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

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 528i (E39) 2000 BMW 528i (E39) 2000 BMW 528i (E39) Technical Service Bulletin # 330192 Date: 991201

Differential - Final Drive Synthetic Oil Recommendations

427

GROUP 33

Rear Axle

Bulletin Number

33 01 92

Woodcliff Lake, NJ

December 1999

Product Engineering

This Service Information bulletin supersedes S.I. 33 01 92 dated May 1996 which should be removed and discarded from your S.I. binder.

SUBJECT:

Synthetic Oils for Final Drives

MODELS:

All

Situation:

All models are factory filled with a synthetic final drive oil.With the introduction of the Z3 roadster a new synthetic final drive oil for all vehicles

with a multi-plate limited-slip differential was released.

The new BMW final drive oil SAF-XJ replaces the old final drive oil SAF-XLS.

The SAF-XLS final drive oil (If still in BMW center stock) is not to be used in the final drive of Z3 roadster or M5 (562) model with multi-plate

limited-slip differential.

Use only the SAF-XJ in the final drive of Z3 roadster and M5 models with multi-plate limited-slip differentials.

Note:

The M5 requires a final drive oil change at the 1200 mile service. Refer to Service Information 00 01 99 for further information.

Mineral based final drive oils are no longer recommended due to the release of synthetic final drive oils for all vehicles with or without limited-slip

differentials.

Any current BMW center stock of the old SAF-XLS differential oil can be used in all vehicles with a multi-plate limited-slip differential except Z3

roadster and M5 models.

Note:

If a non limited-slip differential oil is used in a limited-slip differential a whining or chattering sound can be heard on very tight turns and will

eventually result in a failure of the differential.

Parts Information:

These oils are available under the following part numbers:

Warranty Information: Information Only.

Notes:

A one (1) liter quantity of part number 83 22 9 407 768 can be claimed using part number 83 22 0 002 094.

A one (1) liter quantity of part number 83 22 1 470 080 can be claimed using part number 83 22 1 467 993.

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 330192 Date: 991201

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 330192 Date: 991201

Differential - Final Drive Synthetic Oil Recommendations

415

GROUP 33

Rear Axle

Bulletin Number

33 01 92

Woodcliff Lake, NJ

December 1999

Product Engineering

This Service Information bulletin supersedes S.I. 33 01 92 dated May 1996 which should be removed and discarded from your S.I. binder.

SUBJECT:

Synthetic Oils for Final Drives

MODELS:

All

Situation:

All models are factory filled with a synthetic final drive oil.With the introduction of the Z3 roadster a new synthetic final drive oil for all vehicles

with a multi-plate limited-slip differential was released.

The new BMW final drive oil SAF-XJ replaces the old final drive oil SAF-XLS.

The SAF-XLS final drive oil (If still in BMW center stock) is not to be used in the final drive of Z3 roadster or M5 (562) model with multi-plate

limited-slip differential.

Use only the SAF-XJ in the final drive of Z3 roadster and M5 models with multi-plate limited-slip differentials.

Note:

The M5 requires a final drive oil change at the 1200 mile service. Refer to Service Information 00 01 99 for further information.

Mineral based final drive oils are no longer recommended due to the release of synthetic final drive oils for all vehicles with or without limited-slip

differentials.

Any current BMW center stock of the old SAF-XLS differential oil can be used in all vehicles with a multi-plate limited-slip differential except Z3

roadster and M5 models.

Note:

If a non limited-slip differential oil is used in a limited-slip differential a whining or chattering sound can be heard on very tight turns and will

eventually result in a failure of the differential.

Parts Information:

These oils are available under the following part numbers:

Warranty Information: Information Only.

Notes:

A one (1) liter quantity of part number 83 22 9 407 768 can be claimed using part number 83 22 0 002 094.

A one (1) liter quantity of part number 83 22 1 470 080 can be claimed using part number 83 22 1 467 993.

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.

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 000199 Date: 000301

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 000199 Date: 000301

Maintenance - Requirement Revision

March 2000

00 01 99

Service Engineering

Maintenance and General Hints

This Service Information bulletin supersedes S.I. 00 01 99 dated October 1999.

Changes to this revision are identified by a black bar and asterisks.

