Wiring harness engine BMW 525i 2001 E39 Service Manual

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330-23
Rear Suspension
Remove rear control arm:
Remove inner control arm bolt
(A).
Detach plastic wiring harness support (B).
* Remove outer control arm ball joint nut (C). Press ball joint
out of rear wheel bearing carrier.
Installation is reverse of removal, noting the following:
Always use new self-locking nuts.
Malte sure all threaded bolts, nuts and mating surfaces are
clean.
Inner control arm mounting bolt must thread to rear (bolt
head at front).
Tighten fasteners to final torque only afler vehicle has
been lowered and suspension has settled.
Have car professionally aligned when job is complete.
Tightening
torques
Control arm to subframe (M12) 110 Nm (81 ft-ib)
Control arm
ball joint to wheel bearing 142 Nm (105 ft-lb)
carrier
(M14)
Quick coupling screw to air shock absorber
2 Nm (18 in-lb)
Road wheel
to hub 120-flONm
(89 i7 ft-lb)
Upper rear control arm, removing and
installing (Sport Wagon models)
CAUTIOG
Disable air supply pump by disconnecting electrical plug be-
fore
perlorming any repairs. Pump is located beneath a cover
under the spare tire in the floor of the
carqo compartment.
- Raise rear end of car and remove wheel.
WARNING -
Make sure the car is firmly supported on jaclc stands de-
signed for the purpose.
Place jaclc stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
Models with rear coil springs: Remove cargo compartment
floor carpet.
Worlting at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring from under car.

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330-25
Rear Suspension
Remove rear control arm:
Remove inner control arm bolt
(A). Push shock absorber
out of the way to slide bolt out.
Detach plastic wiring harness support
(B).
Remove outer control arm ball joint nut (C). Press ball joint
out of rear wheel bearing carrier.
Installation is reverse of removal, noting the following:
* Always use new self-locking nuts.
Maite sure
ail threaded bolts, nuts and mating surfaces are
clean.
Inner control arm mounting bolt must thread to front
(bolt . head at rear).
Make sure long lower shock absorber bushing fits in hole
in suspension swing arm.
* Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Have car professionally aligned when job is complete.
Tightening torques Control arm to
subframe (M12) 110 Nm (81 ft-ib)
Control arm ball joint to wheel bearing
142 Nm (105 ft-lb)
carrier
(M14)
Quick coupling screw to air shocit absorber
2 Nm (18 in-lb)
Road wheel to hub
Shoclc absorber to lower control arm 127 Nm (94 it-lb)
Upper front control arm (traction strut),
removing and installing
- Raise rear end of car and remove wheel.
WARNING-
Maice sure the car is firmly supported on jack stands de-
signed for the purpose. Place
jack stands underneath struc-
tural chassis points. Do not place jack stands under
< Mark location of inner control arm eccentric washer (rear toe

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-- I
I: ... . -. Rear Suspension! -- .- -
Air compressor pump relay, removing and
installing
- Working in cargo compartment, remove spare wheel.
4 Remove air supply pump fasteners (arrows). Turn pump
over.
- Turn relay plug 45" and remove relay.
EHC control module, removing and
installing
The EHC control module is mounted on the right side of the
spare tire
well in the cargo compartment.
- Remove spare tire.
4 Remove electrical components cover (A).
- Release control module wiring harness plug loclting clip (B)
and remove module.
- Installation is reverse of removal.
- After assembly, reset ride height using BMW diagnostic scan
tool DIS.
Air supply unit, removing and installing
CAUTION-
Maintain high levels of cleanliness around air line connec-
tions when disassembling and assembling air suspension
components. Even small dirt particles can cause
leakage in
the pressurized system.
When the airsupply unit is removed for any reason, reset ride
height using BMW scan tools DIS or
MoDiC.
- Remove spare tire.
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Rear Suspension
4 Remove air line fittings (A) from bottom of air distribution con-
nectors.
Cut off wire ties.
WARNING-
Vehicle will lower when the air pipes are opened.
4 Rotate air line distribution connector (A) 45" in direction of
arrow to remove.
Rotate electrical connector
(B) 45" in direction of arrow to
remove.
Compress wiring connector locking clips
(arrows) and dis-
connect wiring harness.
< Remove air supply unit mounting fasteners (arrows) and re-
move unit.
- Installation is reverse of removal.
When installing air lines always match line colors.
a After assembly, reset ride height using BMW diagnostic
scan tool DIS.

