center console BMW 525i 2001 E39 Workshop Manual

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230-1 8
Manual Transmission
- Unbolt clutch slave cylinder from side of transmission. Do not
disconnect fluid hose. Suspend slave cylinder from chassis
using stiff wire.
CA UTIOG
Unbolt clutch slave cylinder slowly to prevent air being
drawn into hydraulic system.
. Do not operate clutch pedal with slave cylinder re-
moved from transmission.
4 Put BMW special tool 11 7 370 or appropriate sized spacer
between engine oil sump and front axle support. Lower trans-
mission until engine is supported on spacer.
0 V-8 vehicle: Turn front wheels to prevent strain from being
placed on center tie rod.
All vehicles: Tilting the engine to lower the transmission
can lead to damage to various components due to lack
of clearance at rear of engine. Lower transmission
slowly
- Support front of engine with floor jack.
4 Disconnect shift rod from selector shaft coupling
- Disconnect shift console from top of transmission. See 250
Gearshift Linkage.
6-cylinder: Remove transrnisslon mounting Torx-head bolts
(arrows). Note length and locatlon of bolts.
Remove
transrnlssion by pulling backward untll transmls-
sion Input shaft clears clutch d~sc spl~nes, then pull down-
wards. Lower
transmlsslon jack to remove transrnlsslon. -
- - -
-

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Gearshift ~inkaael
Gearshift lever, removing
(manual transmission)
Use the accompanying illustration as a guide when removing
and installing the gearshift linkage.
- Remove shift knob by pulling knob straight off shift lever.
NOTE-
Pull up on the shift knob with about 90 lbs. of force. Do not
twist
knob or locating key can be damaged.
- Squeeze sides of shift boot to unclip from center console.
Pull boot up and off shift lever.
- Remove sound insulation at base of shift lever.
- Raise vehicle to gain access to underside of vehicle.
- --
WARNING-
Male sure the car is stable and well supported at all tfmes.
Use a professional automotwe hft orjaclc stands designed for
the purpose.
A floorjaclc 1s not adequate support.
- Remove complete exhaust system. See 180 Exhaust
System.
- Remove driveshaft. See 260 Driveshaft.
- Support transmission with transmission jack. Remove
crossmember from rear of transmission.
- Lower rear of transmission to access gearshift linkage.
CA UTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.
4 Working above transmission, disconnect selector rod:
* Pull off shift rod retaining circlip (A).
Remove washer (6).
Disengage selector rod (C) from gearshift lever.

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250-4
I Gearshift Linkage
Release gearshift lever mounting ring from below using BMW
special spanner 25 1 110. Turn tool 90' ('I, turn)
counterclockwise.
Push shift lever up to remove from shift console,
Raise transmission and temporarily install transmission
crossmember.
Lower vehicle. Working from inside passenger compart-
ment, pull up on shift lever to remove it together with inner
rubber boot and shift lever mounting ring.
Gearshift lever, installing
(manual transmission)
- Clean old grease from shift lever ball and mounting ring.
Also clean shift console bowl. Lubricate with molybdenum
disulfide grease.
- Insert shift lever together with inner boot and mounting ring
into center console.
4 Align shift lever mounting ring locking tabs with slots
(arrows) in shift console bowl. Press down until ring
snaps into place.
NOTE-
lnstall mounting ring witli arrow pointing toward front of car.
4 Pull inner rubber boot over shift console bowl (arrows) to
seal base of shift lever.
NOTE-
lnstall rubber boot witli arrow pointing toward front of car.
- Raise car and support transmission. Remove transmission
crossmember and lower transmission to access base of shift
lever.
CAUTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.

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Suspension, Steering and Brakes - ~enerail
The main components of the system are the wheel speed
(pulse) sensors, the
ABSIASC or ABSIDSC control module,
and the hydraulic control unit.
Traction control also comes into operation during decelera-
tion. Decelerating on snowy or icy road surfaces can lead to
rear wheel slip. If a rear wheel starts to drag or lock up, the
ASC system can limit the problem by adjusting throttle, fuel
injection and ignition timing.
4 A switch (arrow) on the center console is used to toggle the
ASC on or off.
NOJE-
Even with the ASC system turned off, if the ASC control mod-
ule senses a difference in wheel speed (one wheel spinning)
the
ASC system applies modulated braling force to the slip-
ping wheel until traction is regained. There is no override of
fuelinjection function.
The ASC system is designed to be maintenance free. There
are no adjustments that can be made. Repair and trouble-
shooting of the ASC system requires special test equipment
and knowledge and should be performed only by an autho-
rized
BMW dealer.
ABSIASC traction
I 1.
control system
Wheel speed sensor
Wheel speed pulse wheel
Brake disk
Brake caliper
ABSIASC hydraulic unit
Brake master cylinder
Pedal operated throttle valve
ASC controlled throttle valve
Engine control module (ECM)
Accelerator pedal
ABSlASC control module

