Situation 2: Covered under the terms of the BMW New Vehicle Limited Warranty2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 620399 Date: 990201

Check Control - Brake Light Failure Indicated

Group 62

254

Instruments

Bulletin Number

62 03 99

Woodcliff Lake, NJ

February 1999

Product Engineering

SUBJECT:

Brake Light Failure Indicated in Check Control or Pictogram

MODEL:

E38, E39, E46 vehicles produced November 1998 to January 1999

Situation:

For vehicles fitted with an IKE, the Check Control message "Check brake light" is displayed. For vehicles with other instrument clusters, the

pictogram shows a brake bulb failure.

The brake lights function correctly.

Cause:

Faulty brake light switch

Correction:

On a customer complaint basis, replace the brake light switch.

The replacement switch should have either a silver dot (1) marked next to the date code, or no color dot at all.

Parts Information:

Part Number Description

61 31 8372 647 Brake light switch

Warranty Information:

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

Defect Code: 61 31 90 14 00

Labor Operation: Remove and replace brake light switch

Labor operation Labor Allowance

Main Work 61 31 310 4 FRU (E39, E46)

3 FRU (E38)

Associated Work +61 31 810 3 FRU (E39, E46)

1 FRU (E38)

Note:

The following explanations will spell out the correct use of the work times.

Main Work:

Use this labor operation number when the only repair performed is the listed warranty repair.

OR

+Associated Work:

Use this labor operation number when other repairs or services are performed along with the listed warranty repair. Under no circumstances

should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in claim processing and

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 040499 Date: 990201

Special Tools - Headlamp Cleaning System Adjuster

Group 04

Tools and Equipment

Bulletin Number

04 04 99

Woodcliff Lake, NJ

February 1999

Product Engineering

SUBJECT:

Headlight Cleaning System Adjuster

MODEL:

E39

Situation:

Distribution of the following tool will not be through the Automatic Tool Shipment Program. Tools may be purchased through your PDC. Refer to

Parts Information bulletin 01 01 95 for tool warranty details.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 630199 Date: 990201

Lamp Control Module - New Introduction

Group 63

Lights

Bulletin Number

63 01 99

Woodcliff Lake, NJ

February 1999

Product Engineering

SUBJECT:

Introduction of LCM III

MODEL:

E38 (7 Series), E39 (5 Series)

General Information:

A new Lamp Control Module (LCM III) was introduced into series production from 9/98.

The earlier (LCM II) module was recognizable by its large external aluminum heat-sink. The new (LCM III) module is all plastic construction with

no external heat-sink.

The LCM III is retrofittable on earlier vehicles and will replace LCM II when parts stocks are used up.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 230199 Date: 990201

M/T - Difficult to Shift, Diagnostic Tips

Group 23

Manual Transmission

Bulletin Number

23 01 99

Woodcliff Lake, NJ

February 1999

Product Engineering

This Service Information bulletin supersedes S.I. 23 01 88 (1581) dated February 1988 which should be removed and discarded from your S.I.

binder.

SUBJECT:

Manual Transmission Difficult to Shift - Diagnostic Tips

MODEL:

All with Manual Transmission

Situation:

Transmission may be difficult to shift especially first gear engagement and/or gear shift linkage is binding.

Note:

Field observations have indicated that a transmission which is difficult to shift (especially into first gear) is primarily a clutch related problem

and only in isolated cases a failure in the transmission itself.

Procedure:

If the above customer complaint is received the following diagnostic tips will assist in troubleshooting a clutch, gear shift linkage or transmission

problem.

Verify the customer complaint:

Note:

Engage the parking brake and assure that no people or objects are in the vehicle's path.

- Run the engine at idle speed

- Press the clutch pedal to the floor

- From the neutral stick shift position engage first gear

If first gear is difficult to engage, hold the stick shift at the resistance point (approximately half of the total stick shift travel) with constant force.

Then switch the ignition off with the other hand.