SUBJECT

New Vehicle Preparation and Maintenance Requirements

MODEL

* 2000 3 Series, 5 Series, 7 Series, Z3, Z8 *

SITUATION

425

* The Z8 is a 2-passenger roadster which features aluminum as the predominant body shell material, being utilized for the space frame, the bolt-on

body panels, and for many of the suspension pieces. Other major components are the S62 engine and 6-speed S6S420G manual transmission also

found in the M5 sedan, an electrohydraulic semiautomatic soft top with plastic rear window, and brakes derived from the 750iL sedan. *

Quality Certification I (QCI):

The 1999 QCI checklist (item 5D92-104) may be used on all 2000 model year vehicles, including the Z8.

Electronic Battery Disconnect Switch (EBS):

* As of approx. February 00 production, a new electronic battery disconnect switch is being introduced on 2000 model 3 Series sedans which are not

equipped with the optional fold-down rear seat, nor with the optional ski sack. The EBS takes the place of the mechanical disconnect switch used

previously. The EBS consists of a magnetic sensor (mounted near the top edge of the windshield), the switch itself (mounted on the positive terminal

of the battery), a wiring harness (connects these two components), and a magnetic activation "pen" (clipped to a holder on the windshield). The

sensor, switch and the pen holder must be removed during QCI. Additionally, the harness is to be tied back under the rear seat. Please refer to SI 61

01 00 for additional information *

A new Service Maintenance Checklist (item 5D92-121) has been developed for the 2000 models. It contains only a few changes compared to the

1999 checklist. The Checklist 5D92-121 has been updated to include all new models mentioned above (except the Z8- see below).

* A separate Service Maintenance Checklist (item 5D92-1 56) has been developed for the 2000 Z8. While the overall maintenance requirements are

almost identical to those of the MS sedan, the checklist now incorporates space to record values called for in specific checking operations. These

include disc brake pad thickness, tire pressures, parking brake lining thickness, and the freeze point temperatures of the engine coolant and of the

windshield washer fluid. Additionally, there is a space provided on the checklist header to list the mileage remaining until the next service, as

calculated by the Service Interval Indicator.

A copy of the Service Maintenance Checklist for the Z8 is included as an attachment. *

Copies of the QCI, and Service Maintenance checklists applicable for 2000 models are included as attachments.

Service Maintenance:

* M5, Z8:

QCI: *

The MS and the Z8 feature the Tire Pressure Warning System (RDW) as standard equipment. RDW is a system that will warn the driver of gradual

pressure losses in one or more of the tires through the Check Control display. The system must be initialized during QCI after the tire pressures have

been set to the values listed on the Tire Information Placard, located on the driver's side B-pillar. The initialization can be performed as part of the

QCI Road Test.

* Initialize the RDW by pressing the instrument panel button (to the right of the steering column on the MS; in the radio access panel on the Z8) at

least 4 seconds, just before driving off. "Tire Pressure Set" * will be displayed briefly in the Check Control matrix display. The system is now in the

learn mode and after driving off, the RDW's control module will start to store the values for the rolling circumference of the tires based on road

speed. The control module must receive useable speed signals (speeds greater than approx. 7 mph) for at least 4 minutes to enable initialization.

1200 Mile Service:

* A new maintenance service is required on the M5 and the Z8 to ensure maximum life and longevity of various components. It includes:

^ Replace the transmission fluid (M5 only; not required on the Z8)*

^ Replace the differential oil

^ Read out the diagnostic system

426

^ Check all warning/indicator lights and check control

^ Perform road test

The engine oil does not need to be changed at this service. Do not reset the Service Interval Indicator at the 1200 Mile Service!

* Every M5 and Z8 has a small yellow "1200 Mile Service Required" reminder label on the center console, ahead of the shift lever. This label should

be removed when the 1200 Mile Service has been performed. *

Inspection II

7 Series only:

Replacement of the IHKA recirculated air filters has been rescheduled from every second Insp. to every Insp. II.

M roadster M coupe, M5:

Replace the M-Mobility System sealant cartridge every 3 years (invoice separately).

* Note: the Z8 does not utilize the M-Mobility System, due to the introduction of run-flat tires and special hump wheels in conjunction with the

RDW Tire Pressure Warning System as standard equipment. The tires are designed with reinforced sidewalls with special steel inserts and rubber

compounds that are extremely temperature resistant. Even if a tire has suffered a total loss of air pressure, its shape, the driving and handling

characteristics are largely maintained for up to 300 miles. The specially designed extended hump wheels maintain the damaged tire's proper position

on the wheel. *

General Notes:

Service Interval Indicator:

* The E46 (sedan and coupe) and the Z8 are the only models which are equipped with the new * generation Service Interval Indicator (SII 4), which

displays the miles remaining until the next service is due.