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300-1 4
I Susoension. Steerina and Brakes - General
DSC system I
Dynamic Stability Control (DSC)
Dynamic Stability Control (DSC) utilizes many principles and
components of the ASC traction control system. DSC is ac-
tive throughoutthe driving range, unlike ASC which is only ac-
tive during acceleration and braking. DSC helps stabilize the
vehicle in cornering and avoidance maneuvers by adjusting
engine controls such as throttle, ignition, fuel injection and the
application of
brake pressure individually to the wheels.
Inputs
fi- 0
2 4-* .. o
[11-' IJ
411m4
3?-
G
4 The DSC control module uses various inputs to determine
vehicle instability during braking, cornering, or reduced trac-
tion situations. Based upon these inputs the ABSIDSC con-
trol module sends outputs to the engine control module and
the ABSIDSC hydraulic unit to activate torque reduction pro-
tocols and braking intervention.
-
ABSIDSC control module
OUI~YIS
4
The DSC system can be toggled on and off by a switch
mounted on the center console. Turning off the DSC system
does not disable ABS or ASC functions.
+
Measure ride height (A) from center of fender arch to bottom
of wheel rim.
Car in normal loaded position on the ground. See Normal
loaded position.
Engine
control
module
Specified tires and wheels, correct tire pressure, even tire
wear
-'* 9-
.%A
Correct wheel bearing play
T'== ..t, 9 B
-.m
Model with air suspension (EHC): Disconnect electrical har-
ness connector to air supply pump to prevent automatic
height regulation.
When finished, reset ride height using BMW diagnostic
scan tools DIS or
MoDiC.
NOTE-
Airsupply pump is located beneath a cover under the spare
tire in the floor of the cargo compartment.
- If ride height is outside specification listed, install new
springs. Suspension spring removal and installation is cov-
ered in
310 Front Suspension and 330 Rear Suspension.
Normal loaded position
Each front seat 68 kg (150 Ib)
Center of rear seat 68 kg (150 lb)
Trunk 21 kg (46 lb)
Fuel tank full

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Steering and Wheel Alignment
4 Release lock (A) and pull up on harness connector (6) to dis-
connect ignition switch harness.
. Remove wire harness bracket fastener (C).
4 Remove shear bolts (arrows) using a chisel or punch.
NOTE-
The shear bolts can be drilled and then removed using an
easy-out.
- Remove steering column lock housing.
- Installation is reverse of removal.
Tighten new shear bolts until bolt heads shear off.
ignition interlock cable, removing and
installing (models
with automatic
transmission)
- Remove steering column trim panels as described earlier.
4 Loosen and disconnect interlock cable (arrow) from ignition
lock assembly.
- Remove center console trim panel.

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320-1 4
Steering and Wheel Alignment
Remove cable mounting fastener (arrow). Disconnect cable
from shift
linkage.
Remove old cable and replace with new cable.
Reinstall trim.
Interlock cable, adjusting
(models with automatic transmission)
- Remove center console trim panel.
- Place gear shift selector lever in PARK.
4 Loosen cable mounting fastener (A).
- Remove ignition key.
- Press down on interlock lever (B) and tighten cable mounting
fastener (A).
Steering column, removing and installing
- Disconnect negative cable from battery.
CAUTIOI\C
Prior to disconnecting the battea read the battery discon-
nection cautions given
in 001 General Cautions and
Warninqs.
- Remove steering wheel as described earlier.
m
- Remove steering column trim panels as described earlier.
' \L/>I - Remove steerinq shaft collar
Automatic transmission models: Loosen and disconnect in-
terlock shift cable (arrow) from ignition lock assembly.
4 - Disconnect steering angle sensor electrical harness.

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340-24
Brakes
4 Remove brake shoe retaining pins using BMW special tool
34 4 000 or equivalent.
Rotate retainer
114 turn to release.
Spread shoes apart and lift out.
4 Note position of bralte shoe adjuster (arrow).
Right side is illustrated. Left is mirror image of this.
- Apply thin coat of grease to sliding parts and pins before re-
assembly.
- Installation is reverse of removal. Be sure to adjust parlting
bralte cables as described earlier.
Tightening torque
Road wheel to
hub 120 i lo Nm (89 i 7 ft-lb)
Parking brake cable, replacing
The parking brake is actuated by two separate Bowden ca-
bles. Each cable can be replaced separately.
- Working inside car, gain access to base of parking brake -
handle by removing center console storage tray and center
armrest, as necessary.
4 Use BMW special tool 34 1 030 or equivalent deep 10 mm
socket to remove parlting brake cable
loclc nuts (A) at base of
parking brake handle.
- Raise rear of car.
WARNING -
Male 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 jaclc stands under suspension
Darfs.

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513-1
51 3 lnterior Trim
General . . . . . . . . . . . . . . . . . . . . . . . . . . . ,513-2
Interior trim repairs . . . . . . . . . . . . . . . . . . . ,513-2
Center Console . . . . . . . . . . . . . . . . . . . . .513-3
Center console, removing and installing . . . 213-3
Dash Panel . . . . . . . . . . . . . . . . . . . . . . . . ,513-7
Lower dash panel assembly,
removing and installing
. . . . . . . . . . . . . . . . ,513-7
Upper dash assembly,
removing and installing
. . . . . . . . . . . . . . . ,513-1 1
Window and door post trim panels,
removing and installing
. . . . . . . . . . . . . . . 513-12
Dash panel support,
removing and installing
. . . . . . . . . . . . . . . 513-15
Rear parcel shelf panel,
removing and installing
. . . . . . . . . . . . . . . 513-15
Glove compartment,
removing and installing
. . . . . . . . . . . . . . . 513-16

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513-3
Interior ~rirnl
The console between the two front seats starts behind the shifler housing. It houses the parking brake handle, optional
telephone and oddments storage tray. The rear portion of the
console houses the ashtray and covers the emergency brake
cable ends.
NOTE-
The accompanying photos illustrate a model with automatic
transmission. Manual transmission models are similar.
Center console, removing and installing
4 Remove shift knob by pulling straight up (arrow).
Gently pry shift bezel
harness (arrow). up
out of console and disconnect wiring
Models equipped with automatic transmission remove neu-
tral safety switch fasteners (arrows) and remove bezel with
switch.