Diagnosis 1:

If first gear now engages completely, i.e. the stick shift moves to the end position without any additional pressure applied, there is a problem in the

clutch system.

354

Explanation:

Because the clutch does not uncouple completely, a residual torque is transmitted to the transmission input shaft when the engine is running. This

inhibits the release and meshing of the sliding sleeve, in the transmission, at the end of the synchronization process.

Turning the engine off relieves the input shaft of this torque thus simulating a completely uncoupled clutch.

Diagnosis 2:

If the stick shift remains at the resistance point, there is a problem in the external gear shift linkage or in the transmission.

Cause:

Diagnosis 1:

Possible causes for a clutch problem as per Diagnosis 1 above are:

- Input shaft taper splines not lubricated properly I grease dried out.

- Clutch disc difficult to move on transmission input shaft.

- Clutch disc wobble.

- Air in the hydraulic system of clutch mechanism.

- Release bearing defective or difficult to move on the guide sleeve.

- Clutch disc or pressure plate broken I worn out.

Diagnosis 2:

Possible causes for gear shift linkage binding and/or internal transmission problems as per Diagnosis 2 above:

- External gearshift linkage binding (shift rod joints stiff).

- Stick shift bellows boot incorrectly installed (positioned too high or too low on the stick shift lever).

- Sound deadening between the outer gear shift linkage and the body incorrectly installed and/or distorted.

Possible causes inside of the transmission:

- Faulty synchronization.

- Internal gear shift linkage binding.

- Water in the transmission fluid. (rare)

Correction:

Diagnosis 1:

- Remove the transmission.

- Remove and/or inspect the pressure plate, clutch disc and release bearing. (Replace components if necessary.)

Note:

The plastic sliding sleeve which the clutch release bearing slides on should never be lubricated since the grease will allow the clutch wear

particles and other contamination to build up and cause an increase in clutch pedal effort. See Service Information bulletin 21 01 94 for further

information.

- Carefully clean the transmission input shaft (tapered splines and guide section of shaft).

- Using a paint brush, apply a thin coating of "Esso UNIREX 82" grease on the transmission input shaft (tapered splines and guide section of the

shaft).

Note:

"Esso UNIREX S2" taper spline grease was phased into production approximately 4/98 and replaces "Microlube G~61 BMW" grease. The new

grease has proven to be more resistant to lubrication breakdown under all operating conditions and is available under BMW part number 83 23 9

416 138.

Only use "Esso UNI REX 82" taper spline grease when repairs become necessary which involve the cleaning and lubrication of the transmission

355

input shaft.

- Reinstall the transmission.

For additional information on troubleshooting the clutch refer to the repair manual section 2190.

Diagnosis 2:

- Carefully inspect the gear shift linkage areas described in Diagnosis 2 section above. Repair as necessary.

- If the gear shift linkage is functioning properly without binding the cause is an internal fault in the transmission.

Note:

If the transmission is replaced due to an internal fault, using a paint brush apply a thin coating of "Esso UNIREX 82" grease on the transmission

input shaft (tapered splines and guide section of the shaft) before installing the new transmission.

Parts Information:

Part Number Qty Description

83 23 9416 138 1 "Esso UNIREX 82" (40g tube)

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 650399 Date: 990201

Cruise Control - Intermittently Inoperative

255

Group 65

Sound System, Cruise. Alarms. Monitors

Bulletin Number

65 03 99

Woodcliff Lake, NJ

February 1999

Product Engineering

SUBJECT:

Cruise Control Intermittently Inoperative

MODEL:

E38, E39, E46 Vehicles produced November 1998 to January 1999

Situation:

The cruise control, intermittently, cannot be switched on. The fault can only occur when, before starting off, the ignition is switched on twice within

a period of 6 to 30 seconds.

Cause:

Faulty brake light switch

Correction:

On a customer complaint basis, replace the brake light switch.

The replacement switch should have either a silver dot (1) marked next to the date code, or no color dot at all.

