410 BMW 525i 2001 E39 Workshop Manual

Downloaded from www.Manualslib.com manuals search engine
YOU are now in Volume I
I
Foreword ................... .. ........................................................................\
.......... v
Index
........................ .. ................................................................ rear of manual
General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder
Maintenance OiO 020 Maintenance
Engine
100 Engine-General 110 Engine Removal and Installation
113 Cylinder Head Removal and
Installation
116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain
119 Lubrication System
200 Transmission-General
2 Transmission 210 clutch 230 ManualTransmission
I20 Ignition System
121 Battery, Starter, Alternator
130 Fuel Injection
160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System
180 Exhaust System
240 Automatic Transmission
250 Gearshift Linkage 260 Driveshaft
Suspension, 300 Suspension, Steering and 330 Rear Suspension
Brakes-General 331 Final Drive
Steering and No Front Suspension 340 Brakes
320 Steering and Wheel Alignment
400 Body-General
410 Fenders, Engine Hood 411 Doors
412 Trunk Lid, Tailgate
510 Exterior Trim, Bumpers 512 Door Windows
Equipment 513 Interior Trim
7
Equipment and 720 seat Belts
Accessories 721 Airbag System (SRS)
OBD On-Board Diagnostics
. ............ ..
515 Central Lociting and
Anti-Theft
520 Seats 540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rear of manual
Electrical
6 system
600 Electrical System-General 620 Instruments
610 Electrical Comoonent Locations 630 Liohts
611 wipers and washers 612 Switches eati in^ and Air Conditioning
Radio
. ........... ........ .........................
Electrical Wiring Diagrams

Downloaded from www.Manualslib.com manuals search engine
I Engine Removal and Installation
Engine removal and installation are covered in this repail
group.
See 100 Engine-General for engine identification details
and engine codes.
Transmission removal is required for all models before the
engine can be removed. This is best accomplished with the
car raised on an automotive lift. For additional procedures re-
quired during engine removal, refer to the following repair
groups:
020 Maintenance
0 121 Battery, Alternator, Starter
170 Radiator and Cooling System
180 Exhaust System
4 230 Manual Transmission
0 240 Automatic Transmission
410 Fenders, Engine Hood
Special tools
Some special tools are required for engine removal and in-
stallation. Be sure to have the necessary equipment on hand
before starting the job.
Engine lifting tool
(Tool No. BMW
11 0 000)
4 Cooling fan counterhold tool
(Tool No. BMW
11 5 030)
< Cool~ng fan wrench
(Tool No. BMW
11 5 040)

Downloaded from www.Manualslib.com manuals search engine
11 0-4
/Engine Removal and Installation
- Disconnect negative (-) cable from battery.
CAUTION- Prior to disconnecting the
batteg read the battery discon-
nection cautions
in 001 General Cautions and Warnings.
- Remove engine hood, or place in service position. See 410
Fenders, Engine Hood.
4 Remove left and right interior ventilation ducts (lefl side
shown):
Release ventilation filter cover latch (A) and remove cover.
Release plastic loclting tab
(6) or release locking tabs on
top of duct (later models).
Rotate duct counterclocltwise to
unloclt from bulkhead and
remove (arrow).
Disconnect electrical harness from hood switch (C).
Release spring
loclt (D).
Slide filter housing away from inner fender to remove.
Removal of right side ventilation duct is similar.
Remove rear bulkhead panel:
Remove rubber sealing gasket (arrow).
- Remove 3 mounting clips (A).
Remove
4 retaining screws (6).
Lift off panel.
Remove complete air filter housing:
Loosen
intalte duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control line from intalte duct
(6) and (where applicable) disconnect idle speed control
valve electrical harness connector.
Disconnect harness connector (C) from mass air flow sen-
sor.
Remove air filter housing mounting screw (D).
Disconnect vent tube
(E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.

Downloaded from www.Manualslib.com manuals search engine
110-16
Engine Removal and Installation
ENGINE, REMOVAL AND
INSTALLATION (V-8 MODELS)
NOTE-
Engine removal procedures are similar for all V-8 models.
When differences exist, they are noted at the beginning of
each step. Engine are referred to by engine code. If neces-
sary, See
100 Engine-General for engine code andappli-
cation information.
Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse gaskets, O-rings or seals during reassembly
WARNING
-
Due to risk ofpersonal injury, be sure the engine is cold be-
fore beginning the
removal procedure.
- Disconnect negative (-) cable from battery.
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove engine hood or place hood in service position. See
410 Fenders, Engine Hood.
Remove
intake manifold cover, version 1:
Remove plastic trim caps (arrows).
Remove cover mounting fasteners and
lift off cover.
Remove intake manifold cover, version
2:
Press down on locking pins (arrows) to release locks
Lifl cover straight
up to remove.

