air suspension BMW 525i 2001 E39 Repair Manual
[x] Cancel search | Manufacturer: BMW, Model Year: 2001, Model line: 525i, Model: BMW 525i 2001 E39Pages: 1002
Page 767 of 1002
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Brakes
Troubleshooting
Brake performance is mainly affected by three things:
Q Level and condition of brake fluid
Ability of bralte system to create and maintain pressure
Condition of friction components
Air in bralte fluid will
make the brake pedal feel spongy during
braking
orwill increase the bralte pedal force required to stop.
Fluid contaminated by moisture or dirt can corrode the sys-
tem. lnspect the brake fluid inside the reservoir. If it is dirty or
murky, or is more then two years old, replace fluid.
To
check the function of the master cylinder hold the bralte
pedal down hard with the engine running. If the pedal slowly
falls to the floor, either the master cylinder is leaking internal-
ly, or fluid is leaking externally.
lnspect the rotors for glazing, discoloration and scoring.
Steering wheel vibration while braking at speed is often
caused by warped rotors, but can also be caused by worn
suspension components.
When troubleshooting, keep in mind that tire inflation, wear
and temperature can all have an affect on braking. See
300
Suspension, Steering and Brakes-General for additional
suspension and brake system troubleshooting.
The table Brake system troubleshooting lists symptoms of
brake problems, probable causes, and suggested corrective
actions. Unless noted otherwise, relevant repairs are de-
scribed later in this repair group.
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340-6
1 Brakes
Brake system troubleshooting
/symptom I Probable cause 1 Repairs
Brake squeal
Pedal goes to floor when
bralting
Low pedal after system bleeding
Pedal spongy or brakes work
only when pedal is pumped
Excessive braking effort
Brakes pulsate, chatter or grab
Uneven
bralting, car pulls to one
side, rear braltes
loclt
Brakes drag, bind or overheat Brake
pad carriers dirty or corroded or
pads loose (poor fit) in pad carrier
Braite pads heat-glazed or oil-soaked
Wheel bearings worn (noise most
pronounced when turning)
Incorrectly Installed brake pads,
parking bralte shoes, or bralte parts
Brake fluid loss due to system leaks
Master cylinder or traction control
system faulty
Master cylinder faulty
Air in braite fluid
Master cylinder or traction control
system faulty
Brake pads wet
Brake pads
heat-glazedorfluid-soalted
Vacuum booster or vacuum hose
connections to booster faulty
--- Warped brake rotors
Brake pads worn
Brake pads heat-glazed or oil-soaked Remove
brake pads and clean calipers. Use original
equipment pads for proper fit and use BMW anti-squeal
compound during installation,
Replace brake pads. Ciean rotors. Replace leaking caliper:
as required.
Replace worn bearings. See 310 Front Suspension
or33C
Rear Suspension.
Check component installation. Checldreplace anti-rattle
springs.
Checlt fluid level and inspect for signs of leakage.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Replace master cylinder.
Bleed system using factory or compatible diagnostic tool.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Use light pedal pressure to dry pads while driving.
Replace
bralte pads and rotors. Replace leaking calipers.
lnspect vacuum lines. Test vacuum booster and replace as
required. Test vacuum non-return valve for one-way flow.
Resurface or replace rotors.
Replace brake pads.
Clean rotors. Replace leaiting calipers.
Incorrect tire pressures or worn tires
Brake pads on one side of car heat-
glazed or fluid-soaked
Caliper or brake pads binding
Worn suspension components
Brake caliper or brake pads binding
Master cylinder or traction control
system faulty lnspect
tire condition. Checlt and correct tire pressures.
Replace brake pads. Clean rotors. Replace leaking
calipers.
Clean and recondition brakes.
Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Ciean or replace caliper.
Replace master cylinder. Diagnose traction control system
using faclory or compatible diagnostic tool.
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340-1 2
Brakes Brake pads, checking and replacing
Brake pads can be replaced without disconnecting the brake
fluid hose from the caliper or having to bleed the brakes. The
rotors can be replaced without disassembling wheel hub and
bearing. Always machine or replace rotors in pairs. Replace
pads in sets.
