DISCLAIMER2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 110101 Date: 010601

Engine - MIL ON/Codes Set/Tapping/Rattling Noise

GROUP 11

Engine

11 01 01

Woodcliff Lake, NJ

June 2001

Service Engineering

This Service Information bulletins supersedes S.I. 11 05 90 dated May 1990.

SUBJECT

Hydraulic Bucket Tappets (HVA) Troubleshooting Tips

MODEL

All with M42, M44, M50, M52, M54, M60, M62, S50, S52 and S62 engines

SITUATION

Two common reasons for the replacement of hydraulic bucket tappets (HVA) are:

1. Tapping / rattling noise from the valve train area or

2. Binding HVA element

CAUSE

Tapping / rattling noise from the valve train area may have various different causes depending on engine oil level, engine / oil temperature, when the

noise is heard (cold start, engine hot), etc.

The following Complaint, Cause and Correction scenarios will assist in troubleshooting for HVA element noise:

SITUATION 1A

Tapping / rattling noises from the area of the valve train up to 20 seconds after a cold start.

CAUSE

These noises can be traced back to the higher viscosity of cold mineral based engine oil.

For a brief moment insufficient oil reaches the high pressure chamber of the HVA element via the high pressure valve after start up. This results in

clearance between the HVA element and the camshaft lobe which then causes a tapping / rattling noise.

Influencing factors for this complaint:

Viscosity of engine oil used

Ambient temperature

This condition is not caused by mechanical damage to any engine components and has no damaging effect on the service life of the engine.

CORRECTION

Check that oil viscosity is matched to ambient temperature range at which the vehicle is being operated. Refer to Owners Manual or Operating Fluids

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Manual (Temperature - Viscosity chart) for further information.

SITUATION 1B

Tapping / rattling noises in the area of the valve train for the first 8 - 10 consecutive cold starts.

This condition usually occurs after the engine has been turned off at normal operating temperature and then not warmed up to full operating

temperature during the next series of cold starts.

This operating condition can occur, for example, on new vehicles which have been delivered to your BMW center (due to loading and unloading

from the transport trucks, etc.).

CAUSE

Hot engine oil initially escapes from the oil galley of the HVA elements when the engine is stopped. A small amount of oil also escapes through the

gaps between the HVA elements and the HVA housings in the cylinder head.

The oil then contracts while the engine is cooling down and allows air to enter the oil system.

During the subsequent cold start, this air can be forced into the HVA elements (causing air pockets) through the build up of engine oil pressure. The

resulting clearance between the HVA elements and the camshaft lobes causes the tapping / rattling noises.

This HVA tapping / rattling noise is not dependent on the amount of time the engine is off, but rather on:

The temperature of the engine when it was turned off (operating temperature - hot)

The number of subsequent cold starts without the engine being warmed up to operating temperature.

CORRECTION

Run the engine to dissipate (bleed) the air trapped in the high pressure chamber of the HVA elements.

Refer to the HVA bleeding procedure described below.

SITUATION 1C

Tapping / rattling noises in the area of the valve train after extreme cornering/lateral acceleration (engine oil level at or below minimum).

Note:

These valve train noises will not stop until the engine is run for approximately 10 - 15 minutes at an engine speed of at least 2,500 rpm with the

oil at the proper level.

CAUSE

During extreme cornering/lateral acceleration with the engine oil level at or below minimum, air can be drawn in by the oil pump (oil foaming). The

air which is drawn into the oil system can enter the HVA elements. The resulting clearance between the HVA elements and the camshaft lobes

causes the tapping / rattling noises.

Correction:

Run the engine to dissipate (bleed) the air trapped in the high pressure chamber of the HVA elements.

Refer to the HVA bleeding procedure described below.

HVA BLEEDING PROCEDURE:

-- Check oil level - correct if necessary.

-- Let engine idle at operating temperature with the hood open to verify valve train tapping / rattling noise.

-- If a tapping / rattling noise can be heard from the valve train, run the engine for 3 minutes without load at approximately 2,500 to 3,000 rpm

(bleeding procedure).

-- Then with the engine at idle listen for valve train noises again.

Note:

Only listen for noises when the engine has reached minimum oil pressure, i.e. after a waiting period (at idle) of approximately 15 - 30 seconds.

-- If no more noises can be heard, the test procedure is complete. No further action is necessary, the engine is working properly.

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-- If the tapping / rattling noises can still be heard, the bleeding procedure must be repeated (run the engine for 3 minutes at 2,500 - 3,000 rpm).

If necessary, repeat this procedure up to five times.

-- If the tapping / rattling noises can still be heard, the bleeding procedure must be performed one final time for approximately 15 minutes.

-- If no more noises can be heard, the test procedure is complete. No further action is necessary, the engine is working properly.

If the tapping / rattling noise is still heard after performing the above HVA Bleeding Procedure the following scenarios will assist in further

troubleshooting for HVA element noise:

If the noise is coming from all HVA elements an oil supply problem is the most likely cause.

Check engine oil pressure as outlined in the appropriate repair manual, group 11.

If the oil pump pressure (at idle = minimum pressure or regulated = maximum pressure) is below specification a visual inspection of the oil pump

and oil pump pick up in the oil pan should be performed with emphasis on the pick up gasket and control valve 0 ring were applicable. See repair

manual group 11, section 11 41 000 for further oil pump information.

Notes:

A faulty oil pump control valve 0 ring or oil pump pick up gasket (slight tear in 0 ring or gasket) may not always result in a low oil pressure

indication when performing an oil pressure check.

The air drawn in to the lubrication system via a defective gasket or 0 ring will cause oil foaming and HVA tapping / rattling noises.

If the noise is still coming from an individual HVA element after performing the above HVA Bleeding Procedure the suspected element(s) can be

isolated as follows:

-- Remove cylinder head cover.

-- Turn the engine over (normal direction of rotation) until the camshaft lobe of the HVA element to be checked is pointing away from the HVA

element. (engine valve completely closed)

-- Repeatedly apply a force of approximately 10N (2.25 lb.f.) to the HVA element with your thumb or using a folding arm tool BMW special tool

number 90 88 6 009 321 (included in the BMW assembly wedge kit PN 90 88 6 009 310) or a hard wood wedge.

If the HVA element collapses slightly as though it is spring loaded, this is a sign that air is trapped in the high pressure chamber.

-- Apply a force of approximately 20 - 30N (4.50 - 6.75 lb.f.) for 10 - 15 seconds to the HVA element using your thumb, folding arm tool or a hard

wood wedge.

If clearance between the camshaft lobe and the HVA element is created when the force is applied, this indicates that the check valve incorporated in

the HVA element is not closing / sealing properly due to contamination.

Release the applied force from the HVA element and using a feeler gauge measure the clearance between the HVA element and the camshaft lobe.

If any clearance is detected this indicates that the HVA element is sticking.

