62 TU

Manual transmissions coveredGetrag S5D 250G, S6S 420GZF S5D 320Z

Automatic transmissions coveredA4S 270R, A4S 310RA5S 360R, A5S 390RA5S 325ZA5S 560Z, A5S 440Z

BentleyPublishers.com

Detailed instructions on replacing front struts310 Front Suspension

bentley_b503_new.product.announcement.pdf

Engine and cylinder head service, including Double VANOS timing chain setup and adjustment.117 Camshaft Timing Chain

Access Diagnostic Trouble Codes (DTCs) to diagnose engine management problems. 130 Fuel Injection

Two Volume SetVol. 1 - MechanicalVol. 2 - Electrical