Troubleshoot BMW 525i 2001 E39 Service Manual

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WARNING
Your common sense, good
judgement, and general alertness are
crucial lo sale and
successlul service
work. Belore attempling any work on
your BMW, be sure to read 001
General Warnings and Cautions
and lhe copyright page
a1 llle Iron1 01
the manual. Review lliese warnings
and cautions each time you prepare
lo work on your
BMW Please also
read any warnings and
caulions lhal
accompany the procedures In !he
manual.
Component locations
see Electrical system
Compression test
113-5
Compressor see
AlC
Condenser see
AlC
Constant velocity (CV) joint
see Maintenance
see also
Driveshall
see also Drive axles
Consumer cutoff
600-10
Control arm see Front suspension
see also Rear suspension,
suspension arms
Coolant (antifreeze) see Maintenance
see also Cooling system
Coolant pump
see Cooling system Cooling system
coolant bleeding
170-14 6-cylinder engine, draininglfilling
170-10
V-8 engine, draininglfilling 170-12
coolant pump 170-3
6-cyiinder engine, replacing 170-1 9
V-8 engine, replacing 170-20 cooling fan 170-4
viscous ciutch fan, removingi
installing 170-14
electric fan, removlngiinstailing 170-1 5
expansion tank, removinglinstalling
170-22
electrically heated (ciiaracterislic
map) therrnostat 170-4
radiator, removinglinstaliing 170-22
service
see Maintenance
therrnostat 170-16
transmission fluid heat exchanger
170-5 troubleshooting 170-7
combuslion leal( test 170-10
pressure test
170-9
Crankshaft oil seals
iront
117-6
rear 11 9-6
Crankshaft speed sensor
see Ignition syslem
Crash sensor
see
Airbag system (SRS), side-impact
airbag crasii sensor
Cruise control clutch switch 612-9
CV joint
see Maintenance
see also Driveshalt
see also Drive axles
CV joint boot
see Maintenance
see also Drive axles
Cylinder head removinglinslaliing
M52 engine 113-8
M52 TU / M54 engine 113-22
M62 engine 113-56
Cylinder head and valvetrain
hydraulic lifters, checking and
replacing
116-7 leak test 116-5 valves 11 6-56
see
alsocylinder head Dashboard
513-7
Deck
lid
seeTrunk lid
Diagnostic monitors
OED-4
Diagnostic trouble codes
(DTCs)
080-7
Digital multimetel
010-17
Differential see Final drive
DLC (data
link connector) 020-4, OED-4
DME (digital motor electronics)
see
130 under appropriate fuel
injection system
see also ignition system
DM-TL (detection module-tank leak)
see
Fuel lank, leak deteclion unit
Drive
belts
see Maintenance
Dome light
seeLighls, interior lights
Door
door
check, replacing 411-4
hinge adjustment 41 1-5
loci(
see Door lock see also Central locking
removinglinslaliing 41
1-2
panel, removinglinstaliing 41 1-7 window
see Door window
Door
check
see Door
Door
handle
see Door lock
Door glass
see Door window
Door
lock
handles and loci(s 515-16
see also Central locking
Door
molding
510-13
Door panel see Door