-- Conduct the checks as described above on all HVA elements.

-- Mark any suspect "soft" HVA element(s) for further examination.

Remove HVA elements as outlined in the appropriate repair manual, group 11 and visually inspect. Replace any suspect "soft" HVA element(s) and

check others for extreme wear (deep grooves, scratches, etc.) which may also need to be replaced.

Note:

Always reinstall used HVA elements in the same bore which they were removed from. This avoids possible binding due to different wear

patterns between the bore in the HVA housing and HVA element.

SITUATION 2

Binding HVA element.

CAUSE

An HVA element which is binding (element stuck in the extended position) will not allow a valve (intake or exhaust) to seat properly causing valve

seat leakage.

This type of HVA failure may not cause a tapping / rattling noise but the customer complaint may be: "engine runs rough during the warm up phase

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and runs good when warmed up" and/or the "Check Engine" lamp is on.

If the "Check Engine" lamp is illuminated due to a binding HVA element(s) one or more misfire fault codes may be set in the Engine Control

Module (ECM/DME).

Note:

Basic troubleshooting should be performed first before checking for a binding HVA element to eliminate all other possible factors / components

which could set the misfire faults such as low fuel level, a faulty spark plug, etc.

Refer to Service Information bulletin 12 02 97 for further misfire fault information.

Troubleshooting tips:

-- If there is a binding HVA element in one or more cylinders as described above a misfire fault can typically be reproduced in the affected

cylinder(s) by duplicating the conditions in which the misfire occurred according to the DME/ECM fault code description i.e., at engine

temperature = X, engine speed = X, etc.

-- A binding HVA element which is causing a misfire in one specific cylinder will not "move" to an other cylinder and will always cause a misfire

fault in the affected cylinder.

-- Performing the "Smooth-Running" test (found in the DME control unit functions section of DIS) will assist in pin pointing a cylinder with a

binding HVA element.

A cylinder with a binding HVA element will indicate a high reading when compared to the other good cylinders.

-- Since a binding HVA element may in some cases be intermittent (engine only runs rough when cold) if a cylinder leak down check is used for

troubleshooting this should be performed when the problem exists, for example: compare the cylinder leakage rates to each other with a cold

engine to determine the cylinder with the extreme leakage rate.

A cylinder with a binding HVA element will indicate a leakage rate above 15%.

Remove suspected HVA elements as outlined in the appropriate repair manual group 11 and visually inspect.

-- A binding HVA element will typically have a high pressure piston- (located in the center of the HVA element body) which extends out

approximately 3mm further when compared to the other HVA elements removed from the cylinder head.

Replace any binding HVA element(s) and check others for extreme wear (deep grooves, scratches, etc.) which may also need to be replaced.

Note:

Always reinstall used HVA elements in the same bore which they were removed from. This avoids possible binding due to different wear

patterns between the bore in the HVA housing and HVA element.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 841197 Date: 010601

Navigation System - Numerous Failures/Malfunctions

GROUP 84

Phone, Navigation Systems

84 11 97

Woodcliff Lake, NJ

June 2001

Service Engineering

This Service Information bulletin supersedes S.I. 84 11 97 dated January 2001.

SUBJECT

BMW Nav Operating Software CD V17.0 for MK I, MK II, MK III, and MK III Radio Nav Systems

MODEL

E46, E38, E39, E53, E52

SITUATION

The following Navigation System MK I (up to 09/97 production) failure/malfunction may be experienced by the customers:

1. The words "Enter code" appear on the board-monitor when the ignition is switched on. Intermittently, when the ignition key is turned to

position ON (KL 15), the prompt "Enter code" appears, even though the code function was previously not activated. The Main Menu screen

can be recalled by pressing the "menu" button.

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The following Navigation System MK II (from 09/97 production) failures/malfunctions may be experienced by the customers:

1. Poor readability of map display in the E53 vehicles.

Under certain conditions, it is difficult to read the map display on the board monitor due to inadequate contrast.

2. Inaccurate determination of vehicles position when starting the navigation system and then driving at 900 to the direction vehicle was facing

when parked.

If immediately after activating the navigation system, the vehicle is driven in a direction 900 offset to the direction in which vehicle was facing

while parked, the navigation system may not be able to determine its location correctly (e.g. leaving a parking space before vehicles location

and planned route is established).

3. The faulty display "Incorrect software loaded" appears after the ignition is switched ON.

After turning ignition on (KL 15), the erroneous display "Incorrect software loaded" intermittently appears in the on-board monitor. Situation

can be corrected by turning ignition OFF, waiting at least 1 minute, and then turning it ON again.

NOTE:

With the new operating software (from CD V16.1) loaded into the system, the display "Incorrect software loaded" may still sporadically appear,

however the navigation computer will then automatically reset, and will be restarted with the correct main menu on the display.

4. The screen remains dark or shows only the status bar (at the bottom) after the vehicle was started.

After turning ignition on (KL 15), no display appears in the on-board monitor except for the status bar. The background lighting of the screen

is dark gray. The remaining displays in the main menu, or the audio menu (if radio was switched ON before) do not appear. Time display in

the status bar is not being updated. Situation can be corrected by turning ignition OFF, waiting at least 1 minute, and then turning it ON again.

5. The screen darkens during driving ("black" or "blank" screen) and the system reboots.

The on-board monitor intermittently blanks-out during driving when the Navigation System is operating. After a few seconds, the screen

reappears and the system reboots. Then, the main menu (if radio was previously turned off) or the audio/BC display shows on the screen.

In some cases the screen remains black, and reappears again only after turning ignition OFF, waiting at least 1 minute, and then turning it ON

again. In the "main menu" screen the "Navigation" feature cannot be selected (Navigation button is not highlighted).

6. A route intermittently runs in a loop.

Intermittently, the map of the planned route appears on the on-board monitor as a loop, or the route guidance instruction runs in a loop (e.g. at

the intersection route guidance proposes a different direction then the one which was calculated initially, and after following this direction for

a while, either: instructs to make a "U-turn", or describes a route back to the original junction where the turn was executed).

7. Inaccuracies in the vehicle position indicator or implausible route guidance information. Extended "reaction" time of the Navigation System in

route guidance and planning, after vehicle departs from the originally planned route.

Intermittently, incorrect distances are displayed at intersections or highway exits (e.g. 200 feet or more). Situation is sporadic and cannot be

reproduced in the same location (reproducible faults would indicate error in the CD map).

Or, vehicle position cursor on the map display drifts away from the road or runs alongside the road. This situation results in implausible

guidance information (system "tries" to return to the originally planned route), and in some cases the message: "You are leaving the

digitized area" is sent by the system.

8. On-board computer (BC) data not displayed on the board monitor.

After ignition key is turned "ON" (KL 15) and screen is changed from "main menu" to radio/BC display, the displayed board computer data is

not complete (or appears with significant time delay). In most cases the missing values are: Range, Ambient Temperature, or Fuel

Consumption. Sometimes, those values may reappear during driving of the vehicle.

