Seat BMW 525i 2001 E39 Service Manual

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21 0-1 8
Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- Install SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques Clutch to flywheel
- M8 (8.8 grade)
MB 110.9 orade)
24 Nm (1 8 it-lb)
34 Nm (25
ft-lb)
Use 14 mm Allen wrench to unscrew (clocltwise or counter-
clockwise) lock plate in center of pressure plate.
NOTE-
The spring lockplate may make snapping noises while being
unscrewed.
Using large bolt, pull out clutch centering tool
Remove flywheel locking tool
4 Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CAUTIOG
Do not grease guide sleeve. Ifguide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- lnstall transmission. See 230 Manual Transmission.
Tightening torques
- - - Transmlsslon to engine -
. MB (Torx) 22
Nm (16 it-lb)
MI0 (Torx) 43 Nm (32 it-lb)
* M12 (Torx) 72 Nm (53 it-lb)
.-

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1 Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- lnstall SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques
Clutch to flywheel
- M8 (8.8 grade)
M8 (10.9 grade) 24
Nm (18
ft-ib)
34
Nm (25 ft-lb)
- Slip out clutch centering tool using large bolt.
- Remove flywheel locking tool.
Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CA U TIOG
Do not grease guide sleeve. If guide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- Install transmission. See 230 Manual Transmission
Tightening torques
Transmission to engine
- ME (Torx)
. M1O (Torx)
. M12 (Torx) 22
Nm (16 ft-lb)
43
Nm (32 ft-lb)
72
Nm (53 it-lb)

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Manual Transmission
Input shaft seal, replacing
(transmission removed)
- Remove transmission from vehicle as described later in this
group.
- Remove clutch release bearing end release bearing lever
from inside bellhousing.
4 Remove bolts (arrows) for clutch release-bearing guide
sleeve, noting bolt lengths
(Getrag trensmission shown).
Remove sleeve and any spacers (shims) under it.
Two covered removal holes (arrows) are present in seal.
Thread BMW special tool
23 0 490 or equivalent slide ham-
mer seal puller into one hole and remove seal.
- Getreg S5D 250G transmission:
Place BMW special tool
23 2 460 or similar protective
sleeve over input shaft.
Coat sealing lip of new
seel with trensmission oil and push
over protective sleeve up to transmission housing.
Remove protective sleeve from input shaft.
Use BMW special tool
23 2 430 or similar drifl to drive seal
until fully seated.
- ZF S5D 3202 transmission:
Place BMW special tool
23 2 380 or similar protective
sleeve over input shaft.
Coat sealing lip of new seal with transmission oil and push
over protective sleeve up to transmission housing.
* Remove protective sleeve from input shaft.
Use BMW special tool
23 2 340 or similar drift to drive seal
until fully seated.
- 6-speed transmission:
Fit
cap of BMW special tool 23 2 492 over tool sleeve.
Coat sealing
lip of new seal with transmission oil and push
on tool sleeve. Remove tool cap from tool sleeve.
- Push sleeve with seal on input shaft.
- Use BMW special tool 23 2 491 or similar drift to drive seel
until fully seated.
Remove protective sleeve from input shaft.

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240-1 3
Automatic ~ransmissionl
- Blow out oil cooler lines with low-pressure compressed air
and flush cooler with clean ATF twice before reattaching lines
to transmission.
CA UTIOG
Wear safety glasses when worling with compressed air:
@ Do not reuse ATF used for flushing.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Reinstall driveshafl using new nuts.
Install new sealing washers on transmission cooling line
banjo bolts.
Install new O-rings on transmission cooler lines, where
applicable.
Inspect engine drive plate (flywheel) for cracks or elongat-
ed holes. Replace
if necessary.
Be sure bellhousing alignment dowel sleeves are located
correctly. Replace damaged sleeves.
Checlc to be sure torque converter is seated correctly in
transmission during final installation.
Use
BMW special tool 24 2 300 to align three mounting
tabs on torque converter with indentations on drive plate
(flywheel).
Fill transmission with clean ATF until oil level is even with
fill hole. Then check fluid level as described earlier.
Adjust gearshift mechanism. See
250 Gearshift Linkage.
NOTE-
In order to avoid difficulties in transmission removal at a fu-
ture time, use washers with Torx-head mounting bolts.