Front and rear brake pad replacement procedures are identical.
WARNING -
* Altllough semi-metallic andmetallic brale friction materials
in brake pads or shoes no longer contain asbestos, they
produce dangerous dust.
Treat all
brale dust as a hazardous material.
Do not create dust by grinding, sanding, or cleaning
brake friction surfaces with compressed air.
CAUTION--
Pressing caliper piston in may cause brake fluid reservoir to
overflow To prevent this, use a clean syringe to first remove
some fluid
from reservoir.
Raise car and remove wheels,
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
/ 4 To measure brake pad lining thickness, insert BMW special
n 1 tool 34 1 260 at either frontilght wheel or left rear wheel -
Move wheel until notch for brake wear indicator can be
seen through wheel opening.
Insert tip of tool into notch so that the body of tool rests on
brake pad backing plate
(A), and tip touches bralte disc
(B).
Replace pads if thickness is 3.0 mm (0.12 in) or less.
Pry off
bralte calipe~ , anti-rattle spring (arrow).
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Body shell
Exterior and aerodynamics
Crash behavlor -frontal impact
-side impact
Body
-rear impact Structural body components -rigidity
-rollover -strength -vibrations -acoustics
Bumpers compartment lid -bendable Seets,.steerlng system .dents -vibrations bars -vibration patterns
Fenders -aerodvnamic
With its traditional styling features, such as the ltidney grille.
circular headlights behind a glass cover (for reasons of
streamlining), and the
"kiclt" in the rear most roof pillar (C-pil-
lar), the E39 can be immediately recognized as a BMW.
The BMW 5 Series chassis is a unibody design constructed of
high strength steel. Attaching parts, such as the front fenders,
rear quarter panels, doors,
trunk lid and hood are also con-
structed of
steel.
Computer aided design (CAD) techniques have been used in
refining the
E39 body to reduce vehicle weight while retaining
strength and increasing torsional rigidity. For good handling
purposes, the more rigid the structure the more precisely the
suspension can operate.
Wind resistance
Windows bonded flush to the body and the guided flow of
cooling air into the engine compartment provide the
carwith a
good coefficient of drag (Cd).
E39 cars have been designed
for balanced aerodynamics but not necessarily an extremely
low Cd. See table below.
Windshield wipers are designed for effectiveness at speeds
up to and beyond 200
ltph (124 mph).
Coefficient of aerodynamic drag (Cd)
6-cylinder sedan 0.30
V-8 sedan 0.31
6-cylinder Sport Wagon 0.31
V-8 Sport Wagon 0.33
Fenders
The exterior panels are corrosion-resistant zinc coated (gal-
vanized) steel. The front fenders are bolted on. For front fend-
er replacement information, see
410 Fenders, Engine
Hood.
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400-4
I Bodv-General
Bumpers
The front and rear bumpers are clad in high quality
deform-
able plastic and, at solid barrier impact speeds of 4 kph (2.5
mph), provide protection with virtually no damage to the
bumper
orthe vehicle. In addition to hydraulic dampeners.
which absorb the initial impact energy, these bumpers are
backed by compressible tubes. These deform in a controlled
manner at impact speeds greaterthan that
forwhich bumpers
and hydraulic dampeners are designed. This helps avoid ex-
pensive damage to the body at impact speeds up to 14 kph (9
mph).
The E39 Sport Wagon was introduced to the US market in
911 998 (model year 1999). It shares many components with
the E39 sedan and is identical to it from the B-pillar forward.
US
marltet 5 Series Sport Wagons are available in two vari-
ants:
6-cylinder
(5251, 528i) powered by the 2.8 liter M52 TU en-
gine (1 999) or the 2.5 liter M54 engine (2000 and later)
* V-8 (540i) powered by the 4.4 liter M62 TU engine
The wheelbase of the Sport Wagon is the same as the sedan.