Parts Information:

Part Number Description

61 31 8 372 647 Brake light switch

Warranty Information:

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

Defect Code: 61 31 90 14 00

Labor Operation: Remove and replace brake light switch

Labor operation Labor Allowance

Main Work 61 31 310 4 FRU (E39, E46)

3 FRU (E38)

Associated Work +61 31 810 3 FRU (E39, E46)

1 FRU (E38)

Note:

The following explanations will spell out the correct use of the work times.

Main Work:

Use this labor operation number when the only repair performed is the listed warranty repair.

OR

+Associated Work:

Use this labor operation number when other repairs or services are performed along with the listed warranty repair.

Under no circumstances should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in

claim processing and payment.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 120799 Date: 990201

Engine Controls - Motor Driven Throttle Valve (MDK)

Group 12

Engine Electrical

Bulletin Number

12 07 99

Woodcliff Lake, NJ

February 1999

Product Engineering

SUBJECT:

Motor Driven Throttle Valve (MDK)

MODEL:

E39 - 528ViA with M52TU engine produced 9/98 -

E46 - 323ViA & 328ViA with M52 TU engine produced 6/98 -

Z3 - Roadster with 2.5L/2.8L engine and Mcoupe with 2.8L engine produced 9/98 -

Situation:

Customer complains that the "Check Engine" lamp is illuminated and one or more of the following faults are set in the Engine Control Module

(ECM/DME):

Cause:

The above listed faults may set as a result of the following:

1. Break/open in the wiring from the DME to the throttle motor (MDK).

2. Contamination of the actuator or potentiometers within the MDK.

400

Procedure:

If any of the above listed faults are set perform the following:

1. Using a breakout box check the wiring from the DME to the MDK for open or short to ground.

2. If the wiring is correct then the MDK should be replaced.

Parts Information:

Part Number Description Qty

13 54 1 433 414 Throttle Housing Assembly 1

Warranty Information:

Parts and labor will be reimbursable under the terms of the applicable BMW Emissions or New Vehicle Limited Warranty.

Defect Code: 1 3 54 91 96 00

Labor Operation: 13 54 031 - Replacing complete throttle assembly

Labor Allowance: E46 - 11 FRU

E39 - 12 FRU

Z3 - 12 FRU

OR Associated Work

Labor Operation: +13 54533 - Replacing complete throttle assembly

Labor Allowance: E46 - 10 FRU

E39 - 10 FRU

Z3 - 10 FRU

Note:

The following explanations will spell out the correct use of the work times.

Main Work:

Use this labor operation number when the only repair performed is the listed warranty repair.

OR

+Associated Work:

Use this labor operation number when other repairs or services are performed along with the listed warranty repair.

Under no circumstances should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in

claim processing and payment.

2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 651998 Date: 990201

DSP Amplifier - Mutes After Vehicle is Started

Group 65

Sound System, Cruise, Alarms, Monitors

428

Bulletin Number

65 19 98

Woodcliff Lake, NJ

February 1999

Product Engineering

PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES THE NEXT TIME THEY

ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.

SUBJECT:

DSP Amplifier may "Mute" after Vehicle is Started

MODEL:

E38, E39

Situation:

The amplifier may switch to "mute" mode(no sound) approximately 30 seconds after the vehicle is started. The "mute" mode may only be cancelled

by switching the amplifier off/on again.

Affected Vehicles:

E38, E39 with DSP (option 677) produced 7/98 - 9/98.

In order to determine if a specific vehicle is affected by this Service Action, it will be necessary to utilize the "Service Menu" of the DCS (Dealer

Communication System). Based on the response of the system, either proceed with the corrective action or take no further action.

The Chassis Number Ranges listed below are only for informational purposes and are not to be considered as the only deciding factor

Correction:

Check the amplifier for a "Red Dot" and yellow label next to the connectors. If the amplifier does not have the "red dot" and yellow label, replace

the amplifier. If the amplifier does have the "red dot" and yellow label, do not replace the amplifier.