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260-1 0
/ Driveshaft
Driveshaft, installing
- Prepare CV joint for reinstallation:
Extend joint to limit.
Clean off old grease and fill with fresh grease
Install new seal.
- Bend driveshaft slightly at center universal joint to install
CAUTION-
Do not allow CVjoint seal to become displaced.
- Align matchmarlts on driveshaft to matchmarks on final drive
and transmission flanges.
- Fit constant velocity joint to final drive input flange. Alternate-
ly tighten two opposite nuts to draw constant velocity joint
evenly into the final drive input flange. Once seated, tighten
down remaining nuts.
I CAUTION-
I Do not reuse self-locking nuts. These nuts are designed to be /
I used onlv once. 1
- Insert bolts in front of driveshafl to transmission output
flange. Counterhold each bolt while tightening nut.
CAUTION-
. Do not reuse self-locking nuts. These nuts are designed to
be used only once.
Avoid stressing the flex-disc when torquing the bolts.
Do this by counterholding the bolts and turning the nuts
on the flange side.
- Position center support bearing and install mounting nuts.
Use new self-locking nuts.
- Install heat shields.
- Install rear transmission support crossmember.
- Install exhaust system. See 180 Exhaust System.
Reconnect oxygen sensor wiring harnesses and reattach
wiring harness retainers to rear transmission support
crossrnernber.

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300-1 4
I Susoension. Steerina and Brakes - General
DSC system I
Dynamic Stability Control (DSC)
Dynamic Stability Control (DSC) utilizes many principles and
components of the ASC traction control system. DSC is ac-
tive throughoutthe driving range, unlike ASC which is only ac-
tive during acceleration and braking. DSC helps stabilize the
vehicle in cornering and avoidance maneuvers by adjusting
engine controls such as throttle, ignition, fuel injection and the
application of
brake pressure individually to the wheels.
Inputs
fi- 0
2 4-* .. o
[11-' IJ
411m4
3?-
G
4 The DSC control module uses various inputs to determine
vehicle instability during braking, cornering, or reduced trac-
tion situations. Based upon these inputs the ABSIDSC con-
trol module sends outputs to the engine control module and
the ABSIDSC hydraulic unit to activate torque reduction pro-
tocols and braking intervention.
-
ABSIDSC control module
OUI~YIS
4
The DSC system can be toggled on and off by a switch
mounted on the center console. Turning off the DSC system
does not disable ABS or ASC functions.
+
Measure ride height (A) from center of fender arch to bottom
of wheel rim.
Car in normal loaded position on the ground. See Normal
loaded position.
Engine
control
module
Specified tires and wheels, correct tire pressure, even tire
wear
-'* 9-
.%A
Correct wheel bearing play
T'== ..t, 9 B
-.m
Model with air suspension (EHC): Disconnect electrical har-
ness connector to air supply pump to prevent automatic
height regulation.
When finished, reset ride height using BMW diagnostic
scan tools DIS or
MoDiC.
NOTE-
Airsupply pump is located beneath a cover under the spare
tire in the floor of the cargo compartment.
- If ride height is outside specification listed, install new
springs. Suspension spring removal and installation is cov-
ered in
310 Front Suspension and 330 Rear Suspension.
Normal loaded position
Each front seat 68 kg (150 Ib)
Center of rear seat 68 kg (150 lb)
Trunk 21 kg (46 lb)
Fuel tank full

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31 0-9
Front Suspension
Front strut assembly
components
(6-cylinder models)
1. Cap
2. Upper strut self-locking nut
3. Washer
4. Strut bearing reinforcement
5. Strut mount self-locking nut
6. Upper strut mount
7. Dust protector collar
8. Spacer
9. Upper spring seat
10. Spacer
11. Upper spring pad
12. Coil spring
13. Rubber stop
14. Dust boot
15. Lower strut pad
16. Strut with lower spring seat
Front strut assembly, disassembling
and assembling
Replacing the strut, upper strut mount or spring requires that
the strut assembly first be removed from the car
and disas-
sembled. For a guide to parts used during component re-
placement, see the accompanying diagram.
NOTE-
Illustration shows components ior 6-cylinder models (525i,
528i, 530;). V-8 models (540i) are similar but not identical.

