20 pin BMW 525i 2001 E39 Workshop Manual

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512-9
Door Windows
Vertical adjustment
- Adjustments are made with window in open position
4 Loosen window clamping fasteners (arrows), but do not
remove.
Adjust rear clamp and tighten fastener.
Tighten front clamp fastener.
4 Raise door window up to stop:
Check gap (A) at window front edge,
Checlc gap (5) at window top edge.
NOJE-
Measure window frame between door window edge and
panel.
Front window gap settings
Front of window
(A) 5.4 mm (0.21 in)
Top of window
(6) 10 mm (0.39 in)
Tightening torque Window regulator guide
rail to door 10 Nm (89 in-lb)
Door window, removing and installing
- Remove door panel as described in 411 Doors
- Reconnect window switch and lower window down to conve-
nient height and disconnect window switch.
- Disconnect negative (-) cable from battery, then remove air-
bag unit and vapor barrier from door. See 721 Airbag Sys-
tem (SRS).
WARNING -
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Warnings and
Cautions.

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Door Windows
Worlting carefully with a plastic prying tool, remove window
trim strip from door.
Starting from rear of inner window trim strip, carefully
on trim strip clips
(arrows) to remove window trim.
< Loosen 1 clamping jaw ' fasteners (arrows)

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51 5-2
/Central Locking and Anti-Theft
This section covers repair information for door, trunk and car-
go compartment locks, central locking, electronic
immob~liza-
tion (EWS) and anti-theft alarm (DWA).
€39 cars are equipped with sophisticated self-diagnostic elec-
trical systems. When experiencing malfunctions relating to
central locking. EWS or anti-theft systems, start the diagnosis
process using the
BMW service tester DIS, GT 1, MoDiC or
equivalent scan tool. An advanced diagnostic scan tool can
usually pinpoint electrical faults quickly and safely.
Additional electrical information can be found in:
610 Electrical Component Locations
ELE Electrical Wiring Diagrams
Central locking in E39 vehicles controls the door
locks, trunk
or tailgate lock and fuel filler flap lock. The control module for
the Central Body Electronics system (ZKE
Ill), lknown as the
General Module (GM
Ill), controls central locking.
ZKE
Ill manages the following central locking related func-
tions:
Central locking
* Keyless entry
Key memory
Power trunk release
Electric opening of tailgate
DWA alarm system
Diagnosis
General Module
4 The General Module (GM) (arrow) is responsible for the op-
eration of central body electronics. The GM is located behind
the glove compartment.
Based on input information, the GM uses internal transistors
to switch current flow (providing voltage or ground) through
circuits and actuators. Actuators are the final controlling de-
vices used by GM to operate or control various output func-
tions such as relays and motors.
The accompanying schematic, Central locking inputs and
outputs, illustrates the GM central locking system.

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Central Locking and Anti-Theft
DWA alarm
The DWA alarm system is
armedldisarmed when thevehicle
is locked / unlocked from either the door or trunk.
Convenience closing
I opening
The windows and sun roof can be closed or opened by hold-
ing the key in the
loclc I unlock position.
Crash sensor
The crash sensor is located in the left front
kick panel. It func-
tions by unlocking all doors in the event of an accident.
NOTE-
Continuous and repeated locliing / unlocking may cause
timedarrest of
the locliing system. When activated, the timed
arrest lasts for two minutes. The timed arrest does not affect
the crash sensor
unlocliing the doors in case of an accident.
Door locks
The driver's door lock location is the only point outside of the
vehicle where the ltey can mechanically control all of the cen-
tral locking system functions.
4 Door key positions for electrical / manual loclting and
unlocking are:
1. Manual unlock
2. Unlock, DWA disarmed, convenience open
(hold until activated)
3. Neutral position
4. Lock, DWA armed, convenience closing
(hold until activated)
5. Manual lock
The door lock actuators are sealed. self contained units with
no replaceable parts. The
actuators use Hall effect sensors in
place of pin contacts and microswitches to provide DOOR
OPEN
I DOOR CLOSED status signal. Each door lock button
only affects the actuator it controls. There is no effect on the
other doors.
An automatic locking feature activates door locks when a
road speed signal of 4 mph is detected via the K-Bus. The fac-
tory default coding for this feature is OFF, but can be coded
ON for individual users with the Key Memoryfunction. See
Car Memory
1 Key Memory later in this section.