9. Route guidance intermittently remains active following "Destination Reached" display.

If the vehicle's ignition was turned "OFF" in the very moment the" Destination Reached" message was displayed on the board monitor, the

route guidance to that destination may remain active the next time the vehicle is driven (Navigation instructions are given, even though the

"Navigation" button was not selected from the "main menu" screen).

10. System resets (screen "blanking") when selecting a road junction from the list with numerous entries.

When entering a road junction to a selected street during a "destination input", after approximately two minutes of calculations the system

reboots. After the reset, in the "main menu" screen the "Navigation" feature cannot be selected (Navigation button is not highlighted). The

failure described above may occur only when the selected street leads to a large number of intersections (example: 5th Avenue, New York

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City).

11. Turn guidance instructions are linguistically incorrect.

The following voice commands: "Left turn", "Right turn", "Left turn ahead", and "Right turn ahead" with introduction of CD V17.0 have been

change to: "Turn left", "Turn right", Turn left ahead", and "Turn right ahead".

12. Sound and arrow guidance intermittent failure.

The acoustic commands, together with the graphic guidance intermittently fail during navigation. When switched to the map display mode,

system operates correctly (vehicle's icon moves in the selected destination), but still the voice commands are not generated.

The following Radio Navigation System MK II and MK III on Z8 (E52) vehicles failures/malfunctions may be experienced by the customers:

1. Missing menu items in radio display.

Intermittently after turning ignition ON (KL 15), the menu items are missing from the MIR radio display. The full menu is restored again after

switching ignition OFF and ON again (with one minute interval).

2. Menu item "Navigation" intermittently fails to appear in radio display.

Intermittently during driving, the "Navigation" menu line is missing from the MIR radio display. The radio-navigation cannot be selected. The

full menu is restored again after switching ignition OFF and ON again (with one minute interval).

3. On-board computer (BC) data not displayed on the board monitor.

After ignition key is turned "ON" (KL 15) and screen is changed from "main menu" to radio/BC display, the displayed board computer data is

not complete (or appears with significant time delay). In most cases the missing values are:

Range, Ambient Temperature, or Fuel Consumption. Sometimes, those values may reappear during driving of the vehicle.

4. Turn guidance instructions are linguistically incorrect.

The following voice commands: "Left turn", "Right turn", "Left turn ahead", and "Right turn ahead" with introduction of CD V17.0 have been

change to: "Turn left", "Turn right", Turn left ahead", and "Turn right ahead".

5. Sound and arrow guidance intermittent failure.

The acoustic commands, together with the graphic guidance intermittently fail during navigation. When switched to the map display mode,

system operates correctly (vehicle's icon moves in the selected destination), but still the voice commands are not generated.

The following Navigation System MK III (E46 from 06/00, E38/E39 from 09/00, E53 from 10/00 production) failures/malfunctions may be

experienced by the customers:

1. On-board computer (BC) data not displayed on the board monitor.

After ignition key is turned "ON" (KL 15) and screen is changed from "main menu" to radio/BC display, the displayed board computer data is

not complete (or appears with significant time delay). In most cases the missing values are:

Range, Ambient Temperature, or Fuel Consumption. Sometimes, those values may reappear during driving of the vehicle.

2. Turn guidance instructions are linguistically incorrect.

The following voice commands: "Left turn", "Right turn", "Left turn ahead", and "Right turn ahead" with introduction of CD V17.0 have been

change to: "Turn left", "Turn right", Turn left ahead", and "Turn right ahead".

3. Sound and arrow guidance intermittent failure.

The acoustic commands, together with the graphic guidance intermittently fail during navigation. When switched to the map display mode,

system operates correctly (vehicle's icon moves in the selected destination), but still the voice commands are not generated.

CAUSE

Software errors in the Operating Software of Navigation System MK I, MK II and MK III.

Important:

None of the complaints described above are valid reasons for replacement of the Navigation Computer.

CORRECTION

On a customer complaint basis only, load the Navigation Computer with the updated version of Navigation operating software (CD V17.0).

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NOTE:

Also, in case of a hardware failure (not related to the situations described above) after replacement of the Navigation computer (on MK I, MK II,

or MK III systems), or the video module (on MK I only) the units have to be coded, and the computer must be loaded with the new CD V17.0

operating software.

DISCLAIMER

Procedure

To load the new software:

1. Turn ignition to position 1 (terminal R).

Do not cycle the key or perform diagnosis while installing the new software. Make sure that the power supply is stable, i.e. do not switch on

any electrical toads.

2. Activate "GPS-Navigation" and acknowledge the screen disclaimer by pushing the rotary knob.

3. Remove the map CD from the navigation computer by pressing "eject" button.

4. Insert the Software CD V17.0 into the Navigation computer (the CD-ROM V17.0 bears the P/N 01 59 9 789 299 Index "u").

5. Mark I System (up to 9/97 production):

After a few seconds, the BMW roundel will appear on the board monitor and will be "filled in" clockwise to show the progress of loading

(approx. 3-4 minutes).

Mark II System (from 9/97 production),

Mark III System (E46 from 06/00, and E38/E39/E52 from 09/00 production):

After a few seconds, a menu of notes on loading procedure and "progress" bar appear on the board monitor.

When the loading process has been completed, the message "Software has been successfully loaded" is displayed.

6. First remove the operating software CD, and then confirm the end of the loading process by pressing the rotary push-button on the board

monitor. "OK" appears in the display.

7. Reinsert the map CD into the Navigation computer.

8. Mark III System with "Wide Screen" on-board monitor:

The "Wide Screen" (6.5" diagonal measurement) was introduced as a running production change on E38/E39 vehicles from 09/00, and on E53

vehicles from 04/01. (For detailed description of features and operation of the new board monitor, please refer to Service Information Bulletin

84 11 00 from September 2000).

On the "Wide Screen" board monitor, the radio country specific functions, such as "RDS" (Radio Data System), and "Ply" (Programming

Type) are no longer activated via dedicated buttons, but by the "soft-keys". The "soft-keys" appear on the screen by pressing the "INFO"

button (see illustration).

IMPORTANT:

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To enable the country specific radio functions of the soft-keys to be correctly activated by the navigation system, switch the radio briefly ON and

OFF again after loading of the navigation operating software has been completed. (Also, radio should be turned ON and OFF briefly, every time

the vehicle's battery has been disconnected and reconnected again).

CD V17.0 contains the operating software as shown.

Note:

The Navigation Computer automatically recognizes the required version when the software is loaded.