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Brakes
Brakes, bleeding
The procedure below requires a BMW Service Tester (DIS-
pluslGTl/MoDiC).
- Determine type of traction control (ASC, DSC with precharge
pump, DSC without precharge pump). Be sure to use correct
specification brake fluid, according to application table below.
Brake fluid applications
ABS I ASC and ABS / DSC models DOT 4 brake fluid
with precharge pump (to 911998)
ABS I DSC models without precharge DOT 4 low viscosity
pump (911998 and later) brake
fluid
< Remove left side interior ventilation microfilter housing:
Remove upper cover and microfilter loclting clip
(A).
Release locking clamp (B), and rotate air tube in direction
of arrow to remove.
Disconnect wiring harness from hood switch
(C).
Release filter body mounting clamp (D) and remove lower
microfilter housing.
- Top off bralte fluid in reservoir and connect BMW Service
Tester to
20 pin Data Link Connector (DLC) under hood or 16
pin
DLCIOBD I1 connector under dash.
- Call up service function Bleeding ABS / ASC or service func-
tion Bleeding ABS
/ DSC, depending on installed system.
- Fill pressure bleeding device with the correct brake fluid and
connect to brake fluid reservoir and apply pressurize.
Do not exceed a pressure of
2 bar (29 psi) when pressure
bleeding the
brake system. Excessive pressure will damage
4 Starting at right rear wheel, connect bleed hose and fluid re-
ceptacle to bleeder screw (arrow).
CA UTlON-
Bleeder hose must always remain submersed in clean brake
fluid whenever the bleeder valve is open.

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Brakes
Master cylinder, removing and installing
CAUTlOI\C
Brake fluid is highly corrosive and dangerous to the environ-
ment. Dispose of it properly.
4 Remove left side interior ventilation microfilter housing:
Remove upper cover and microfilter locking clip
(A).
- Release locking clamp (B), and rotate air tube in direction
of arrow to remove.
Disconnect wiring harness from hood switch
(C).
Release filter body mounting clamp (D) and remove lower
microfilter housing.
4 Remove side trim panel from left rear of engine compartment
by releasing clips
(arrows).
4 Disconnect bralte fluid level sensor connector (A) from fluid
reservoir. Remove reservoir cap.
. Using a clean syringe, empty bralte fluid reservoir.
Where applicable, disconnect hydraulic clutch system sup-
ply line from fluid reservoir duct
(5). Keep supply line sup-
ported and above clutch master cylinder to prevent air
bubbles from reaching clutch hydraulic system.
Where applicable, disconnect DSC system precharge
pump supply line from fluid reservoir duct
(C). Secure sup-
ply line in vertical position to prevent fluid loss.
Plug open brake fluid lines and ducts to prevent fluid leak-
age or contamination.
- Remove brake fluid reservoir by tilting sideways.

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340-28
Brakes
- Remove sensor mounting screws. Lift sensor away from
bracket.
- Installation is reverse of removal.
CAUTION-
Be sure to tighten the DSC acceleration sensor(s) and
mounting bracket, if applicable, to specified torques. The
sensor
is vibration sensitive and subject to cause DSC
malfunctions if installed improperly.
a After replacing the sensor, perform sensor adjustment
using either DIS or
MoDiC under Service Functions
menu.
Tightening
torques
Lateral acceleration I rotational rate sensor 8 Nm (6 R-ib)
to bracket
Sensor bracket to body
8 Nm (6 ft-lb)
DSC steering angle sensor, removing and
installing
4 Remove lower dash panel mounting fasteners (A) and (5).
- Remove steering column lower trim panel. See 320 Steering
and Wheel Alignment.
Remove steering shaft clamping bolt (arrow).
Disconnect sensor wiring harness connector.

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Fenders, Engine ~ood/
Hood, removing and installing
With hood open:
Remove hood wiring harness mounting clip
(A)
Disconnect electrical harness connector (B).
Unplug windshield washer hose (C).
WARNING-
The hood is heavy Before removing the hoodsupports, be
sure to have an assistant help
support the hood.
Mark position of hinge plates.
With the help of a assistant, support hood and remove retain-
ing clips
(A) on upper end of pressurized lifting struts. Pull
struts off hood.
Loosen upper hinge bolts
(B)
Remove lower hinge bolts (C). Lift hood off carefully.
Installation is reverse of removal.
* Repair any paint damage and paint any exposed metal
Check hood alignment. See
Hood, aligning.
NOTE-
The hood was fitted and attached to an unfinished body at
the factory Unfinished
sun'aces exposed by this procedure
must be touched up with paint,

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WARNING -
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures relating to the
airbag system.
Door trim panel, removing and installing
Disconnect negative (-) battery cable.
CAUTION--
Prior to disconnecting the battem read the batfew discon-
nection cautions given in
001 General Cautions and warn-
ings.
Q Open door, and remove screw (arrow) located
in air
duct.
< Pry out seat memory switch and disconnect wiring harness.

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I
< Unclip door panel from door perimeter using a plastic trim
panel tool. Pry panel retaining clips off one at a time.
- Lift bottom of door trim panel up and away from window trim
to release clips.
- Pull door panel upwards to release center mount clip.
- Disconnect radio speaker wiring harness.
- Remove door trim panel.
< Before installing door trim panel, replace any damaged plas-
tic clips (arrows).
NOTE-
Yellow door trim clips (white arrows) at front are longer than
white door trim clips (blaclc arrows).
4 Checlt if support clip for door bracltet remains on door (ar-
row).
4 If so, remove support clip from door and replace in bracltet on
door trim panel (arrow).
- Remainder of installation is reverse of removal. Note the fol-
lowing:
Align metal retainers on window sill with openings on top
of door panel.
Checlc door-lock mechanism and window for ease of
movement.