BMW M5 (E39) V8-4941cc 5.0L DOHC (S62) Page 1 Technical Service Bulletin # 110504 Date: 080301 Emissions - MIL ON/Codes 81 and 81 in DME Memory SI B11 05 04 Engine

March 2008 Technical Service

This Service Information bulletin supersedes S.I. B11 05 04 dated July 2006.

[NEW] designates changes to this revision

SUBJECT M62TU/S62 Secondary Air Diagnostics and Air Delivery Passage Cleaning Procedure

MODEL E38 (7 Series), E39 (5 Series), E53 (X5) and Z8 with the M62TU or S62 Engine

SITUATION

When accumulated vehicle usage exceeds 35,000 miles, a small number of vehicles listed may experience illumination of the Check Engine Light and the setting of the secondary air system fault codes 80 and 81 in DME memory.

CAUSE

If all relevant components (air pump, one way valve, solenoid valve etc.) are determined to be functioning properly and the condition still exists, the cause may be clogged secondary air delivery passages within the heads.

Excessive / deposits may be attributed to usage of fuels with inadequate level of detergents. BMW recommends exclusive use TOP TIER Gasoline to prevent an excessive deposit build-up.

CORRECTION

A tool kit has been developed that will remove the guesswork in the diagnosis of clogged secondary air passages and provide a method to remove the built-up carbon deposits which are causing the fault. This tool has already been distributed to all centers via the Automatic Tool Shipment Program. Additional cleaning kits, Part Number 99 00 0 006 668, may be purchased through your PDC. Refer to Parts Information bulletin 01 01 95 for tool warranty details. [NEW] NOTE:

Main secondary air passages core plugs (12 mm) are not included in the latest production kits. Core plugs (PN11 12 1 736 330) have to be ordered separately from PDCs (Qty: 3 per vehicle). Replacement reamers and sets of brushes are available under the following part numbers:

^ Reamer 4mm PN 83 30 0 444 759

^ Nylon Clean-up brushes PN 82 11 0 416 754 (set of 12)

^ Brass brushes PN 82 11 0 416 755 (set of 3) of 3)

PROCEDURE

In cases where the check engine light is on and fault code 80, 81 (or both) are stored in DME memory, it is necessary to first verify that all external secondary air components are functioning. After following the applicable test plan in DISplus, proceed with the calibration of the back pressure tool.

Lift red regulator knob (1) and unscrew counterclockwise until the stop is reached.

Insert plug (1) into end of tube (2) and tighten T handle until plug is secure.

Attach pressure transducer (2) from DISplus to fitting on tool. Set DISplus to "Measuring Systems" and "Pressure Bar". The approximate 1 bar reading on the screen is the ambient atmospheric pressure.

Connect shop air (1) and open the yellow flow control valve (2). Turn red regulator knob (3) clockwise.

Rotate until 3.5 bar is registered on the screen. Lock by pressing down on the regulator knob.

Shut off yellow flow control valve, disconnect pressure transducer and remove the plug from end of the pipe.

Testing procedure

Please note that pictures of the engine are for clarity purposes only. At no time during the procedure is the engine removed from the vehicle.

Remove assembly. Refer to Repair Instruction 11 52 020 in WebTIS.

Remove the two 10 mm bolts (2) securing the delivery tube (3) to the cylinder heads at position indicated (1). Position tubing out of the way so that there is access to the ports in the heads.

Insert tool (1) in right cylinder head (1-4) secondary air supply passage (2). Connect pressure transducer from DISplus (3) to tool, connect shop air and open yellow flow control valve to allow the free flow of regulated air to pass through the head. Observe backpressure reading on DISplus. Readings in excess of 1.10 bar indicate restrictions within the head that require cylinder head removal. Repeat test for left side head.

Note: Prior to engine disassembly, perform a thorough engine compression and leakdown test to ensure that there are no engine problems that could cause a short term reoccurrence of the problem.

Parts Information WARRANTY INFORMATION

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

Disclaimer Repair Procedure Caution: When disassembling cylinder head and performing cleaning procedure, always use protective eyeware.

Following Repair Instruction 11 12 505/506, remove cylinder heads from engine. To disassemble cylinder head, refer to Repair Instruction 11 12 503. Mount cylinder head on special tool 11 1 065. Remove .

Using tool 11 3 250, remove the bucket . Utilizing the listed special tools, compress exhaust valve spring.

Remove the valve retainers, and remove valve spring. For reassembly purposes, ensure that all removed spring assemblies and bucket tappets are arranged together in order of removal. Using special tool, remove exhaust valve guide seals.

Push on valve stem until edge of stem is flush with top of valve guide (1). With the valve stem so positioned and using a dial indicator mounted to a suitable holding fixture, rock valve back and forth within guide to measure valve tilt clearance of each exhaust valve. Movement should not exceed 0.5 mm. This procedure, outlined in RA 11 12 595, ensures that the valve stems and guides are within acceptable limits.

Note: If heavy carbon deposits are found in the cylinder head, it is highly probable the other cylinder head will soon develop the same condition. For that reason, it would be advisable to remove the other cylinder head for cleaning.

Using the drill bit (2) supplied in the kit, drill a hole in the 10 mm core plug for the main secondary air supply passage located in the rear of the head (1). Using the core plug remover (2) and a 10 mm socket, thread screw portion of tool into hole and continue to turn clockwise until plug is removed. On the right side cylinder head, perform same procedure to remove core plug from the front of the head.

Note: The left side (cylinder 5-8) cylinder head does not have a front core plug.

Using the 10 mm brass brush (2) from the kit mounted in motorized drill, clean out main secondary air delivery passage 1). Blow out the passage with an air nozzle and shop air and repeat the deaning procedure until no more carbon is present.

Locate the secondary air distribution ports under the removed exhaust valve. Insert the reamer tool (2) in the port (1) and rotate in clockwise direction until no further resistance is felt and the tool has reached the bottom of the passage. Repeat procedure with remaining 7 ports (per cylinder head). Finish the port clean up by using the small 4 mm nylon brush (2) in conjunction with a motorized drill in each of the 8 (per cylinder head) delivery ports (1). Blow out passages with an air nozzle.

Using the core plug installer (3) and a hammer (4), install new core plugs (2) into secondary air distribution passages (1). Core plugs (PN 11 12 1 736 330) have to be ordered separately (Qty: 3 per vehicle).

Prior to cylinder head reassembly, reinstall the back-pressure tool (2) into the passage (1) and retest. The reading on the DISplus should be close to the base atmospheric reading (1 bar) and air flow should be present at all delivery 8 ports. Install protective sleeve over end of valve guide and place new valve seal over sleeve.

Press on valve seal using the tool indicated. Reassemble cylinder heads and reinstall on the engine.