Previously released Navigation Software CD's (V 6.5, V 7,3, V 05, V09, V11, V12, V14, V15, V16.1, V16.2) should be discarded

Changes/improvements for the Mark I (Mk I) system:

-- "Software Status" in the "Set" screen change: The software/hardware version is now displayed as "1-1/72". The numbers have the following

meanings: first digit 1 - is a 1st generation navigation system (Mk1); second digit 1 - is a 1st device variant (top navigation - Mk1c color screen);

the last two digits 72 - are the software version of the graphic component (7.2).

Changes/improvements for the Mark II (Mk II) system:

-- "Software Status" in the "Set" screen change: The software/hardware version is now displayed as "2-1/70". The numbers have the following

meanings: first digit 2 - is a 2nd generation navigation system (Mk2); second digit 1 - is a 1st device variant (top navigation - Mk2c color

screen); the last two digits 70 - are the software version of the graphic component (7.0).

-- A "Mayday" (emergency) phone call is initiated automatically after an airbag is deployed (on vehicles equipped with Navigation MK III MK III,

MRS 3 System and integrated cellular phone CMT 5000VR, CPT 6000VR or digital CPT 7000, CPT8000). MRS 3 System was introduced as

follows: 3/99 on E39/E38, 06/99 on E46 coupe, 9/99 on E46 sedan, and since series introduction on E52, and E53 vehicles.

-- There is no need to manually enter VIN number into the "Telematics Settings" of the "Service Mode" of navigation computer on vehicles with

integrated cellular phones (see SI 84 05 97 from July of 1999). The VIN number is automatically transferred from vehicle ZCS coding data.

-- The distance to destination is now displayed in up to four digits. This feature meets the need of long journeys, planned when using the

nationwide coverage provided on new Map CD's (release "1999.2", available since 7/99).

-- Demonstration Mode ("Taxi Mode") software is now included in the operating software. This feature allows full demonstration of the Navigation

System when vehicle is stationery (e.g. in the showroom). To activate the "Demonstration Mode:

a. Turn ignition to position 1 (terminal R)

b. Select "GPS Navigation" from the "main menu" screen, and then press OK on the disclaimer screen

c. Verify that the current location is stored in the memory of the computer (to check current location, from the "main menu" select

"Emergency". The next screen displays current vehicle location).

NOTE:

Vehicle must be located in the digitized area to have its position evaluated correctly.

d. In the "Input Destination" menu, enter the desired destination

e. Press and hold Menu button for at least one second. The screen goes back to the "main menu", then select "GSP Navigation" again.

f. With known current position and destination, select "Direction" from the destination input menu screen. The "Demonstration Mode" is

activated (system will give guidance instructions, distance to destination changes, in the route map mode the vehicle icon moves).

g. To exit the "Demonstration Mode" turn the ignition OFF, or start driving the vehicle.

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The "Route Direction Arrow" is displayed as a framed arrow instead of a filled one, to enhance the guidance screen appearance.

-- The quantity of language selections (from "SET" menu selection) in the system is reduced to two for US market (American English and Spanish),

due to software changes for European markets. (It is still possible to change languages and voice gender by using DIS/MoDiC

IKE Coding/Conversion procedure - see SI 84 01 98 for details).

Changes/improvements for the Mark III (Mk III) system:

-- The new generation of navigation computer with the designation "MK III" was introduced into E46 series production starting 06/00, and into

E39/E38/E52 models since 09/00.

-- The main new features of the MK III computer are: integration of the GPS receiver into the unit, and utilization of a new, faster processor (125

MHz).

-- This computer can be installed in vehicles with either radio navigation system (monochrome display - E52), or with top navigation (on-board

color monitor).

-- "Software Status" in the "Set" screen for MK III system: the software/hardware version is displayed as "3-1/30" or "3-2/30". The numbers have

the following meanings: first digit 3 - is a 3rd generation navigation system (Mk3); second digit 1 - is a 1st device variant (top navigation - Mk3c

color screen), or 2 - is a 2nd device variant (radio navigation - Mk3m monochrome display); the last two digits 30 - are the software version of

the graphic component (3.0).

-- When replacing a defective MK III computer, a configuration signal is required to allow the new computer to load the correct software for its

respective application. This is generated by using DIS coding program "Coding ZCS C25.0" and the Navigation System operating software CD

V 17.0:

1. Connect DIS/MoDiC 3 tester to vehicle

2. From the DIS Coding/Programming select "1 ZCS Coding"

3. Select appropriate engineering series (E38, E39, etc.)

4. Select "4 conversion"

5. Select "3 IKE/Kombi"

6. Select "2 Language"

7. At prompt "Is the CD-ROM present?" - select "Yes", but do not insert CD V17.0 into the NAV computer yet!

8. First select the main language and then an additional language (the choices are: English, French, Italian, Spanish, German)

9. Select announcer's voice gender: male or female

10. After activation of the automatic coding, the DIS tester tells you to follow the instructions on the monitor for CD V17.0 installation

11 Place the CD V17.0 in the navigation computer CD drive

IMPORTANT:

Do not switch ignition OFF during software loading procedure.

Do not use any other Nav Software CD's except CD V17.0.

12. Once loading has been completed, remove the CD and then confirm completion by pressing the rotary push-button on the monitor

13. Turn ignition OFF for 10 seconds, then turn it ON and conduct a functional check

14. After this step has been finished, encode the navigation computer in the regular manner using the path "1 Recoding".

If the Navigation Computer is already configured for a navigation system (Radio Nav, or Top Nav), the procedure described above is not necessary

during the subsequent operating software updates.

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PARTS INFORMATION

WARRANTY INFORMATION

Covered under the terms of the BMW New Vehicle Limited Warranty.

2000 BMW 328i (E46) Technical Service Bulletin # 841197 Date: 010601

2000 BMW 328i (E46) Technical Service Bulletin # 841197 Date: 010601

Navigation System - Numerous Failures/Malfunctions

GROUP 84

Phone, Navigation Systems

84 11 97

Woodcliff Lake, NJ

June 2001

Service Engineering

This Service Information bulletin supersedes S.I. 84 11 97 dated January 2001.

SUBJECT

BMW Nav Operating Software CD V17.0 for MK I, MK II, MK III, and MK III Radio Nav Systems

MODEL

E46, E38, E39, E53, E52

SITUATION

The following Navigation System MK I (up to 09/97 production) failure/malfunction may be experienced by the customers:

1. The words "Enter code" appear on the board-monitor when the ignition is switched on. Intermittently, when the ignition key is turned to

position ON (KL 15), the prompt "Enter code" appears, even though the code function was previously not activated. The Main Menu screen

can be recalled by pressing the "menu" button.

The following Navigation System MK II (from 09/97 production) failures/malfunctions may be experienced by the customers:

1. Poor readability of map display in the E53 vehicles.

Under certain conditions, it is difficult to read the map display on the board monitor due to inadequate contrast.

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2. Inaccurate determination of vehicles position when starting the navigation system and then driving at 900 to the direction vehicle was facing

when parked.