Procedure:

To check and replace the DSP amplifier:

Examine the amplifier at the connections to verify if the "red dot" and yellow label is attached.

With "Red Dot" and Yellow Label

Do not replace amplifier. No work needed.

Without "Red Dot" and Yellow Label

Replace the DSP amplifier.

429

1. Remove the navigation computer and CD changer if equipped.

2. Remove the navigation computer bracket attaching bolts(1) and bracket (if equipped) to access the DSP Amplifier connectors

3. Remove the connectors and the two top attaching bolts(black arrows) and loosen the bottom two attaching bolts(not necessary to remove).

Remove the amplifier from the vehicle by lifting up and out(white arrows).

4. Install the DSP Amplifier and Navigation computer/CD changer(if equipped). Refer to Service Information Bulletin 65 14 98 for coding

instructions.

5. Verify correct DSP operation.

Parts Information:

Part Number Description

65 12 8 386 281 DSP Amplifier - uncoded

Service Action Label Instructions:

This Service Action has been assigned code number 236. After the vehicle has been checked, and corrected if necessary, obtain a label (SD 92-095)

and:

a) emboss your BMW dealer warranty number in the middle of the label (1);

b) punch out code number 236 printed on the label and,

c) affix the label to the B pillar as shown:

If the vehicle already has a label from a previous Service Action/Recall Campaign, affix the new label next to the old one. Do not affix one label on

top of another one because a number from an underlying label could appear in the punched-out hole of the new label.

Warranty Information:

Defect Code: 00 65 27 01 00

Work Package #1 Check the DSP Amplifier for the "red dot"/yellow label no replacement needed:

Labor Operation: 00 52 549

Labor Allowance: 3 FRU

Work Package #2 Check the DSP Amplifier and replace on vehicle without CD changer:

Parts Allowance: 65 12 8 386 281

430

Labor Operation: 00 52 523

Labor Allowance: 4 FRU

Work Package #3 Check the DSP Amplifier and replace on vehicles with CD changer:

Parts Allowance: 65 12 8 386 281

Labor Operation: 00 52 524

Labor Allowance: 6 FRU

Disclaimer2000 BMW 328i (E46) Technical Service Bulletin # 620399 Date: 990201

Disclaimer2000 BMW 328i (E46) Technical Service Bulletin # 620399 Date: 990201

Check Control - Brake Light Failure Indicated

Group 62

Instruments

Bulletin Number

62 03 99

Woodcliff Lake, NJ

February 1999

256

Product Engineering

SUBJECT:

Brake Light Failure Indicated in Check Control or Pictogram

MODEL:

E38, E39, E46 vehicles produced November 1998 to January 1999

Situation:

For vehicles fitted with an IKE, the Check Control message "Check brake light" is displayed. For vehicles with other instrument clusters, the

pictogram shows a brake bulb failure.

The brake lights function correctly.

Cause:

Faulty brake light switch

Correction:

On a customer complaint basis, replace the brake light switch.

The replacement switch should have either a silver dot (1) marked next to the date code, or no color dot at all.

Parts Information:

Part Number Description

61 31 8372 647 Brake light switch

Warranty Information:

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

Defect Code: 61 31 90 14 00

Labor Operation: Remove and replace brake light switch

Labor operation Labor Allowance

Main Work 61 31 310 4 FRU (E39, E46)

3 FRU (E38)

Associated Work +61 31 810 3 FRU (E39, E46)

1 FRU (E38)

Note:

The following explanations will spell out the correct use of the work times.

Main Work:

Use this labor operation number when the only repair performed is the listed warranty repair.