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51 5-6
(Central Locking and Anti-Theft
Each rear door is equipped with the child lock-out lever, pre-
venting the door from being opened from the inside regard-
less of loclc button position.
Starting with models produced afler
911997, the General
Module and electronic immobilizer (EWS) interface via the
K-
Bus to monitor double lock status and to initiate double loclc
override. This feature allows the doors to be opened from the
inside if a key accepted by EWS is switched on in the ignition.
See Single lock and double lock function.
The door loclc buttons are mechanically uncoupled from the
actuators when locked. The remote keyless entry system
(FZV) is standard equipment. This allows for elimination of
the passengers side door
loclt cylinder.
Another function of the locking system is the
sofl close trunk
(SCA) system, where applicable.
Single lock and double lock function
(2000 and later models)
On models produced after
911999, each door lock actuator in-
corporates two motors:
Single lock motor controls the mechanical loclc mechanism
when the central lock switch is pressed to single loclc the
vehicle. The loclc mechanism is fully locked at this point but
can stil. be openeo from
the interor by pulng the appropri-
are interior door nandle lwce or by pressing rhe central
lock switch again. When single
lock'function is activated,
the fuel filler flap actuator is not locked.
Double lock motor, also known as central arrest, is activat-
ed only when the vehicle is locked from the outside at the
driver's door lock with a key or when the GM receives a
lock request from the remote entry (FZV) system. In this
case the double lock motor is activated simultaneously
with the single lock motor. The function of the double loclc
motor is to mechanically offset an internal rod in the loclc
actuator, disabling it from unlocking the vehicle from the in-
terior. This prevents the doors from being unloclted by any
means except from an unlock request at the driver's door
or via the FZV remote key.
Lock cylinder safety
4 The driver's door loclc and the trunk loclc incorporate an over-
running loclc cylinder similar to the ignition lock. If any key
other than the vehicle key, or a tool such as a screwdriver or
dent-puller, is inserted into the cylinder, it will cause the cyl-
inder to freewheel or spin.

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51 5-21
Central Locking and Anti-Theft
Trunk lid gap
measurements 4 When installing, or adjusting trunk lid alignment, adjust posi-
tion of trunk
loclc striker with mounting bolts finger tight.
* Check trunk lid loclc operation with lid open.
Adjust trunk lid alignment. See
412 Trunk Lid, Tailgate for
lid adjustment specifications.
NOTE-
Do not lubricate lock or lock striker with grease.
Tailgate lock, emergency release
4 In case of electrical failure, there is an emergency tailgate
loclk release. The release is located in the tailgate behind the
tool door.
- With tool door open, remove access cover and pull to the
right to release tailgate.
ELECTRONIC ~MMOBILIZATION (EWS)
E39 cars are equipped with a passive theft-prevention sys-
tem. The Electronic Immobilization System (EWS) makes it
impossible to
startthe engine using any means other than the
special lkeys furnished with the vehicle.
NOTE-
Replacement EWS control modules or DME control modules
must be electronically aligned to each before the vehicle will
start. This requires the use of the BMW Service Tester
(DIS-
plus, GT1, or MoDiC). Without alignment, the engine will not
crank (for example: swapping a
known good DME control
module into another vehicle for test purposes will result in a
no crank situation).
In the EWS system, the ignition key is embedded with
acom-
puter chip (EEPROM) and coded. The key communicates
with the vehicle using a transponder in the lkey and a ring an-
tenna surrounding the steering lock cylinder. Up to
6 replace-
ment keys are permissible. Only an authorized
BMW dealer
can provide replacement keys.

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520-5
Seats
1
4 Release mounting tabs (arrows) and remove switch module.
Front seat, removing and installing
- Turn ignition switch to OFF position.
Remove front and rear rail trim panels:
Raise center of trim panel
(A) to release loclting pin.
Unlock and lift out inner mounting clips tabs
(6).
Slide trim panel off rail (arrow) to remove.
< Remove seat belt mounting fastener (arrow) from seat
frame.