If immediately after activating the navigation system, the vehicle is driven in a direction 900 offset to the direction in which vehicle was facing

while parked, the navigation system may not be able to determine its location correctly (e.g. leaving a parking space before vehicles location

and planned route is established).

3. The faulty display "Incorrect software loaded" appears after the ignition is switched ON.

After turning ignition on (KL 15), the erroneous display "Incorrect software loaded" intermittently appears in the on-board monitor. Situation

can be corrected by turning ignition OFF, waiting at least 1 minute, and then turning it ON again.

NOTE:

With the new operating software (from CD V16.1) loaded into the system, the display "Incorrect software loaded" may still sporadically appear,

however the navigation computer will then automatically reset, and will be restarted with the correct main menu on the display.

4. The screen remains dark or shows only the status bar (at the bottom) after the vehicle was started.

After turning ignition on (KL 15), no display appears in the on-board monitor except for the status bar. The background lighting of the screen

is dark gray. The remaining displays in the main menu, or the audio menu (if radio was switched ON before) do not appear. Time display in

the status bar is not being updated. Situation can be corrected by turning ignition OFF, waiting at least 1 minute, and then turning it ON again.

5. The screen darkens during driving ("black" or "blank" screen) and the system reboots.

The on-board monitor intermittently blanks-out during driving when the Navigation System is operating. After a few seconds, the screen

reappears and the system reboots. Then, the main menu (if radio was previously turned off) or the audio/BC display shows on the screen.

In some cases the screen remains black, and reappears again only after turning ignition OFF, waiting at least 1 minute, and then turning it ON

again. In the "main menu" screen the "Navigation" feature cannot be selected (Navigation button is not highlighted).

6. A route intermittently runs in a loop.

Intermittently, the map of the planned route appears on the on-board monitor as a loop, or the route guidance instruction runs in a loop (e.g. at

the intersection route guidance proposes a different direction then the one which was calculated initially, and after following this direction for

a while, either: instructs to make a "U-turn", or describes a route back to the original junction where the turn was executed).

7. Inaccuracies in the vehicle position indicator or implausible route guidance information. Extended "reaction" time of the Navigation System in

route guidance and planning, after vehicle departs from the originally planned route.

Intermittently, incorrect distances are displayed at intersections or highway exits (e.g. 200 feet or more). Situation is sporadic and cannot be

reproduced in the same location (reproducible faults would indicate error in the CD map).

Or, vehicle position cursor on the map display drifts away from the road or runs alongside the road. This situation results in implausible

guidance information (system "tries" to return to the originally planned route), and in some cases the message: "You are leaving the

digitized area" is sent by the system.

8. On-board computer (BC) data not displayed on the board monitor.

After ignition key is turned "ON" (KL 15) and screen is changed from "main menu" to radio/BC display, the displayed board computer data is

not complete (or appears with significant time delay). In most cases the missing values are: Range, Ambient Temperature, or Fuel

Consumption. Sometimes, those values may reappear during driving of the vehicle.

9. Route guidance intermittently remains active following "Destination Reached" display.

If the vehicle's ignition was turned "OFF" in the very moment the" Destination Reached" message was displayed on the board monitor, the

route guidance to that destination may remain active the next time the vehicle is driven (Navigation instructions are given, even though the

"Navigation" button was not selected from the "main menu" screen).

10. System resets (screen "blanking") when selecting a road junction from the list with numerous entries.

When entering a road junction to a selected street during a "destination input", after approximately two minutes of calculations the system

reboots. After the reset, in the "main menu" screen the "Navigation" feature cannot be selected (Navigation button is not highlighted). The

failure described above may occur only when the selected street leads to a large number of intersections (example: 5th Avenue, New York

City).

11. Turn guidance instructions are linguistically incorrect.

The following voice commands: "Left turn", "Right turn", "Left turn ahead", and "Right turn ahead" with introduction of CD V17.0 have been

change to: "Turn left", "Turn right", Turn left ahead", and "Turn right ahead".

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12. Sound and arrow guidance intermittent failure.

The acoustic commands, together with the graphic guidance intermittently fail during navigation. When switched to the map display mode,

system operates correctly (vehicle's icon moves in the selected destination), but still the voice commands are not generated.

The following Radio Navigation System MK II and MK III on Z8 (E52) vehicles failures/malfunctions may be experienced by the customers:

1. Missing menu items in radio display.

Intermittently after turning ignition ON (KL 15), the menu items are missing from the MIR radio display. The full menu is restored again after

switching ignition OFF and ON again (with one minute interval).

2. Menu item "Navigation" intermittently fails to appear in radio display.

Intermittently during driving, the "Navigation" menu line is missing from the MIR radio display. The radio-navigation cannot be selected. The

full menu is restored again after switching ignition OFF and ON again (with one minute interval).

3. On-board computer (BC) data not displayed on the board monitor.

After ignition key is turned "ON" (KL 15) and screen is changed from "main menu" to radio/BC display, the displayed board computer data is

not complete (or appears with significant time delay). In most cases the missing values are:

Range, Ambient Temperature, or Fuel Consumption. Sometimes, those values may reappear during driving of the vehicle.

4. Turn guidance instructions are linguistically incorrect.

The following voice commands: "Left turn", "Right turn", "Left turn ahead", and "Right turn ahead" with introduction of CD V17.0 have been

change to: "Turn left", "Turn right", Turn left ahead", and "Turn right ahead".

5. Sound and arrow guidance intermittent failure.

The acoustic commands, together with the graphic guidance intermittently fail during navigation. When switched to the map display mode,

system operates correctly (vehicle's icon moves in the selected destination), but still the voice commands are not generated.

The following Navigation System MK III (E46 from 06/00, E38/E39 from 09/00, E53 from 10/00 production) failures/malfunctions may be

experienced by the customers:

1. On-board computer (BC) data not displayed on the board monitor.

After ignition key is turned "ON" (KL 15) and screen is changed from "main menu" to radio/BC display, the displayed board computer data is

not complete (or appears with significant time delay). In most cases the missing values are:

Range, Ambient Temperature, or Fuel Consumption. Sometimes, those values may reappear during driving of the vehicle.

2. Turn guidance instructions are linguistically incorrect.

The following voice commands: "Left turn", "Right turn", "Left turn ahead", and "Right turn ahead" with introduction of CD V17.0 have been

change to: "Turn left", "Turn right", Turn left ahead", and "Turn right ahead".

3. Sound and arrow guidance intermittent failure.

The acoustic commands, together with the graphic guidance intermittently fail during navigation. When switched to the map display mode,

system operates correctly (vehicle's icon moves in the selected destination), but still the voice commands are not generated.

CAUSE

Software errors in the Operating Software of Navigation System MK I, MK II and MK III.

Important:

None of the complaints described above are valid reasons for replacement of the Navigation Computer.

CORRECTION

On a customer complaint basis only, load the Navigation Computer with the updated version of Navigation operating software (CD V17.0).