OR

+Associated Work:

Use this labor operation number when other repairs or services are performed along with the listed warranty repair. Under no circumstances

should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in claim processing and

2000 BMW 328i (E46) Technical Service Bulletin # 650399 Date: 990201

2000 BMW 328i (E46) Technical Service Bulletin # 650399 Date: 990201

Cruise Control - Intermittently Inoperative

Group 65

Sound System, Cruise. Alarms. Monitors

Bulletin Number

65 03 99

Woodcliff Lake, NJ

257

February 1999

Product Engineering

SUBJECT:

Cruise Control Intermittently Inoperative

MODEL:

E38, E39, E46 Vehicles produced November 1998 to January 1999

Situation:

The cruise control, intermittently, cannot be switched on. The fault can only occur when, before starting off, the ignition is switched on twice within

a period of 6 to 30 seconds.

Cause:

Faulty brake light switch

Correction:

On a customer complaint basis, replace the brake light switch.

The replacement switch should have either a silver dot (1) marked next to the date code, or no color dot at all.

Parts Information:

Part Number Description

61 31 8 372 647 Brake light switch

Warranty Information:

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

Defect Code: 61 31 90 14 00

Labor Operation: Remove and replace brake light switch

Labor operation Labor Allowance

Main Work 61 31 310 4 FRU (E39, E46)

3 FRU (E38)

Associated Work +61 31 810 3 FRU (E39, E46)

1 FRU (E38)

Note:

The following explanations will spell out the correct use of the work times.

Main Work:

Use this labor operation number when the only repair performed is the listed warranty repair.

OR

+Associated Work:

Use this labor operation number when other repairs or services are performed along with the listed warranty repair.

Under no circumstances should both labor operation numbers be claimed. Attempts to claim both times will result in an unnecessary delay in

claim processing and payment.

2000 BMW 328i (E46) Technical Service Bulletin # 511098 Date: 990201

2000 BMW 328i (E46) Technical Service Bulletin # 511098 Date: 990201

Rear Bumper Cover - Poor Fit/Alignment

Group 51

Body Equipment

Bulletin Number

51 10 98

Woodcliff Lake, NJ

February 1999

Product Engineering

SUBJECT:

Rear Bumper Cover Loose

MODEL:

E46

Situation:

On some E46s the rear bumper cover may not align properly with the body in the area of the rear wheel well, and tends to stick out from the body.

344

Cause:

Temperature changes may cause the bumper cover to distort slightly.

Correction:

In case of customer complaint, an additional retainer clip, part number 5112 4015 053 can be installed to hold the bumper cover in proper alignment.

Procedure:

Remove the rear wheel and wheel house liner for access.

Using a utility knife (2) carefully trim the plasticized undercoating (3) from the lip on the quarter panel in the area immediately in front of the tab (1)

on the bumper cover. Use care to ensure that the paint does not get damaged.

Hold the bumper cover up against the body and install retaining clip (1) to hold the cover in place. The hooked end of the clip goes on the bumper

cover.

Apply a bead of Sikaflex windshield adhesive (2) over the clip and on each side of it to help hold the clip in place and provide corrosion protection.

Parts Information:

This repair requires one or two retaining clips, part number 51 12 4 015 053.

Warranty Information:

Covered under the terms of the BMW new car limited warranty.

Defect Code: 51 12 90 40 00

Parts Allowance: 51 12 4 015 053 (1 or 2 as required)

Labor Operation: 51 99 000 one side 3 FRU

2000 BMW 328i (E46) Technical Service Bulletin # 230199 Date: 990201

2000 BMW 328i (E46) Technical Service Bulletin # 230199 Date: 990201

M/T - Difficult to Shift, Diagnostic Tips

Group 23

Manual Transmission

Bulletin Number

23 01 99

Woodcliff Lake, NJ

February 1999

Product Engineering

This Service Information bulletin supersedes S.I. 23 01 88 (1581) dated February 1988 which should be removed and discarded from your S.I.

binder.

SUBJECT:

Manual Transmission Difficult to Shift - Diagnostic Tips

MODEL:

All with Manual Transmission

Situation:

Transmission may be difficult to shift especially first gear engagement and/or gear shift linkage is binding.