All other models use the SII 3, which utilizes the green/yellow/red LEDs.

Service and Warranty Information booklet:

* Model Booklet

3 Series (E46) SD92-122

Z3, 5, 7 Series SD92-123

X5 SD92-141

Z8 SD92-154 *

BMW High Performance Synthetic Engine Oil (5W-40):

All models are factory-filled with this oil (except the M roadster and M coupe, which use mineral-based oil, and the M5 and Z8- see below). It is

strongly recommended for service use as well. Please refer to SI 11 08 98 for more information. The 5W-40 synthetic engine oil can be ordered

under P/N 07 51 0 002 545 (1 quart).

427

Vehicles filled with the High Performance Synthetic Oil (formerly "long life") also have a label applied to the front of the engine compartment

(exact locations differ slightly by model). The label has a different size and shape than that first used last year. The dimensions of the new label are

1-1/2" x 6". It can be ordered under P/N 01 00 0 002 569.

* M5 and Z8 Engine Oil:

The S62 engine in the M5 and the Z8 requires a different synthetic oil than the BMW High- Performance Synthetic Oil (5W-40) used on most other

BMWs. *

* The only approved oil for the M5 and the Z8 is Castrol Formula RS 10W-60 Synthetic Oil.*

This oil has been specially developed and formulated for BMW Motorsport. Do not use any other engine oil on S62 engines. The Castrol oil should

also be used when topping up between oil changes. If it is not available for topping up, use small amounts of synthetic engine oil meeting the API

specification SH.

Castrol Formula RS 10W-60 Synthetic Oil can be ordered under BMW P/N 07 51 0 009 420 (1 liter).

*Checking the Engine Oil Level on the M5 and Z8:*

The S62 engine requires a different procedure than conventional practice to check the oil level, which must be followed accurately to give a true

indication of the fill level:

^ the engine must be at operating temperature

^ let the engine idle for at least 15 seconds

^ turn the engine off

^ wait at least 1 minute for the oil to drain down into the sump

^ check the level using the dipstick

* Engine Oil Label for M5 and Z8:

M5 and Z8 vehicles filled with the Castrol Formula RS 10W-60 Synthetic Oil have a new label applied * to the front of the engine compartment. The

label has the same size as the "High Performance" oil label on most other BMWs, but has yellow print to distinguish it from that label. The label for

the MS and Z8 not only lists the BMW part number for the Castrol oil, but also contains the procedure described above for checking the oil level.

The MSIZ8 label can be ordered under P/N 99 00 0 001 805.

* Extended (approx. 15,000 mi) Service Interval: *

All models (except the M roadster and M coupe), including the MS and Z8, feature the extended oil change service interval.

428

Keys:

Most models as of 9/99 production feature a new style key. The key features a blue and white- colored BMW roundel in the center of the upper

surface, and a new button arrangement with sequential operation. There is no longer a serviceable battery in the key. The battery is charged by

induction from the EWS ring antenna on the steering column, which takes place during regular vehicle operation.

As a result of this new key, the operation "replace batteries in all master keys" at Inspection I is now changed to "Recharge or replace batteries for

remote controls in all vehicle master keys."

Oil Change Time Interval:

Due to improvements in oil quality provided by synthetic oil, the interval to change engine oil on vehicles driven less frequently has been increased

from 1 to a maximum of 2 years on all models except the M coupe or M roadster (engine oil may be changed as infrequently as every two years

unless indicated otherwise by the Service Interval Indicator).

Parts Information

Additional copies of the checklists for 2000 models can be ordered from Product Engineering as listed below:

A pre-printed Material Order Form is enclosed.

WARRANTY INFORMATION

2000 Model Year QCI payments will be automatically issued to BMW centers upon reporting a 2000 model year vehicle as retailed, or placing the

vehicle in service as a BMW center demonstrator or Service/Loaner vehicle. The payments, processed via a miscellaneous billing, will be based on

the display and delivery check flat rates as published and each BMW center's warranty labor rate. With this change, the QCI line item on the repair

order should be charged internally to the New Car Sales Department.