NOTE:

Also, in case of a hardware failure (not related to the situations described above) after replacement of the Navigation computer (on MK I, MK II,

or MK III systems), or the video module (on MK I only) the units have to be coded, and the computer must be loaded with the new CD V17.0

operating software.

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DISCLAIMER

Procedure

To load the new software:

1. Turn ignition to position 1 (terminal R).

Do not cycle the key or perform diagnosis while installing the new software. Make sure that the power supply is stable, i.e. do not switch on

any electrical toads.

2. Activate "GPS-Navigation" and acknowledge the screen disclaimer by pushing the rotary knob.

3. Remove the map CD from the navigation computer by pressing "eject" button.

4. Insert the Software CD V17.0 into the Navigation computer (the CD-ROM V17.0 bears the P/N 01 59 9 789 299 Index "u").

5. Mark I System (up to 9/97 production):

After a few seconds, the BMW roundel will appear on the board monitor and will be "filled in" clockwise to show the progress of loading

(approx. 3-4 minutes).

Mark II System (from 9/97 production),

Mark III System (E46 from 06/00, and E38/E39/E52 from 09/00 production):

After a few seconds, a menu of notes on loading procedure and "progress" bar appear on the board monitor.

When the loading process has been completed, the message "Software has been successfully loaded" is displayed.

6. First remove the operating software CD, and then confirm the end of the loading process by pressing the rotary push-button on the board

monitor. "OK" appears in the display.

7. Reinsert the map CD into the Navigation computer.

8. Mark III System with "Wide Screen" on-board monitor:

The "Wide Screen" (6.5" diagonal measurement) was introduced as a running production change on E38/E39 vehicles from 09/00, and on E53

vehicles from 04/01. (For detailed description of features and operation of the new board monitor, please refer to Service Information Bulletin

84 11 00 from September 2000).

On the "Wide Screen" board monitor, the radio country specific functions, such as "RDS" (Radio Data System), and "Ply" (Programming

Type) are no longer activated via dedicated buttons, but by the "soft-keys". The "soft-keys" appear on the screen by pressing the "INFO"

button (see illustration).

IMPORTANT:

To enable the country specific radio functions of the soft-keys to be correctly activated by the navigation system, switch the radio briefly ON and

OFF again after loading of the navigation operating software has been completed. (Also, radio should be turned ON and OFF briefly, every time

the vehicle's battery has been disconnected and reconnected again).

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CD V17.0 contains the operating software as shown.

Note:

The Navigation Computer automatically recognizes the required version when the software is loaded.

Previously released Navigation Software CD's (V 6.5, V 7,3, V 05, V09, V11, V12, V14, V15, V16.1, V16.2) should be discarded

Changes/improvements for the Mark I (Mk I) system:

-- "Software Status" in the "Set" screen change: The software/hardware version is now displayed as "1-1/72". The numbers have the following

meanings: first digit 1 - is a 1st generation navigation system (Mk1); second digit 1 - is a 1st device variant (top navigation - Mk1c color screen);

the last two digits 72 - are the software version of the graphic component (7.2).

Changes/improvements for the Mark II (Mk II) system:

-- "Software Status" in the "Set" screen change: The software/hardware version is now displayed as "2-1/70". The numbers have the following

meanings: first digit 2 - is a 2nd generation navigation system (Mk2); second digit 1 - is a 1st device variant (top navigation - Mk2c color

screen); the last two digits 70 - are the software version of the graphic component (7.0).

-- A "Mayday" (emergency) phone call is initiated automatically after an airbag is deployed (on vehicles equipped with Navigation MK III MK III,

MRS 3 System and integrated cellular phone CMT 5000VR, CPT 6000VR or digital CPT 7000, CPT8000). MRS 3 System was introduced as

follows: 3/99 on E39/E38, 06/99 on E46 coupe, 9/99 on E46 sedan, and since series introduction on E52, and E53 vehicles.

-- There is no need to manually enter VIN number into the "Telematics Settings" of the "Service Mode" of navigation computer on vehicles with

integrated cellular phones (see SI 84 05 97 from July of 1999). The VIN number is automatically transferred from vehicle ZCS coding data.

-- The distance to destination is now displayed in up to four digits. This feature meets the need of long journeys, planned when using the

nationwide coverage provided on new Map CD's (release "1999.2", available since 7/99).

-- Demonstration Mode ("Taxi Mode") software is now included in the operating software. This feature allows full demonstration of the Navigation

System when vehicle is stationery (e.g. in the showroom). To activate the "Demonstration Mode:

a. Turn ignition to position 1 (terminal R)

b. Select "GPS Navigation" from the "main menu" screen, and then press OK on the disclaimer screen

c. Verify that the current location is stored in the memory of the computer (to check current location, from the "main menu" select

"Emergency". The next screen displays current vehicle location).

NOTE:

Vehicle must be located in the digitized area to have its position evaluated correctly.

d. In the "Input Destination" menu, enter the desired destination

e. Press and hold Menu button for at least one second. The screen goes back to the "main menu", then select "GSP Navigation" again.

f. With known current position and destination, select "Direction" from the destination input menu screen. The "Demonstration Mode" is

activated (system will give guidance instructions, distance to destination changes, in the route map mode the vehicle icon moves).

g. To exit the "Demonstration Mode" turn the ignition OFF, or start driving the vehicle.

The "Route Direction Arrow" is displayed as a framed arrow instead of a filled one, to enhance the guidance screen appearance.

-- The quantity of language selections (from "SET" menu selection) in the system is reduced to two for US market (American English and Spanish),

due to software changes for European markets. (It is still possible to change languages and voice gender by using DIS/MoDiC

210

IKE Coding/Conversion procedure - see SI 84 01 98 for details).

Changes/improvements for the Mark III (Mk III) system:

-- The new generation of navigation computer with the designation "MK III" was introduced into E46 series production starting 06/00, and into

E39/E38/E52 models since 09/00.

-- The main new features of the MK III computer are: integration of the GPS receiver into the unit, and utilization of a new, faster processor (125

MHz).

-- This computer can be installed in vehicles with either radio navigation system (monochrome display - E52), or with top navigation (on-board

color monitor).

-- "Software Status" in the "Set" screen for MK III system: the software/hardware version is displayed as "3-1/30" or "3-2/30". The numbers have

the following meanings: first digit 3 - is a 3rd generation navigation system (Mk3); second digit 1 - is a 1st device variant (top navigation - Mk3c

color screen), or 2 - is a 2nd device variant (radio navigation - Mk3m monochrome display); the last two digits 30 - are the software version of

the graphic component (3.0).