Howeverthe body is 30
mm (1.2 in) longer and 10 mm (0.4 in)
higher.
The Sport Wagon rear suspension was redesigned to elimi-
nates the upper rear spring strut mounting on the E39 sedan.
The use of separate coil springs and
shoclc absorbers results
in a flat, wide floor in the cargo area. See
300 Suspension,
Steering and Brakes-General.
The self-leveling air spring suspension system (electronic
height control or EHC) is standard on Sport Wagon V-8 mod-
els and optional on 6-cylinder models.
Sport Wagon cargo capacities are shown below.
Sport Wagon load capacities
Cargo capacity
Rear seat up 909 liters (32.1 cu ft)
Rear seat folded down I809 liters (63.9 cu ft)
Load limit
Cargo compartment
460 Kg (1014 lb)
Roof
I00 Kg (220 lb)
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[Fenders, Engine Hood
This repair group covers replacement of the front fenders and
removal and installation of the engine hood.
NOJE-
The body is painted at the factory affer assembly Realign-
ment of body panels may expose unpainted metal. Paint all
exposed metal once the work is complete.
Special tools
Most body repairs can be performed using regular automotive
service tools. Some BMW special tools are required to set
body pieces into the
service positions.
Front fender, removing and installing
- Raise front of vehicle and remove wheel
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose.
Placejaclr stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
- Raise hood to service position. See Hood, raising to ser-
vice position.
4 Working beneath vehicle, remove fasteners (arrows) from
left side floor panel and remove panel.
- Remove inner plastic liner from wheel housing.
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INDEX 'tl
WARNING
Your common sense, good
judgemenl, and general alertness are
crucial to sale and successiul service
worlr. Belore attempting any work on
your
BMM be sure lo read 001
General Warnings and Cautions
and the
copyriglll page at the front 01
the manual. Review these warnings
and
caulions each lime you prepare
lo work on your BMW. Please also
read any warnings and cautions that
accompany
tile procedures in the
manual.
312-way valve (running losses)
see Fuel tank
Abbreviations, commonly used 600-14
ABS (antilock brake system)
see
Bral(es
A/C air distribution motors
see stepper motors (below)
blower final stage (resistor pack),
replacing
640-16
blower, removinglinslalling
640-1 5
compressor, replacing
640-24 condenser, replacing 64045
control panellmodule, removing1
installing
640-1 1
evaporakr, removinglinstalling 640-29
evaporator temperature sensor
640-12 expansion valve, removinglinstailing
640-27
IHKA/ IHKR system description 640-5
receiveridrier, replacing 640-26
stepper motors 640-1 3 ventilation microiilter, replacing
020-22. 640-17
see also Heating
Accelerator
iinlcage
see Maintenance
Activated carbon canister
see Fuel tank
ADS (auxiliary throttle valve)
130-57
Air compressor
330-44
Air conditioning
see
AIC
Air distribution (flap) motors
seeNC, stepper motors
Air filter see Maintenance
Air spring
300-6, 330-12
Airbag system (SRS)
2-stage
airbag 721-4
control module, replacing 721-7 driver airbag, removinglinstalling
721-8
iiead protection airbag 721-12 components 721-1 1
indicator
lighl721-4
passenger airbag, removinglinstalling
721-9 side-impact airbags crash sensor,
replacing
721-7
Airflow sensor see 130 under appropriate
fuel
injection system
Air pump
see 130 under appropriate fuel
injection system, secondary air
injection system
Air suspension
see Electronic height control
(EHC)
Alarm
see Anti-theft alarm
Alignment see
Wheei alignment
Aluminum suspension components
300-2
Antenna 650-6
Alternator see Battery, starter, alte rnator
Amplifier
650-4
Anti-theft alarm (DWA)
515-24 emergency disarming 515-31