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31 0-1 0
Front Suspension
4 Clamp spring compressor (BMW special tool 31 3 340 or
equivalent) in shop vise.
WARNING-
* Do not attempt to disassemble the strut assembly without
a spring compressor designed specifically for this job.
Prior to each use,
checlc special tool for functionality.
Do not use a damaged tool.
Do not make any modifications to tool. Use correct size spring retainers when compressing
coil spring.
I When assembling BMW spring compressor (special
tool
31 3 340), make sure spring retainerplates are felt
and heard snapping into place. Check seating of spring
retainers carefully.
Position coil spring between spring holders so that
3 coils lie
between spring holders
(arrows). Compress spring.
WARNING -
When tensioned, the spring coils must rest completely in
the spring holder recess.
Never tighten or loosen spring compressor with an im-
pact tool.
Only tighten down the coil springs until stress on the
thrust bearing is relieved.
a Only loosen strut nut if spring coils are completely in-
serted in the spring holder grooves. If
necessarx loos-
en compressor, reposition and recompress.
Use
BMW special tool 31 2 21 0 or equivalent to remove strut
nut. Counterhold strut shaft using
6 mm Allen wrench.
CAUTION-
Do not remove strut nut with impact tool.
Remove upper strut bearing and related components.
If a new coil spring is being installed, relieve tension on
spring compressor and remove coil spring.
Check strut dust boot, rubber stop and spring pads. Replace
as necessary.
Replace strut, upper strut mount or spring, as needed

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Front Suspension
/ Front strut top mount assembly
< Replace springs in matched pairs only. BMW ID number is
stamped near end
(A).
4 Assembly is reverse of disassembly, noting the following:
Use a new upper strut self-loclting nut
(A). Tighten nut
fully before releasing spring compressor.
CAUTION-
Do not tighten strut nut with impact tool.
NOTE-
illustration shows components for 6-cylinder models (5257,
528i, 5300. V-8 models (5400 are similar but not identical.
4 Be sure upper and lower spring pads (arrows) are correctly
installed to spring seats before releasing spring compressor.
Release spring compressor carefully and evenly, allowing
spring to expand slowly.
Have car professionally aligned when job is complete.
Tightening torques Upper strut mount to strut shaft
64 Nm (47 ft-lb)
Strut mount to strut tower (ME) 24 Nrn (18 fi-lb)

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Steering and Wheel Alignment
- Tighten nut while counterholding adjusting bolt,
- Tighten nut only after car has been lowered to ground and
suspension has settled.
Preparing for alignment
- The following conditions are necessary prior to wheel align-
ment:
Correct wheels and tires are installed, in good condition,
and are at the correct inflation pressures.
All steering and suspension parts and bushings are un-
damaged and show no signs of abnormal wear. Wheel
bearings are in good condition.
Ride height is in accordance with specifications. See
300
Suspension, Steering and Brakes-General.
Car is in normal loaded position. See below.
* Cars with air suspension: Remove air suspension power
fuse.
Normal loaded position
Each front seat
68 Kg (I50 lb)
Center of rear seat
Trunlc
Fuel tank
68 Kg (150 lb)
21 Kg (46 lb)
Full
Alignment specifications tables
In the alignment specification tables that follow, reference is
made to the various types of suspension used in
E39 cars.
The type of suspension can be identified by loolting at the la-
bel on the front strut tube.
Identifying symbol
None
Solid circle
Solid triangle
M5
Circle
Triangle Version
Standard suspension
Sports
suspension
Sports suspension
M sport package
Standard suspension
Sports suspension Model
Sedan
6-cylinder sedan
V-8 sedan
V-8 sedan
Touring (Sport Wagon)
Touring (Sport Wagon)