Note:

Field observations have indicated that a transmission which is difficult to shift (especially into first gear) is primarily a clutch related problem

and only in isolated cases a failure in the transmission itself.

Procedure:

If the above customer complaint is received the following diagnostic tips will assist in troubleshooting a clutch, gear shift linkage or transmission

problem.

Verify the customer complaint:

Note:

Engage the parking brake and assure that no people or objects are in the vehicle's path.

- Run the engine at idle speed

- Press the clutch pedal to the floor

- From the neutral stick shift position engage first gear

If first gear is difficult to engage, hold the stick shift at the resistance point (approximately half of the total stick shift travel) with constant force.

Then switch the ignition off with the other hand.

Diagnosis 1:

If first gear now engages completely, i.e. the stick shift moves to the end position without any additional pressure applied, there is a problem in the

clutch system.

Explanation:

Because the clutch does not uncouple completely, a residual torque is transmitted to the transmission input shaft when the engine is running. This

inhibits the release and meshing of the sliding sleeve, in the transmission, at the end of the synchronization process.

Turning the engine off relieves the input shaft of this torque thus simulating a completely uncoupled clutch.

Diagnosis 2:

If the stick shift remains at the resistance point, there is a problem in the external gear shift linkage or in the transmission.

348

Cause:

Diagnosis 1:

Possible causes for a clutch problem as per Diagnosis 1 above are:

- Input shaft taper splines not lubricated properly I grease dried out.

- Clutch disc difficult to move on transmission input shaft.

- Clutch disc wobble.

- Air in the hydraulic system of clutch mechanism.

- Release bearing defective or difficult to move on the guide sleeve.

- Clutch disc or pressure plate broken I worn out.

Diagnosis 2:

Possible causes for gear shift linkage binding and/or internal transmission problems as per Diagnosis 2 above:

- External gearshift linkage binding (shift rod joints stiff).

- Stick shift bellows boot incorrectly installed (positioned too high or too low on the stick shift lever).

- Sound deadening between the outer gear shift linkage and the body incorrectly installed and/or distorted.

Possible causes inside of the transmission:

- Faulty synchronization.

- Internal gear shift linkage binding.

- Water in the transmission fluid. (rare)

Correction:

Diagnosis 1:

- Remove the transmission.

- Remove and/or inspect the pressure plate, clutch disc and release bearing. (Replace components if necessary.)

Note:

The plastic sliding sleeve which the clutch release bearing slides on should never be lubricated since the grease will allow the clutch wear

particles and other contamination to build up and cause an increase in clutch pedal effort. See Service Information bulletin 21 01 94 for further

information.

- Carefully clean the transmission input shaft (tapered splines and guide section of shaft).

- Using a paint brush, apply a thin coating of "Esso UNIREX 82" grease on the transmission input shaft (tapered splines and guide section of the

shaft).

Note:

"Esso UNIREX S2" taper spline grease was phased into production approximately 4/98 and replaces "Microlube G~61 BMW" grease. The new

grease has proven to be more resistant to lubrication breakdown under all operating conditions and is available under BMW part number 83 23 9

416 138.

Only use "Esso UNI REX 82" taper spline grease when repairs become necessary which involve the cleaning and lubrication of the transmission

input shaft.

- Reinstall the transmission.

For additional information on troubleshooting the clutch refer to the repair manual section 2190.

Diagnosis 2:

- Carefully inspect the gear shift linkage areas described in Diagnosis 2 section above. Repair as necessary.

- If the gear shift linkage is functioning properly without binding the cause is an internal fault in the transmission.

349

Note:

If the transmission is replaced due to an internal fault, using a paint brush apply a thin coating of "Esso UNIREX 82" grease on the transmission

input shaft (tapered splines and guide section of the shaft) before installing the new transmission.

Parts Information:

Part Number Qty Description

83 23 9416 138 1 "Esso UNIREX 82" (40g tube)