Antifreeze (engine coolant)
see Maintenance
see also Cooling system
Antilock brake system (ABS) see Brakes
ASC see Brakes
ATF (automatic transmission fluid)
see Automatic transmission
see also Cooling systern
Automatic headlight adjustmenl
(LWR) see Lights
Automatic seat belt tensioner
720-4
Automatic shiftloclc
see
Gearshift
Automatic transmission
applications
200-3, 240-4
ATF 020-10, 200-4
capacity 240-8 checking 240-6
drainingifilling 240-7
heat exchanger 170-5
fluid pan and strainer 240-9 gearshift
see Gearshift
ID tag
200-3 range switch 610-6
removaliinstallation 240-10
steptronic see Gearshift
Auxiliary cooling fan
see
Coollng system, electric Ian
Auxiliary throttle valve (ADS)
130-57
Axle joint
see Drive axle
Back-up light switch
automatic transmission see Automatic transmission. range switch
- .~.~~~
manual transmission 230-8 -
- I
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2 INDEX
Battery, starter, alternator
alternator (generator)
121-10
6-cylinder engine, removingi
installing 121-15
M62 engine 121-16
M62 TU engine (water cooled)
121-18
battery
121-5 charging 121-9
safety terminal 121-3
testing 121-5 charging system, troubleshooting
121-12
starter
121-1 9
6-cylinder engine, removingi instaliinq 121-20 . V-8 engine, rernovinglinsialiing
121-21
solenoid, removinglinstalling
121-23 troubleshooting 121-19
see also Maintenance
Bearing, wheel
see Front suspension
see also Rear suspension
Belts see Maintenance, drive belts
Blade, wiper
see Wipers and Washers
Blower motor see
A/C
BMW emblem
see Exterior trim
BMW special tools 010-18 see also special tools section at
beginning
of each repair group
Body dimensions 400-2
interior features
400-9 salety and security 400-7
Body side molding
see Exterior trim
Bonnet see Engine hood
Boot see Trunk
Brake fluid
020-24, 340-8
Brake fluid pressure sensor
340-30
Brakes
ABS, ASC or DSC system
300-12
component replacement 340-26
ASCIDSC switch
see Switches
bleeding
bralces 340-8
brake booster 340-1 9 bralce Dads. caiioers and rotors ,., 340-1 1
descriotion 300-10
e~ectrdnic brake & stability 300-11
light switch
see Switches
master cylinder
340-16 pariking brake 340-22
troubleshooting 340-5
Bulbs see Lights
Bumper
lront 510-6 height, adjusting 510-12
rear 510-9
Bus system
600-4
Camber
320-33
Camshaft
removingiinslaiiing
M52 engine 116-12
M52 TU
/ M54 engine 116-1 9 M62 engine 11 6-39
wear
116-6
Camshaft position sensors
see ignition system
Camshaft timing chain
adjusting M52 engine
117-22
M52 TU I M54 engine 117-43
M62 engine 117-79 removinglinstalling
M52 engine 117-26
M52TU 1 M54 engine 113-46.116-
28
M62 engine 117-66
Capacities, fluid
020.10
Car rnemorvlicev memorv . . 600-10
see also Centrai
lociking
Carbon canister, activated
see Fuel
tank
Caster
320-33
Catalytic converter and oxygen sensor 020-19
see also Exhaust system: exhaust
manilolds
Cautions
001-3
CD changer
650-4
Center bearing, driveshaft
see Driveshait
Center brake light
sedan
630-13
Center console
513-3
Centrai body electronics (ZKE 111)
600-6
Central locking
car memoryiey memory 515.12 general module iunctions 515-2
remote entry (FZV) 515-8
remote lkey initialization 515-10 single lociddouble ioclk 515-6
switch 515-4
Chain
see Camshaft liming chain
Characteristic map (electrically heated) thermostat
see Electrically heated thermostat
Charging system
see Battery, starter, alternator
Cluster see instruments
Clutch fluid see Maintenance
hydraulics
210-4
mechanical 210-9
switch
see Switches, pedal ciuster
variations
210.10
Codes, fault OED-1
Coil
see Ignition system
Coil spring
see Front suspension
see also Rear
suspe nsion
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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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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