BMW Company Cars

Reimbursement for performing the QCI on BMW company cars (of any model year) must still be requested by submitting a claim through DCS

using the Spot Delivery codes as listed below:

1200 Mile Service

429

The 1200 Mile Service required on the 2000 Model Year M5 and Z8 may be claimed using DCS claim entry.

IMPORTANT:

As with all work that is reimbursed by BMW, the repair order, time recording and record keeping requirements outlined in the Warranty Policy

and Procedures Manual must be strictly observed.

Quality Certification I and 1200 Mile Service payments are subject to audit.

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 240998 Date: 011201

Covered under the terms of the BMW New Vehicle Limited Warranty.2000 BMW 328i (E46) Technical Service Bulletin # 240998 Date: 011201

A/T - GM5 Clunk Noise

GROUP 24

Automatic Transmission

24 09 98

Woodcliff Lake, NJ

Service Engineering

December 2001

This Service Information bulletins supersedes S.I. 24 09 98 dated December 1998.

SUBJECT

E46 GM5 Transmission "Clunk" Noise

MODEL

E46 - 323iA, 328iA produced from 05/98 up to 03/00 with A5S360R (GM5) Transmission

SITUATION

A "Clunk Noise" is heard/felt during situations of load reversal. The situation can occur during downshifts, release of accelerator pedal at 20-30 mph

with 2000-2500 rpm or in reverse at 3000 rpm and accelerator pedal released.

This concern involves E46 vehicles with M52TU engines, fitted with transmission A5S360R until transmission serial number 162728.

CAUSE

Excessive axial clearance between transmission output shaft and transmission output flange.

CORRECTION

A production change has been implemented as of transmission serial number 162728.

In the event of a customer complaint on vehicles with a transmission serial number less than 162728 the location of the noise should be determined

during a test drive as follows:

-- With the engine warm, drive the car at a speed between 20 and 25 MPH. While traveling in this speed range, quickly release the accelerator

pedal (causing engine braking to occur).

-- If a muffled knocking noise is heard coming from the rear-axle area after going into decel mode, or shortly thereafter, then the cause is with the

transmission output flange.

Replace transmission output flange with the new version P/N 24 21 7 515 388 with spring washer as per repair instructions 24 21... (available as

of TIS CD 9/98).

-- If the noise does not appear to be coming from the rear axle area further diagnosis is required in order to isolate the source of the "clunk".

443

Recommendation would be to utilize a chassis ear to locate the source of the clunk noise.

The repair kit "Output flange with spring washer" (PN 24 21 7 515 388) can be ordered through the regular parts channels.

PROCEDURE

Installation of the kit on the transmission:

1. Remove the exhaust pipe from the vehicle as per procedure 18 00 020 "Removing and Installing complete exhaust system M52 TU".

2. Remove the propeller shaft from the transmission as per procedure 26 11 000 "Removing and Installing complete propeller shaft"

3. Hold output flange (1) with special tool 23 0 020. Remove hexagon nut. Remove output flange (1). On the transmissions from serial number

7912, remove the retainer (snap ring) from the output shaft Discard the nut, the seal 0-ring of the flange, and the retainer.

4. Prepare the retrofit kit:

5. Install new drive flange 0-ring (1) (from the kit) into the new drive flange (2) using Transmission fluid or petroleum jelly

444

6. Install the "Retainer" (1) included in the kit using snap ring wrench, as deep as possible on the output shaft (2).

Note:

Be careful to not damage lip seal when installing the "Retainer".

7. Install new drive flange with 0-ring onto the transmission output shaft and push the retainer fully into place

8. Install the spring washer (1) from the kit as shown on the drive flange (2) (big diameter face to flange 2, small diameter face to nut).

9. Apply coat of "LOCTITE 242" to the thread of the output shaft.

NOTE:

"LOCTITE 242" is the only thread locker/sealant approved for this repair, and it is available from your local Loctite distributor.

10. Tighten the new nut (1) (included gun the kit) on the output shaft using a Hexagonal M30 Socket

11. Tightening torque: 80 Nm

PARTS INFORMATION

Part Number Description Quantity

24 21 7 515 388 Repair set output flange 1

WARRANTY INFORMATION

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

445

Defect Code 24 21 90 31 00

Labor Operation: 24 211 00

Labor Allowance: 17 FRU