-- When replacing a defective MK III computer, a configuration signal is required to allow the new computer to load the correct software for its

respective application. This is generated by using DIS coding program "Coding ZCS C25.0" and the Navigation System operating software CD

V 17.0:

1. Connect DIS/MoDiC 3 tester to vehicle

2. From the DIS Coding/Programming select "1 ZCS Coding"

3. Select appropriate engineering series (E38, E39, etc.)

4. Select "4 conversion"

5. Select "3 IKE/Kombi"

6. Select "2 Language"

7. At prompt "Is the CD-ROM present?" - select "Yes", but do not insert CD V17.0 into the NAV computer yet!

8. First select the main language and then an additional language (the choices are: English, French, Italian, Spanish, German)

9. Select announcer's voice gender: male or female

10. After activation of the automatic coding, the DIS tester tells you to follow the instructions on the monitor for CD V17.0 installation

11 Place the CD V17.0 in the navigation computer CD drive

IMPORTANT:

Do not switch ignition OFF during software loading procedure.

Do not use any other Nav Software CD's except CD V17.0.

12. Once loading has been completed, remove the CD and then confirm completion by pressing the rotary push-button on the monitor

13. Turn ignition OFF for 10 seconds, then turn it ON and conduct a functional check

14. After this step has been finished, encode the navigation computer in the regular manner using the path "1 Recoding".

If the Navigation Computer is already configured for a navigation system (Radio Nav, or Top Nav), the procedure described above is not necessary

during the subsequent operating software updates.

PARTS INFORMATION

211

WARRANTY INFORMATION

Covered under the terms of the BMW New Vehicle Limited Warranty.

2000 BMW 328i (E46) Technical Service Bulletin # 650401 Date: 010601

2000 BMW 328i (E46) Technical Service Bulletin # 650401 Date: 010601

CD Changer - Installation

GROUP 65

Sound System, Cruise, Alarm

65 04 01

Woodcliff Lake, NJ

June 2001

Service Engineering

SUBJECT

Nakamichi CD Changer - Installation on E46 with C53 NG Radio

MODEL

E46, 3 Series from 03/01 (with C53 cassette radio)

453

SITUATION

The C53 Business New Generation radio (cassette radio) was introduced into series production in March of '01. (The New Generation in-dash CD53

unit is planned for introduction in September of '01). The NG radios feature increased functionality, and new Siemens connector for the CD changer

/telephone, with revised pin assignments.

During the installation of a Nakamichi CD changer, the data cable (PN 82 11 0 004 617) found in the CD changer installation kit, has to be modified

in order to be compatible with the NG radio. The power/I-Bus cable (PN 82 11 0 004 618) should be installed according to the "Nakamichi CD

Changer Installation Instruction".

PROCEDURE

New Generation C53 radio CD changer connector pin assignments:

New Generation C53 Radio CD changer/Telephone Connector Pin Assignments:

1. From the audio-data cable (PN 82 11 0 004 617), remove metal housing (1) (shielding's ground) from the connector on the radio side (as

shown on the illustration).

454

2. Disassemble the connector housing, by sliding out the white plastic cover (1).

3. Using a small screwdriver (2), carefully press on pin's locking tab, while at the same time gently pulling out a wire from the connector.

Attention:

The AMP connector housing has two locking steps, for that reason the pin's locking tab must be depressed twice.

4. Remove all five female pin connectors (as shown on the illustration).

Important:

The black shielding wire (1) removed from position number 3 is obsolete and should be taped-back to the data cable.

5. From the main radio connector housing, remove the audio CD changer connector - X01026 (1).

Disassemble the connector housing.

455

6. Remove the following female pins (2) from the connector X01026:

- pin 1 (white/blue wire)

- pin 2 (white/red wire)

- pin 6 (white/brown wire)

Important:

The pins: 3 (yellow wire) and 8 (black wire) should be left in the connector (for the telephone audio data).

7. Insert three pin connectors (1) of the audio-data installation cable (previously removed from the connector housing), into the vacant slots of

the connector X01026:

- pin 1 --- white wire

- pin 2 --- red wire

- pin 6 --- black wire

8. Tape-back the removed pin connectors to the radio harness (1).

9. Route both installation cables (power/I-Bus and data) towards glove box, according to the Nakamichi CD changer installation instruction.

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 110101 Date: 010601

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 110101 Date: 010601

Engine - MIL ON/Codes Set/Tapping/Rattling Noise

GROUP 11

Engine

11 01 01

Woodcliff Lake, NJ

June 2001

Service Engineering

This Service Information bulletins supersedes S.I. 11 05 90 dated May 1990.

SUBJECT

Hydraulic Bucket Tappets (HVA) Troubleshooting Tips

MODEL

All with M42, M44, M50, M52, M54, M60, M62, S50, S52 and S62 engines

SITUATION

Two common reasons for the replacement of hydraulic bucket tappets (HVA) are:

1. Tapping / rattling noise from the valve train area or

2. Binding HVA element

CAUSE

Tapping / rattling noise from the valve train area may have various different causes depending on engine oil level, engine / oil temperature, when the

noise is heard (cold start, engine hot), etc.

The following Complaint, Cause and Correction scenarios will assist in troubleshooting for HVA element noise:

SITUATION 1A

Tapping / rattling noises from the area of the valve train up to 20 seconds after a cold start.

CAUSE

These noises can be traced back to the higher viscosity of cold mineral based engine oil.

For a brief moment insufficient oil reaches the high pressure chamber of the HVA element via the high pressure valve after start up. This results in

clearance between the HVA element and the camshaft lobe which then causes a tapping / rattling noise.

Influencing factors for this complaint:

Viscosity of engine oil used

Ambient temperature

This condition is not caused by mechanical damage to any engine components and has no damaging effect on the service life of the engine.

CORRECTION

Check that oil viscosity is matched to ambient temperature range at which the vehicle is being operated. Refer to Owners Manual or Operating Fluids

Manual (Temperature - Viscosity chart) for further information.

SITUATION 1B

Tapping / rattling noises in the area of the valve train for the first 8 - 10 consecutive cold starts.

This condition usually occurs after the engine has been turned off at normal operating temperature and then not warmed up to full operating

temperature during the next series of cold starts.

This operating condition can occur, for example, on new vehicles which have been delivered to your BMW center (due to loading and unloading

from the transport trucks, etc.).

157

CAUSE

Hot engine oil initially escapes from the oil galley of the HVA elements when the engine is stopped. A small amount of oil also escapes through the

gaps between the HVA elements and the HVA housings in the cylinder head.

The oil then contracts while the engine is cooling down and allows air to enter the oil system.

During the subsequent cold start, this air can be forced into the HVA elements (causing air pockets) through the build up of engine oil pressure. The

resulting clearance between the HVA elements and the camshaft lobes causes the tapping / rattling noises.

This HVA tapping / rattling noise is not dependent on the amount of time the engine is off, but rather on:

The temperature of the engine when it was turned off (operating temperature - hot)

The number of subsequent cold starts without the engine being warmed up to operating temperature.

