BMW 525i 2001 E39 Workshop Manual

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Seat Belts
NOTE-
The rear bench seat belt strap may not retract fully due to in-
creased friction between strap and seat cover.
A small re-
maining loop in belt strap when fully retracted is acceptable.
WARNING-
* For maximum protection from injury, seat bells should be
replaced as a set (including all hardware), if they are sub-
ject to occupant loading in a collision.
Seat belts should not be modified or repaired. The seat
belt mounting points should not be changed or modi-
fied.
Do not bleach or dye seat belt webbing. Webbing that
is severely faded or
redyed will not meet the strength
requirements of a collision and must be replaced.
Clean belts with a luke-warm soap solution only:
Seat belts should be periodically inspected for webbing
defects such as cuts or pulled threads.
* Immediately after replacing a damaged or worn seat
belt, destroy the old belt to prevent it from being used
again.

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- -
Seat Belts
Front seat belt tensioner, removing and
installing
- Disconnect battery negative (-) cable in trunk.
The
front seat belt loclts are equipped with pyrotechnic (ex-
plosive charge) automatic tensioners. These tensioners are
designed to automatically retract and tension the seat belt by
55 mm (approximately 2 inches) in the event of an accident.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Warnings and Cau-
tions.
WARNING-
Pyrotechnic seat belt tensioners are powerful devices and
should be handled with extreme care. Incorrect handling
can trigger the tensioner and cause injury
BMW recommends that all repair or replacement work
on pyrotechnic devices must be carried out by a quali-
fied BMW technician.
Be sure to disconnect the battery and wait
5 seconds
before attempting to work on pyrotechnic devices.
Pyrotechnic devices cannot be repaired. Always re-
place them.
Never treat pyrotechnic components with cleaning
agents or grease.
- Do not expose pyrotechnic components to tempera-
tures above
75% (167°F).
Pyrotechnic components can only be tested electrically
when installedusing the
BMWService Tester (DISplus,
GTI, or MoDiC).
Do not fire a pyrotechnic gas generatorprior to dispos-
al. It must be fired by a special disposal company or
shipped
back to BMW in the packaging of the new com-
ponent.
During body straightening and welding with an electric
arc welder, always disconnect the battery and the con-
nection to the pyrotechnic gas generators.
- Remove front seat as described in 520 Seats.
-

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Seat ~eltsl
< Remove tensioner cover:
Cut wire ties (A).
Release wiring harness from tensioner cover clip (B).
- Release tensioner cover locks (C) and slide cover down to
remove.
- When reinstalling:
Replace wire ties to relieve tension on pyrotechnic belt
ten-
sioner harness connector.
Tightening torques . -
Front seat to floor (M10) 42 Nm (31 it-lb)
Seat belt to seat 48 Nm (35 It-lb)
Tensioner mounting bracitet
to seat rail 24 Nm (18 it-lb)
Tensioner to mounting bracket 48 Nm (35 it-lb)

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I Seat Belts
a
Front seat belt assembly
1. Seat belt buckle
2. Seat belt stop button
3. Seat belt
4. Seat belt height adjuster
5.
6-pillar cross brace
6. Seat belt reel mounting bolt
7. Seat belt anchor mounting bolt
8. Seat belt lock with pyrotechnic
tensioner
9. Tensioner mounting bolt
Front seat belt reel, removing and installing
(sedan and Sport Wagon models)
- Detach battery negative (-) cable in trunk.
~~-~
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Warnings and Cau-
l tions. I
- Remove front seat as described in 520 Seats
4 Gently pry up front and rear plastic door sill protector strips
to remove.

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Seat Belts
Remove lower B-pillar (door pillar) plastic trim
Pry carefully along bottom of trim to disengage
pillar.
Slide trim down (arrow) and out to remove. clips
from
4 Carefully pry bottom of upper door post trim away from post
to release clips.
Slide upper trim panel down (arrow) to remove.
Remove automatic reel from B-pillar:
- Remove upper seat belt anchor bolt (A).
Remove cross-brace mounting bolts (B).
Remove sound insulation at base of 8-pillar.
Then remove automatic seat belt reel mounting bolt
(C).
Lift out reel.
If it is necessary to remove sliding seat belt height adjuster,
unscrew mounting bolts from B-pillar.