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4 INDEX
Door window anti-trap
512-4 convenience openinglclosing 512.4
regulator and motor 512-1 1
service
512-5 switches 512-3
see also Switches
Double
VANOS see VANOS
Drive
axle
CV joint 331-15 CV joint boot 331-15
rernovinglinstalling 331-14
Drive belt
see Maintenance
Driveabiiity troubleshooting
100-4
Driveaway protection
see EWS (eiectronic immobilization)
Driveshaft aligning
260-7
center bearing, replacing 260-12 CV joint, replacing 260-14
itex-disc, replacing 260-1 1
iront centering guide, replacing 260-13
rernovinglinstailing 260-6
lroubleshooting 260-3
U-joint 260-3
DSC
see Braires
DTC (diagnostic trouble code)
OBD-8
DWA
see Anti-theft alarm
ECM (engine control module)
see 130 under appropriate
iuei
injection system
ECT (engine coolant temperature)
sensor see 130 under appropriate
iuei
injection system
EDK adaptation
130-69
MS 43.0 130-35
EHC see Electronic iieigiit control (EHC)
Electric cooling fan
see Cooling system, cooling
fan
see also Cooiing system, eiectric fan
Electrical switches
see Switches
Electrical system abbreviations
600-14 bus System 600-4
component location table 610-3
components
photos
610-36
Sport Wagon 610-81 engine 121-2
troubleshooting 600-15
voltage and polarily 600-5 wire color codes 600-12
wiring diagrams 600-12
Electrical wiring diagrams
ELE-1
Eiectricaliy heated thermostat
(characteristic map)
170-4
Eiectronic height control (EHC)
300-8, 330-44
Eiectronic immobilization
see EWS (electronic immobilization)
Eiectronics box
(E-box)
610-37
Emergencies
010-18
Emergency brake see
BraBes, parking brake Engine
see also Cylinder head and valvetrain
applications
100-2
compression, testing 113-5
cooling see Cooiing system
crankshaft front oil seai
see Crankshaft oil seals
cyiinder leak-down test 113-8
diagnostic testing 113-1
drive belts
see Maintenance
driveability troubleshooting
100-4
engine management systems 100-2
see also Ignition
see also Fuel injection
fuel supply
130-6
ground connections 100-5
see also 61 0 identilying ieatures 100-3
lubrication svstem
see
~ubricetion system
mount
on-board diagnostics
OBD-I
oxygensensor
see Fuel injection
see also Exhaust system
Dreventive maintenance
see Maintenance
removal/installation
Engine control module (ECM)
see 130 under appropriate iuel
injection system
Engine cooiant temperature (ECT)
sensor see 130 under appropriate iuel
injection
system
Engine cooling fan
see Cooiing system, electric fan
Engine hood
41
0-6 raising to service position 410-6
Engine troubleshooting
see Engine, driveability troubleshooting
EVa~oratiVe control svstem
160-3 see also 130 under aDDroDriate iuel
injection system
Evaporator see
NC
Evaporator temperature sensor see
NC

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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan

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Gaskets and seals 01
0-9
Gearshift automatic transmission
adjusting
250-7
shift interiock. checkino function " 250-9
shiftloclc. checicino function 250-8 - manual transmission
gearshift lever, removingiinstalling
250-5
steptronic 250-7
General module (GM Ill)
600-8
see also Central locking
Generator see Battery, starter, alternator
Glass see Door window
Glove compartment
513-16
see also
Global positioning system
(GPS)
620-9
Grill
see Exterior trim
Grounds
100-5
Guide link
see Rear suspension, suspension
arms
Halogen headlight
630-5
Hand brake
see Brakes, pariring brake
Handle, door
see Door
locks
Hatch seeTailgate
Hazard warning switch
see Switches Headlight
housing trim
see Exterior trim
washer611-17 see also Lights
Headlight spray
nozzle
611-17
Headlight switch
see Switches
Heater core
see Heating
Heater valve
see Heating
Heating lieater core, replacing
640-18
lheater core temperature sensor,
removingiinstalling
640-12 heater valve, replacing 640-17
IHKA housing, removinglinstallin~
640-21
see also NC
Hood
410-6
Hood latch and release
410-10
Hydraulic valve lifters
see Cylinder head and valvetrain
IAT
(lntalce air temperature) sensor
see 130
under appropriate fuel
injection system
idle speed control valve
see 130
under appropriate fuel injection system
Idle stabilizer
see 130
under appropriate fuel
injection system, idie speed controi
valve
idler arm
320-30
lgnition coll
see lgnition system
lgnition interlock
320-13
lgnition lock cylinder
removingiinstalling
320-1 1. 612-4
lgnition switch
seeSwifches
Ignition system
diagnosis checking for
spark 120-10
disabling ignition system 120-10 misfire detection 120-6
oscilioscope diagrams 120.6
troubleshooting 120-6
camshaft position sensors 120-14 coils 120.10
crankshaft speed sensor 120-12 firing order 120-9
knoclc sensors 120-16
IHKA
see NC
IHKR see NC
Injector
see 130 under appropriate
fuel
injection system, luel injector
Input shaft
oil seal
see Manual transmission, oil seals
Inspection
see Maintenance
Instruments GPS see Global positioning system
(GPSI layout 6202
removingiinstalling 620-8 self-testing 620-6
Intake air temperature sensor (IAT)
see 130 under appropriate fuel
injection system
Intake manifold
removingiinstalling
6-cvlinder enoine 110-10. 113-8. 113-22 -
V-8 engine (M62) 113-56
Integral link
see Rear suspension, suspension
arms
lnterior lights
see Lights
lnterior protection
(FISIUIS) 515-25
lnterior trim
513-13
lnterior ventilation microfilter see
NC, ventilation microfiller

