Seat BMW 525i 2001 E39 Manual PDF

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400 Body-General
........................ General ........................... .40 0.2 Roof paddin~ 400-7
Body Assembly ................... .40 0.2
Body dimensions (in inches)
............ .40 0.2
Bodyshell
........................... 400-3
Exterior and aerodynamics
............. .40 0.3
Sport Wagon ...................... .40 0.4
Tailgate
............................ .40 0.5
Tailgate lock system
.................. .40 0.5
Rear wiper system ................... .40 0.6
Antenna and sound system ............ .40 0.6
Safety and Security Features ....... .40 0.7
Safety cage
......................... .40 0.7
Door locks and door handles
........... .40 0.7
.
........................... Seat belts 400-7
Airbags ............................ 400-8
Battery safety terminal (BST)
........... 400-9
Security
............................ 400-9
Interior Features ................... 400-9
............................. Seats 400-10
Instruments and controls .............. 400-10
Central body electronics
.............. 400-1 1
Heating and Air
Conditioning (IHKA)
............... 400-12

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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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Body-General
SAFETY AND SECURITY FEATURES
A number of new or improved safety and security features are
incorporated in
E39 cars.
Safety cage
4 The body safety cage is a continuation of an established
BMW concept for passenger protection. Tubular impact
structures built into the body provide protection against pas-
senger injury during front or rear impacts.
Door locks and door handles
4 The door handles allow easy door opening, but are secure in
accidents.
Electrical components in the locks are fully encapsulated and
cannot be picked easily. The door handles, latches and
loclc
assemblies offer reliability and security against theft.
Door position and
loclc condition are detected by hall sensors.
Roof padding
In addition to the side and head protection airbags, there is
supplementary padding at the roof pillars and along the roof
above the doors. This is positioned to present energy absorb-
ing
surlaces to passengers thrown around by side impact
forces.
Seat belts
Each front seat belt assembly has a height-adjustable anchor
at the 8-pillar.
An automatic pyrotechnic (explosive charge) tensioner tight-
ens the front belt at the buckle upon impact, snugging up lap
and shoulder segments of the belt. The tensioners are de-
signed to automatically tension the belts by about
2 inches
(55 mm) in the event ofa collision.
A force limiter puts an upper limit on the amount of iorce each
belt can exert on the passenger.

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400-8
Body-General
Airbags
Front airbags, s~de a~rbags, pyrotechnic seat belt tensioners
and the Battery Safety Terminal (BST) are integrated into the
Supplemental Restraint System (SRS) and its variants.
NOTE-
The BMW SRS system is called Multiple Restra~nt System
(MRS). Over the years,
E39 cars were equipped with MRS,
MRS
11, MRS 111. Each version offers varied features and im-
provements over the previous system.
< As many as 8 airbags may be installed in E39 cars, depend-
ing on model and MRS version.
The front
airbags operate without sodium azide propellant,
widely considered an irritant when an
airbag is deployed.
Starting with
1999 models. "smart"front passenger and driver
airbags were installed. These are of the dual-threshold, dual
stage design, including a
sensorto help prevent the unneces-
sary deployment of the passenger side
airbag if the seat is un-
occupied.
MRS control Depend~ng on options chosen, one airbag may be installed in module each door of the sedan and Sport Wagon models, protecting
passengers against
s~de impacts.
Head Protection System (ITS)
airbags strelch diagonally
across the tops of the front doors.
Airbag deployment automatically triggers fuel shutoff, turns
on the hazard and interior lights, and unlocks the doors.
- -
WARNING -
Airbags are inflated by an explosive device. Handled im-
properly or without adequate safeguards,
airbag units can
be very dangerous. Special precautions must be observed
prior to any worlc at or near any of the airbags. See
721 Air-
bag System (SRS).
Always disconnect the battery and cover the negative
(-) battery terminal with an insulator before starting di-
agnostic, troubleshooting or service work on cars fitted
with SRS, and before doing any welding on the
car.

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400-9
Body-General
Battery safety terminal
(BST)
4 Starting with 1999 models (9198 production and later), a py-
rotechnic (explosive charge) device automatically discon-
nects the battery positive terminal during impacts. Key
features,
like power windows and door locks, remain opera-
tional.
Security
Electronic immobilization (EWS)
Ignition key transponder signal All
E39 vehicles incorporate an electronic immobilization sys-
tem known as EWS. This svstem uses a wireless comrnuni-
cation link between a transponder chip in the ignition key and
the ring antenna surrounding the ignition switch. The EWS
control module blocks the starting of the vehicle unless the
correct coded ignition key is used.
NOTE-
Electronic immobilization is sometimes referred to as the
driveaway protection system.
Antitheft alarm (DWA)
This is adealer-installed option for which the E39 vehicles are
factory-wired. When armed, the system monitors door
loci(
contacts and trunk and engine hood locks and sounds a siren
if it detects tampering.
E39 interiors have a unique character, with a combination
of
sporty features and innovativedesign. All body versions were
made in a wide choice of interior and exterior colors. New col-
ors with matching leather or leatherette upholstery were intro-
duced for each model year.
Driving
comfort is enhanced by power steering, tilt steering
wheel, height-adjustable front seats, and electrically adjust-
able and heated rear-view mirrors. Inside the car there are
reading lights at four seating positions.