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540-2
Sunroof
This repair group covers the slide-tilt sunroof assembly.
There are two types of sunroof panels available: steel
01
glass. Service procedures are different for each type.
Component locations, initialization, sunroof panel replace-
ment, and sunroof height adjustment are covered. Replace-
ment of the cable assembly or frame require that the
headliner be removed. Removal and repair of the sunroof as-
sembly and othercomponents inside the roof cavity is beyond
the scope of this manual.
When the sunroof is set to the vent position (rear of panel up),
the inside headliner moves rearward approximately
120 mm
(4.7 in) This provides cabin ventilation with less wind noise. A
water channel is incorporated into the sunroof assembly. It
automatically rises when the sunroof panel is in the vent posi-
tion and prevents water from entering the interior during brak-
ing.
Sunroof electronic controls, initializing
- Initialize the sunroof in the following situations:
Malfunctions
such as lack of one-touch function, lack of
comfort openinglclosing or lack of safety (anti-trapping)
features.
If sunroof motor has been removed and reinstalled.
If power supply to the sunroof has been interrupted.
If repairs have been performed on the slideltilt mechanism.
NOTE -
The initialization sequence is dependent on the software ver-
sion of
tlie sunroof module (in the sunroof drive unit).
I WARNING -
I There is no anti-trapping protection during initialization. I

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I Seat Belts
This section covers repairs to the following seat belts sys-
tems. See the table below.
IMultIple Restraint Systems I
Years
311 996 - 811 997
Multiple Restraint System electronics integrate seat belt op-
erations and
airbag deployment. Airbag repair information is
covered
in 721 Airbag System (SRS).
Troubleshooting
The seat belt reel should lock when driving quicltly through
curves,
during severe braking or in case of a collision. The au-
tomatic reel does not require any servicing and should never
be opened.
- In case of an accident, follow the seat belt troubleshooting
procedures presented
in the table below.
Troubleshooting procedures
Belt creased, unraveled, pinched, cut or
melted. Belt buckle or belt loclt plastic casing Repairs
Replace complete automatic
seat belt.
Also
checlt and replace, if necessary, seat
Problem
Damage to seat
belt.
worn, damaged or missing.
Seat belt bucltle is not ejected with spring
pressure when red button on seat belt loclt is
>--- I I
Automatic belt soueaks when fastened or I~xcessive friction in belt guides. I Replace reel assembly.
Probable
cause
Accident in which bumper impact absorbers
were permanently deformed.
Seat belts aged or worn.
pressed.
Seat belt automatic reel does not lock when
pulled out suddenly.
Seat belt automatic reel jams when pulled
out.
Seat belt does not retract automatically
(see note below).
Automatic reel loose. Return sorino broken inside reel. belt mounting on car body and
seat belt
mounting on seat runner.
Replace complete automatic seat belt.
Seat belt
loclt mechanism worn or
damaged.
Tighten reel mounting bolt Replace reel assembly.
Replace seat belt lock.
Automatic reel defective.
Automatic reel loose. Return spring
broken inside reel.
Automatic reel loose.
Return spring brolten inside reel. Replace reel
assembly.
Tighten reel mounting
bolt.
Replace reel assembly.
Tighten reel mounting bolt. Replace reel assembly.
~ ~-~~ , - I'
Replace complete automatic seat belt.
Also check retaining bracket of belt
Seat belt
pyrotechnic tensioner triggered. Accident triggered pyrotechnic deployment.

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721 -9
Airbaq System ~SRS)~
4 Sport steering wheel:
Insert screwdriver through opening in rear of steering
wheel and push against spring tension to release
airbag
unit lock.
Repeat procedure on other side of steering wheel.
Lift off
airbag unit and detach electrical harness connec-
tors.
WARNING-
Store the removedairbag unit with the horn pad facing up.
If stored facing down, accidental deployment could propel
it violently into the air, causing injury.
Once an
airbag is removed, the car must not be driven.
Do not connect the battery with the
airbag disconnect-
ed. A fault code will be stored, setting off the
airbag in-
dicator light Special tools are needed to reset the fault
memory
Once the
airbag unit is installed and all other service
procedures have been completed, start the engine and
check that the
airbag indicator light goes out. If the in-
dicator light stays on, the
airbag system will not func-
tion as designed. Have the system diagnosed and
repaired by an authorized
BMW dealer.
- Installation is reverse of removal.
MFL steering wheel: Torque airbag using specification list-
ed below.
- Sport steering wheel: Press airbag unit mounting pins into
spring
loclts in steering wheel until they snap in firmly.
CAUTION--
Do notpinch airbag harness in center of steering wheel when
installino
airbaa.
Tightening torque
Airbao to steerino wheel IMFL) 8 Nm (71 in-lb)
Passenger airbag, removing and installing
- Disconnect negative (-) cable from battery and cover nega-
tive terminal with insulating material.
--
WARNING -
After disconnecting the batteg wait 5 seconds before begin-
nina work on airbaa components.
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in001 General Warnings and
Cau-