battery capacity BMW 525i 2001 E39 Workshop Manual

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Battery, Starter, ~iternatorl
The battery is mounted in the right side of the luggage com-
partment, concealed behind a trim panel. Battery capacity is
determined by the amount of current needed to start the vehi-
cle and by the amount of current consumed by the electrical
system. This will vary from model to model.
BMW batteries are rated by
amperelhours (Ah) and cold
cranking amps (CCA) rating, which are listed on the battery.
The Ah rating is determined by the average amount of cur-
rent the battery can deliver over time without dropping below
a specified voltage. The CCA is determined by the battery's
ability to deliver starting current at
On F (-18" C) without drop-
ping below a specified voltage. Always replace the battery
with one having the same or higher ratings.
Battery testing
Battery testing determines the state of battery charge. On
conventional or low-maintenance batteries. the most com-
mon method of testing the battery is that
ofchecking the spe-
cific gravity of the electrolyte using a hydrometer. Before
testing the battery, check that the cables are tight and free of
- corrosion.
Hydrometer testing
Before hydrometertesting, load the battery with 15 amperes
for one minute. If the battery is installed in the vehicle, this can
be done by turning on the headlights without the engine run-
ning. The state of battery charge based on specific gravity
values are given in Table
b. Specific gravity of battery elec-
trolyte at
27" C (80°F).
The hydrometer indicates the specific gravity of the electro-
lyte. The more dense the concentration of sulfuric acid in the
electrolyte, the higher the state of charge
NOTE-
Electrolyte temperature affects hydrometer reading. Checlc
the electrolyte temperature with a thermometer. Add 0.004 to
the hydrometerreading
forevery 6°C (10°F) that the electro-
lyte is above 27°C
(80°F). Subtract 0.004 from the reading
forevery 6°C (10°F) that the electrolyte is below27"C
(80°F).

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.-
err- .- Fuel Tank and Fuel Pump
FUELPUMP AND FUELLEVELSENDER
E39 models use a two-lobed fuel tank. Each lobe of the tank
has its own fuel level sending unit. Each sender has a float
connected to a variable resistance wipercontact. To equalize
fuel level between the two
tank lobes, a siphon pump is in-
stalled in the left lobe.
When replacing asender or fuel pump, always replace hose
clamps,
gasltets and O-rings.
WARNING
-
When removing the fuel level sender or the fuel pump, the
fuel tank should be drained to
1/4 capacity or below as de-
scribed later in this repair group.
NOTE-
The compensating siphon pump maintains the fuel level be-
tween the right and left tank lobes. If fuel level sender resis-
tances are not approximately the same on left and right,
remove the senders and visually inspect the level in each
lobe. If the levels are different, check the siphon pump.
Fuel level sender resistances
Float position
l~est results (Q
Down (empty) 150- 70
Up (full) 1401 -415
Fuel level sender (right side) and fuel
pump, removing
and installing
- Drain fuel from tank as described later.
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- To access top of fuel tank, remove rear seat lower cushion by
lifting front edge
off catches.

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--
I Fuel Tank and Fuel Pump
The plastic fuel tank is mounted underneath the center of the
car (underneath the rear seat). Mounted in the fuel tank are
the fuel pump and fuel level sending units. Connecting lines
for the evaporative emission control system and expansion
tank are also attached to the tank.
Fuel
tank capacity for E39 models
Tank capacity
70 liters (18.5 gal)
Reserve capacity
8 liters (2.1 gal)
Fuel tank, draining
Drain fuel tank into a safe storage unit using an approved fuel
pumping device.
WARNING-
# Before removing tank, be sure that all hot components,
such as the exhaust system, are completely cooled down.
Fuel may be spilled. Do not smoke or
work near heat-
ers or other fire hazards.
- Start engine and allow to run 10 - 15 seconds to fill fuel com-
pensating siphon assembly. This will allow both lobes of fuel
tank to he drawn off through fuel filler pipe,
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given
in 001 General Warnings and Cau-
tions.
- Remove fuel tank filler cap
- Slide suction hose into filler neck about 130 cm (51 in.), twist-
ing as necessary. Withdraw fuel into storage unit.
- Monitor fuel level reduction in both lobes:
- Remove rear seat cushion and access both fuel tank send-
er harness connectors.
Use multimeter to measure resistance at both senders,
Resistance should drop as fuel level drops.
- If siphoning mechanism is faulty, drain left tank lobe sepa-
rately by removing sender cover and pumping fuel directly
out of left lobe.

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Warnings and cautions
Obse~e the following warnings and cautions when worlting
on the cooling system.
WARNING -
. At normal operating temperature the cooling system is
pressurized. Allow the system to cool as long as possible
before opening (a minimum of one hour), then release the
cap slowly to allow safe release ofpressure.
a Releasing the coolant system pressure lowers the cool-
ant boilingpoint and the coolant may boil suddenly. Use
1 heavy and wear eye and face protection to
guard against scalding.
Use extreme care when draining and disposing of en-
gine coolant. Coolant is poisonous and lethal to hu-
mans andpets. Pets are attracted to coolant because
of its sweet smell and taste. Seek medical attention im-
mediately if coolant is ingested.
CAUTIOG
Avoid adding cold water to the coolant while the engine is
hot or overheated. If it is necessary to add coolant to a
hol
system, do so only with the engine running and coolanl
pump turning.
To avoid excess silicate gel precipitation in the cooling
system and loss of cooling capacity, use BMW coolant
or equivalent low silicate antifreeze.
a If oil enters the cooling system, the radiator, expansion
tank and heating circuit must be flushed with cleaning
agent. BMW recommends removal of the radiator and
expansion
tank to flush.
When
worlcing on the cooling system, cover the alter-
nator to protect it against coolant drips.
Prior to disconnecting the battery, read the battery dis-
connection cautions given in
001 General Warnings
and Cautions.
Begin the diagnosis of cooling system problems with a thor-
ough visual inspection.
If no visual faults are found, it is rec-
ommend that the engine control module (ECM) fault memory
be checked for stored diagnostic trouble codes
(DTCs) using
BMW scan tool
DlSplus or equivalent.

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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