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400-1 0
Body-General
Seats
4 Anatomically correct seats are constructed from polyure-
10 way seat adjustment thane foam
containing areas or "zones" of different firmness.
They offer good lateral support without constricting the occu-
pant.
The seats have a passive internal ventilation system: Cylin-
drical cavities within the cushions and backrests generate a
pumping effect as the ride motions cause occupant motion.
This
helps remove moisture and feeds fresh air into the seats.
Other features of the seating system:
The seat bases have steel springs for added support and
strength.
The seat control switches are along the outside edge of
the
seat.
Heated seats are an option in all models
In cars equipped with seat position memory, three different
seat confiaurations can be memorized by the seat control
module(s): Seat memory coordinates with outside mirror
memory. These functions are controlled by the seat mem-
ory
module(s).
* For security reasons, the release lever to fold the rear seat
backrest forward is installed in the trunk.
Sport Wagon models: Rear seat
baclts are split 60140, with
the center armrest on the left seat back.
The center armrest incorporates a non adjustable head-
rest. When folded down, the armrest opens out with
cup-
holders and a storage compartment. See 520 Seats for
more details.
instruments and controls
Everything in the interior passengercompartment essential to
the driver is logically grouped and easy to reach. All instru-
ments and controls have been arranged ergonomically and
are fully integrated into the overall design of the vehicle.
Tilt-telescopic steering wheel has
30 mm (1.2 in) of vertical
and longitudinal adjustment.
Multifunction steering wheel contains two
ltey pads con-
taining controls for the sound system, telephone and
cruise control.
Padded dashboard houses the instrument cluster and the
ventilation and heating system.

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Instrument cluster
Instrument cluster uses large easy-to-read analog instru-
ments and is removable as a unit without removing the dash-
board. On-board computer and Check Control functions are
integrated into the instrument cluster displays.
Service Interval Display
Service Interval Display calculates vehicle service needs
based on current driving patterns, and indicates to the driver
when the car requires
service
On-board navigation
An integrated on-board navigation system, based on Global
Positioning System (GPS) technology, is optionally available
on
E39 cars. When installed, a multifunction monitor is includ-
ed in the center of the dash above the radio. in addition to dis-
playing navigation system information, this monitor accesses
On-Board Computerfunctions, audiosystem controls, mobile
phone dialling and memory, and automatic ventilation.
Park Distance Control (PDC)
Park Distance Control (PDC) is an optional system which
uses ultrasonic sensors in the rear bumper trim to warn the
driver of approaching too close to obstacles when parlting.
Central body electronics
E39 vehicles are equipped with an integrated complex of
electronic modules connected mostly via K-Bus. This system,
called central body electronics (ZKE
Ill), is primarily con-
trolled by the general module (GM
Ill). An overview of ZKE Ill
functions is found in 600 Electrical System-General. Details
of ZKE
Ill functioning is in the following repair groups:
- 512 Door Windows
* 515 Central Locking and Aniti-Theft
520 Seats
a 540 Sunroof
611 Wipers and Washers
620 Instruments

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Fenders, Ensine HOO~I
Hood release cable and spring pins,
adjusting
Before adjusting hood pins, be sure the hood is aligned even-
ly to fenders and front panel.
- Malte sure bowden cable, which connects both hood loclts
together, is seated in lock guide on both left and right loclts.
4 Loosen hood spring pin bolts (A) and retaining hoolt bolts (B)
at hood on left and right sides only enough to allow move-
ment.
- Lower (but do not fully latch) hood several times so pins on
hood center themselves in lower loclts.
NOTE-
Do not let hood lock with latch bolts loose
- Tighten hood spring pin bolts and latch bolts when alignment
is correct.
- Remove one bolt at a time from each side, clean and coat
with
LoctiteB 270 or equivalent, and reinstall. Repeat pro-
cess on all other bolts.
- Adjust rubber stop buffers above headlight assemblies. See
Hood, aligning.
- Test hood for correct closure and opening. If hood does not
spring open, lengthen spring pins.
- To lengthen spring pin, loosen locltnut (arrow) with wrench
inserted through spring, then turn pin counterclocltwise.

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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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51 2-8
Door Windows
Door window, adjusting
Whenever the door window or window regulator is removed,
window adjustment should be checked. The glass should
contact the top of the window squarely and should seat
against the window seal uniformly.
NOTE-
If the window does not contact the window seal uniformly,
wind noise or water infiltration may result.
- Remove door panel as described in 411 Doors.
- Disconnect negative (-) cable from battery. Remove airbag
unit and vapor barrier from door. See 721 Airbag System
(SRS).
WARNING-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in
001 General Warnings and
Cautions.
Longitudinal adjustment
- Adjustments are made with window in open position.
Loosen window guide rail mounting nuts (arrows), but do not
remove.
Slide window glass in longitudinal direction to adjust
Tighten guide rail nuts.
Tightening torque
Window regulator guide rail to door
10 Nrn (89 in-ib)