CORRECTION

Run the engine to dissipate (bleed) the air trapped in the high pressure chamber of the HVA elements.

Refer to the HVA bleeding procedure described below.

SITUATION 1C

Tapping / rattling noises in the area of the valve train after extreme cornering/lateral acceleration (engine oil level at or below minimum).

Note:

These valve train noises will not stop until the engine is run for approximately 10 - 15 minutes at an engine speed of at least 2,500 rpm with the

oil at the proper level.

CAUSE

During extreme cornering/lateral acceleration with the engine oil level at or below minimum, air can be drawn in by the oil pump (oil foaming). The

air which is drawn into the oil system can enter the HVA elements. The resulting clearance between the HVA elements and the camshaft lobes

causes the tapping / rattling noises.

Correction:

Run the engine to dissipate (bleed) the air trapped in the high pressure chamber of the HVA elements.

Refer to the HVA bleeding procedure described below.

HVA BLEEDING PROCEDURE:

-- Check oil level - correct if necessary.

-- Let engine idle at operating temperature with the hood open to verify valve train tapping / rattling noise.

-- If a tapping / rattling noise can be heard from the valve train, run the engine for 3 minutes without load at approximately 2,500 to 3,000 rpm

(bleeding procedure).

-- Then with the engine at idle listen for valve train noises again.

Note:

Only listen for noises when the engine has reached minimum oil pressure, i.e. after a waiting period (at idle) of approximately 15 - 30 seconds.

-- If no more noises can be heard, the test procedure is complete. No further action is necessary, the engine is working properly.

-- If the tapping / rattling noises can still be heard, the bleeding procedure must be repeated (run the engine for 3 minutes at 2,500 - 3,000 rpm).

If necessary, repeat this procedure up to five times.

-- If the tapping / rattling noises can still be heard, the bleeding procedure must be performed one final time for approximately 15 minutes.

-- If no more noises can be heard, the test procedure is complete. No further action is necessary, the engine is working properly.

If the tapping / rattling noise is still heard after performing the above HVA Bleeding Procedure the following scenarios will assist in further

troubleshooting for HVA element noise:

158

If the noise is coming from all HVA elements an oil supply problem is the most likely cause.

Check engine oil pressure as outlined in the appropriate repair manual, group 11.

If the oil pump pressure (at idle = minimum pressure or regulated = maximum pressure) is below specification a visual inspection of the oil pump

and oil pump pick up in the oil pan should be performed with emphasis on the pick up gasket and control valve 0 ring were applicable. See repair

manual group 11, section 11 41 000 for further oil pump information.

Notes:

A faulty oil pump control valve 0 ring or oil pump pick up gasket (slight tear in 0 ring or gasket) may not always result in a low oil pressure

indication when performing an oil pressure check.

The air drawn in to the lubrication system via a defective gasket or 0 ring will cause oil foaming and HVA tapping / rattling noises.

If the noise is still coming from an individual HVA element after performing the above HVA Bleeding Procedure the suspected element(s) can be

isolated as follows:

-- Remove cylinder head cover.

-- Turn the engine over (normal direction of rotation) until the camshaft lobe of the HVA element to be checked is pointing away from the HVA

element. (engine valve completely closed)

-- Repeatedly apply a force of approximately 10N (2.25 lb.f.) to the HVA element with your thumb or using a folding arm tool BMW special tool

number 90 88 6 009 321 (included in the BMW assembly wedge kit PN 90 88 6 009 310) or a hard wood wedge.

If the HVA element collapses slightly as though it is spring loaded, this is a sign that air is trapped in the high pressure chamber.

-- Apply a force of approximately 20 - 30N (4.50 - 6.75 lb.f.) for 10 - 15 seconds to the HVA element using your thumb, folding arm tool or a hard

wood wedge.

If clearance between the camshaft lobe and the HVA element is created when the force is applied, this indicates that the check valve incorporated in

the HVA element is not closing / sealing properly due to contamination.

Release the applied force from the HVA element and using a feeler gauge measure the clearance between the HVA element and the camshaft lobe.

If any clearance is detected this indicates that the HVA element is sticking.

-- Conduct the checks as described above on all HVA elements.

-- Mark any suspect "soft" HVA element(s) for further examination.

Remove HVA elements as outlined in the appropriate repair manual, group 11 and visually inspect. Replace any suspect "soft" HVA element(s) and

check others for extreme wear (deep grooves, scratches, etc.) which may also need to be replaced.

Note:

Always reinstall used HVA elements in the same bore which they were removed from. This avoids possible binding due to different wear

patterns between the bore in the HVA housing and HVA element.

SITUATION 2

Binding HVA element.

CAUSE

An HVA element which is binding (element stuck in the extended position) will not allow a valve (intake or exhaust) to seat properly causing valve

seat leakage.

This type of HVA failure may not cause a tapping / rattling noise but the customer complaint may be: "engine runs rough during the warm up phase

and runs good when warmed up" and/or the "Check Engine" lamp is on.

If the "Check Engine" lamp is illuminated due to a binding HVA element(s) one or more misfire fault codes may be set in the Engine Control

Module (ECM/DME).

Note:

Basic troubleshooting should be performed first before checking for a binding HVA element to eliminate all other possible factors / components

which could set the misfire faults such as low fuel level, a faulty spark plug, etc.

Refer to Service Information bulletin 12 02 97 for further misfire fault information.

159

Troubleshooting tips:

-- If there is a binding HVA element in one or more cylinders as described above a misfire fault can typically be reproduced in the affected

cylinder(s) by duplicating the conditions in which the misfire occurred according to the DME/ECM fault code description i.e., at engine

temperature = X, engine speed = X, etc.

-- A binding HVA element which is causing a misfire in one specific cylinder will not "move" to an other cylinder and will always cause a misfire

fault in the affected cylinder.

-- Performing the "Smooth-Running" test (found in the DME control unit functions section of DIS) will assist in pin pointing a cylinder with a

binding HVA element.

A cylinder with a binding HVA element will indicate a high reading when compared to the other good cylinders.

-- Since a binding HVA element may in some cases be intermittent (engine only runs rough when cold) if a cylinder leak down check is used for

troubleshooting this should be performed when the problem exists, for example: compare the cylinder leakage rates to each other with a cold

engine to determine the cylinder with the extreme leakage rate.

A cylinder with a binding HVA element will indicate a leakage rate above 15%.

Remove suspected HVA elements as outlined in the appropriate repair manual group 11 and visually inspect.

-- A binding HVA element will typically have a high pressure piston- (located in the center of the HVA element body) which extends out

approximately 3mm further when compared to the other HVA elements removed from the cylinder head.

Replace any binding HVA element(s) and check others for extreme wear (deep grooves, scratches, etc.) which may also need to be replaced.

Note:

Always reinstall used HVA elements in the same bore which they were removed from. This avoids possible binding due to different wear

patterns between the bore in the HVA housing and HVA element.