Downloaded from www.Manualslib.com manuals search engine
1 17-3
Camshaft Timing Chain
4 Crankshaft seal installation bushing, V-8
(Tool No. BMW 11 1 220)
4 Upper timing cover Installation tool, V-8
(Tool No. BMW 11
1 41 11412)
4 Crankshaft hub locking tools (6-cylinder engine with 2 piece
vibration dampener) (Tool No. BMW
11 2 150 11 1 2 410)
4 Cranltshaft loclting tool
(Tool No. BMW
11 2 300)
I I 4 Seal extractor tool set
(Tool No. BMW 11 2 380)

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing Chain
4 Crankshaft hub loclting tool. M54 engine
(Tool No.
BMW 11 8 190 11 1 8 200)
4 VANOS test lead, M52 6-cylinder
(Tool No.
BMW 12 6 410)
Crankshaft oil seal, front,
replacing
(M52 engine)
The crankshaft front seal is located in the lower timing cover,
behind the vibration damper.
- Disconnect negative (-) cable from battery.
CAUTIOIG
a Disconnecting the battery may erase fault code(s) stored in
control module memory Check
for fault codes using spe-
cial
BMW diagnostic equipment.
Prior to disconnecting the battery, read
the battery dis-
connection cautions given in
001 General Cautions
and
Warninqs.
- Remove splash guard from beneath engine.
- Remove engine cooling fan assembly. See 170 Radiator
and Cooling System.
NOTE-
Cooling ian nut (32 mm wrench) has left-hand threads.
- Remove drive belts. See 020 Maintenance.
,~R,~",,,~"P,,,,!,.,,,.,"?,,m-A,, P,",,,s

Downloaded from www.Manualslib.com manuals search engine
Camshaff Timing Chain
NOTE-
Mark direction of belt rotation if reusing belt.
- Remove vibration damper mounting bolts and remove vibra-
tion damper and pulley from hub.
NOTE- The M52
6-cylinder engine uses a 2-piece vibration damper
and hub assembly.
4 Install crankshaft holder (BMW special tools 11 2 150
and11 2410).
NOTE
-
Be careful while aligning locator pin hole in special tool 11 2
410 with vibration damper locatorpin.
- While counterholding crankshaft, loosen and remove crank-
shaft center bolt.
CAUTION-
Do not use flywheel locking tool to hold crankshaft stationary
to loosen or tighten crankshaft hub center bolt Use only the
special tools specified, or equivalent hub holding tool.
NOTE- The cranlshaft hub center bolt is torqued to 4
10 Nm
(300
ft-16).
- Remove damper hub and special tools.
4 Install cap (BMW special tool 11 2 383) on end of cranltshaft.
4 Install seal guide (BMW special tool 11 2 385) over end of
crankshaft. Be sure to align tool with keyway on crankshaft
(arrow).

Downloaded from www.Manualslib.com manuals search engine
1 17-8
Camshaft Timing Chain
4 Install oil seal puller (BMW special tool 11 2 380) and screw
in body of puller until it contacts seal. Tighten center screw to
draw seal out of cover.
4 Coat new seal with oil and position in timing chain cover. Use
BMW special tool
11 3 280 and crankshaft center bolt to draw
seal in flush with timing case cover.
4 Align hub with keyway and tap into place. Insert new center
bolt with washer shoulder
(arrow) facing hub.
CAUTION-
Inspect woodruffl - Reinstall cranltshaft holder tool.
NOTE-
Be careful while aligning locator pin hole in special tool 1 I 2
410 with vibration damper locator pin.
- While counterholding cranltshaft, tighten crankshaft center
bolt.
Tightening torque Vibration damoer hub
to crankshaft 410 Nm (302 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
117-10
/Camshaft Timing Chain
NOTE-
The crankshaft hub center bolt is torqued to 410 Nm
(300 ft-lb).
- Install crankshaft damper puller (BMW special tool 11 8 21 0)
to
11 8 200. Use bolt to remove damper from crankshaft.
- Oil seal replacement:
4 Install cap (BMW special tool 11 2 383) on end of crankshaft.
Install seal guide (BMW special tool
11 2 385) over end of
crankshaft. Be sure to align groove with
lteyway on crank-
shaft (arrow).
4 Install oil seal puller (BMW special tool 11 2 380) and screw
in body of puller until it contacts seal. Tighten screw in center
of tool to draw seal out of cover.

Downloaded from www.Manualslib.com manuals search engine
Camshaft Timing chain]
4 Coat new seal with oil and position in timing chain cover. Use
BMW special tool 11
3 280 and crankshaft center bolt to draw
seal in flush with timing case cover.
- Align vibration damper assembly with keyway and tap into
place. Insert new center bolt with washer.
CA
UTIOG
Inspect woodruff key for damage before installing hub
assembly.
- Install crankshaft holding tool malting sure tool locks into
place in openings in damper assembly. While counterholding
cranltshaft, tighten crankshaft center bolt.
- Attach special tools 11 8 20011 1 8 190 to damper assembly.
Counterhold damper with 11 8 190 while tightening center
bolt.
Tightening
torque
Vibration damper hub to crankshaft 410 Nm (302 it-ib)
- Installation is reverse of removal noting the following:
Install drive belts. See 020 Maintenance.
Install cooling fan. See 170 Radiator and Cooling Sys-
tem.
Crankshaft oil seal, replacing
(M62 and M62 TU engines)
- Disconnect negative (-) cable from battery
CAUTIOG
Disconnecting the battery may erase fault code(s) storedin
control module memory. Check for fault codes using spe-
cial BMW diagnostic equipment.
* Prior to disconnecting the battery, read the battery dis-
connection cautions in
001 General cautions and
warnings.
- Remove splash guard from beneath engine
- Remove engine cooling fan assembly. See 170 Radiator
and Cooling System.
NOTE
-
Cooling fan nut (32 mm wrench) has left-hand threads.
- Remove drive belts. See 020 Maintenance.
NOTE-
Marlc direction of belt rotation if reusing belt.