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720-8
I Seat Belts
When Installing automatic reel housing to 5-pillar, slide tab
into locating slot (arrow).
Remainder of installation is reverse of removal
Tightening torques
- -.
Front seat to floor (M10) 42 Nm (31 ft-lb)
Seat belt to seat 48 Nm (35 ft-lb)
Seat belt to height adjuster 31 Nm
(23 it-lb)
Seat belt reel to €3-pillar bottom 31 Nm (23 ft-lb)
Sliding height adjuster to €3-pillar
24 Nm (18 ft-lb)
Rear seat belt assembly
(sedan)
1. Center shoulder belt reel
assembly
(if equipped)
2. Right shoulder belt lock
3. Lap-belt assembly
4. Left shoulder belt lock
5. Bolt MlO
(tighten to 31 Nm, 23 ft-lb)
6. Left shoulder belt reel assembly
7. Center shoulder belt lock
(if equipped)
8. Bolt M12
(tighten to 48 Nm, 35 ft-lb)

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-- -
Seat Belts
Rear seat belts (sedan)
- Remove rear parcel shelf to access shoulder belt assembly
mounting bolts. See 513 Interior Trim.
- Remove rear seat cushion to access rear seat belt lock
mounting bolts. See 520 Seats.
- When installing seat belt lock straps:
Install right lock strap (which is shorter) underneath middle
lock strap.
Install left lock strap underneath middle lap belt strap.
Metal strap ends must rest against stop on floor under-
neath seat.
Rear seat belt assembly
(Sport Wagon)
1. BoltMlO
(tighten to 31 Nm, 23 ft-lb)
2. Right shoulder belt reel
assembly
3. Center belt lock
4. Right belt lock
5. Left belt lock
6. Center shoulder belt reel
assembly
7. Left shoulder belt reel assembly
8. Bolt
MI2
(tighten to 48 Nm, 35 ft-lb)

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720-1 0
Seat Belts
Rear seat belts (Sport Wagon)
- Center shoulder belt:
Remove shoulder belt guide trim at top of seat backrest.
Feed belt out through slot in trim. Working in cargo com-
partment, partially remove backrest cover to access shoul-
der belt reel.
Remove shoulder belt reel mounting bolt inside backrest.
- Outboard shoulder belt:
Remove roof-pillar (C-pillar) trim.
Remove center shoulder belt.
- Lift up rear seat cushion(s) to access rear seat belt loclc
mounting
bolt(s).
- When installing seat belt loclc straps:
Install right belt loclc strap (which is shorter) underneath
center belt lock strap.
Install left belt loclc strap underneath center lap belt strap.
- Metal strap ends must rest against stop on floor underneath
seat.

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721 Airbag System (SRS)
........................... General ............................ 721-2 Airbags 721-8
..... E39Airbags ......................... 721-3 Driver airbag. removing and installing 721-8
Two-stage airbag (MRS 111) ............ .72 1.4 Passenger airbag. removing and installing . 721-9
Airbag indicator light .................. .72 1.4 Door mounted side-impact airbag.
............... Warninas .......................... .72 1.5 removina and installina 721-10 .
..... Head protection airbag components 721
-1 1 Airbag Electronics ................. '721-6 Head protection airbag (HpS) .......... 721-12 MRS ............................... 721-6
MRS
airbag system diagram ........... .72 1.6
MRS control module. replacing ......... .72 1.7
Side-impact crash sensor.
removing and installing
................ .72 1.7

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721 -2
l~irba~ System (SRS)
This repair group covers airbag components and replace-
ment.
Airbag system repairand fault diagnosis is not covered.
Diagnostics, component testing, and
airbag system repair
should be carried out by trained BMW service technicians.
Individual
airbag system components can only be tested elec-
tronically when installed in the car. BMW service testers
DIS
or MoDiC or equivalent must be used for diagnostic work.
WARNING-
Special test equipment is required to retrieve airbag fault
codes, diagnose system faults, and
reseffturn off the air-
bag indicator light. The indicator light will remain on until
any problem has been corrected and the fault memory has
been cleared.
Airbags are part of the BMW Multiple Restraint System
(MRS). Three versions of MRS are available in E39 models.
Multiple Restraint Systems
MRS and MRS II include the following restraint components:
311 996-811 997
911
997-311 999
311 999-2002
Driver and passenger front
airbags (MRSIMRS II)
MRS
MRS
II
MRS Ill
Passenger front two-stage airbag (cars manufactured
from
911998).
The seat occupancy sensor (SBE) is used for detection of
a passenger in the right front seat. MRS uses the SBE in-
put to determine seat belt tensioner
and/or front airbag de-
ployment thresholds.
Side impact
airbag for driver and front passenger
(MRSIMRS II)
Leftlright side impact crash sensors (MRSIMRS 11)
Side impact airbag for rear passenger (MRS II) (optional)
Head Protection System (HPS) for driver and front passen-
ger (MRS
II)
Battery Safety Terminal - BST (MRS II)
Hall Sensor seat belt switches (MRS II)
Front pyrotechnic seat belt tensioners
Fuel pump cut off message