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Manual transmission
applications 200-2. 230-5
back-up light switch, replacing 230-6
gear ratios 230-6
gearshift
see Gearshiit
ID tag 200-2
fluid 020-1 0. 200-4 fluid service 230-6
oil seals
input shaft seal, replacing
230-17
output shalt seal, replacing 230-1 1
selector
shaft seal, replacing 230-8 pilot bearing 210-16
removallinstallation 230-19
see also Maintenance
Map light
see Lights, interior
Mass air flow
(MAF) sensor
see 130 under appropriate fuel
injection syslem
Master cylinder
see Brakes
see also Clutch, hydraulics
MDK
130-42
Microfilter see
NC, ventilation microfilter
see also Maintenance
Mirror see Exterior trim
Misfire see Ignition syslem, diagnosis
Motor mount
see Engine,
mounl
MRS (multiple restraint system)
see Airbag system (SRS)
Muffler
see Exhaust syslem
Neutral safety switch
see Automatic transmission, range
switch
OED II (on-board diagnostics)
OED-l
Oil change equipment 010-16
Oil level sensor
see Lubrication system
Oil pan
see Lubrication system
OH pressure
see Lubrication system
Oil pump
see Lubrication system
Oil service 020-1 1
On-Board Monitor
640-12
On-board diagnostics OED-1
Outside air temperature sensor
610-14
Outside door handle
see Door
loclc
Outside mirror switch
see Switches
Output
shaft oil seal
see Manual transmission, oil seals
Overheating
see Cooling system, troubleshooting
Overload protection
600-11
Oxygen sensors
130-72, 180-8
P codes OED-10
Panic mode operation
515-11
Parking brake
see Brakes
see also Maintenance
Parts, buying
010-11
Pedal cluster switches
see Switches
Pedal position sensor (PWG)
6-cvlinder
enqine
V-8 engine (M62 TU) 130-68
Pitman arm
see Steering
Power steering
see Steering
Power steering
fluid
see Maintenance
Power window switch
512-3 see also Switches
PWG see Pedal position sensor
(PWG)
Racic and pinion steering
see Steering
Radiator see Cooling system
Radiator cooling fan seeCooling system, cooling fan
see also Cooling system, electric fan
Radiator grill
see Exterior
trim
Radio
650-2 see also Antenna
see also Speakers
Rain sensor
611-6
Raising car safely
010-5
Readiness codes
OED-6
Rear door window
see Door window
Rear main seal
see Crankshalt oil seals
Rear parcel
sheif
513-16

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INDEX 9
WARNING
Your common sense, good judgemenl, and general alerlness are
crucial lo seie end successful service
ivork. Beiore attempting any work on
your
BMW be sure to read 001
General Warnings and Cautions and llle copyright page at lhe iron1 of
the manual. Review Niese warnings
and caulions each lime you prepare
lo work on your BMW Please also
read any warnings and caulions lllal accompany the procedures in the
manual.
Rear suspension
ball joints
330-19
bushings 330-13
control arms
seesuspension arms, below
description
300-5
electronic height control (EHC)
330-44
ride height 300-14 ride height sensor 330-46
shoclr absorbers end springs 330-9
stabilizer bar 330-42
struts and springs 330-5 subframe 330.13
suspension arms 330-13
variations 330-4 wheel bearing, replacing 330-32
see also Maintenance
see also Drive axles
see also Final drive
Rear window (Sport Wagon)
see
Tailgate
Rear window defroster 610-17
Receiverldrter
see NC
Relay positions
see Electrical component tocations
table 610-3
Remote entry (FZV)
see Central locking
Reversing light switch
see
Baclc-up light switch
Ride height
300-14
Ride height sensor
see Rear suspension
Ring antenna
see EWS (electronic immobilizalion)
Rotor
see Brakes
Roundel see Exterior trim
Running tosses
(312-way) valve
see Fuel
tenlr
SCA (soft close)
seeTailgate, soft close
see also Trunk lid. soft close
Scan tools
OED-3
Seals gaskets and 010-9
see also Crankshaft seals
Seat front,
removing/instelling 520-10
memory system 520-4 rear 520-13
see also Seat belt
Seat beit front 720-4
rear 720-8
troubleshooting 7202
see also Maintenance
Secondary air injection
see 130 under appropriate
iuel
injection system
Selector shaft seat
see Manual transmission, oil
Seals
Self-adjusting ctulch (SAC)
see Clutch, variations
Service indicator see Maintenance
Shift interlock see Gearshift
Shift lever
see
Gearshift
Shift linkage see Gearshift
Shiftlock see Gearshilt
Shack absorber see Rear suspension
/ Side turn signal assembly
see Lights
Sill trim panel
411-10
Slave cylinder
see Clutch, lhydraulic
Steep mode
600-1 1
Soft close
(SCA) see Tailgate
see also
Trunk lid
Solenoid 121-23
Sound system
650-2
Spare parts kit
010-21
Spark plugs
see Maintenance
Speakers
650-4
Specifications, fluid
020-4
Sport wagon
400-4
Springs
see Front suspension
see also Rear suspension
SRS (supplemental restraint system)
see
Airbag system (SRS)
Stabilizer bar see Front suspension
see also Rear suspension
Starter see Battery, starter, alternator

Downloaded from www.Manualslib.com manuals search engine
WARNING
Your common sense, good
judgement, and general alertness are
crucial to saie and
successiul sewice
work. Beiore attempting any work on
your BMW be sure to read 001
General Warnings and Cautions
and the copyright page
a1 the iront of
the manual. Review tliese warnings
and cautions each time you prepare
to work on your
BMW. Please also
read any warnings and
cautions that
accompany the procedures in the
manual.
Towing 010-20
Traction control
see Brakes, ABS, ASC or DSC
system
Traction strut
see Rear suspension, suspension
arms
Transmission fluid
200-4
see Maintenance
see also Automatic transmission
see also Manuai transmission
Transmission
fluid heat exchanger
see Cooling system
Transmission input shaft oil seat
see Manual transmission
Transmission lubricant
200-4 see also Automatic transmission
see also Manual
lransmission
Transmission output shafl oil seal
see Manual transmission
Transmission pilot bearing
replacing 210-16
Transmission service see Manual transmission, oil seals
Trim, interior
see interior trim
see also Steering, steering column
trim
Trunk lid
412-2 soft close (SCA) 515-13
see also Trunkltailgale loci(
see also Central iocl TrunWtailgate lock
tailgate loci( emergency release
400-5, 515-21 tailgatelrear window locl(ing 515-14
trunk lock 51 5-1 9
lrey positions 515-7
Turn signai assembly
see Switches
see also Lights
UIS see Interior protection
U-joint
see Driveshaft
Upholstery see Maintenance, leather upholstery
and trim Vacuum
booster
see Brakes
Valve guides
see Cylinder
head and valvetrain
Valve seals
see Cylinder head and valvetrain
Valve seats
see Cylinder head and valvetrain
Valves see Cylinder head and
vaivelrain
Valvetrain see Cylinder head and valvetrain
VANOS control unit,
removinglinstalling
M52 engine 117-14
M52 TU i M54 engine 117-36 double VANOS
function
117-34 timing chain service 113-46. 116-28
timing, adjusting
M52 engine 117-22
M52 TU l M54 engine 117-43
Vehicle identification number (VIN)
010-12
Ventilation microfilter
see
AIC
see also Maintenance
Viscous clutch see Cooling
system, cooling tan
Voitage and polarity
600-5
Voltage tests
see Electrical system, troubleshooting