engine wire BMW 525i 2001 E39 Workshop Manual

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001 General Warnings and Cautions
PLEASE READ THESE WARNINGS AND CAUTIONS
BEFORE PROCEEDING
WITH MAINTENANCE AND REPAIR WORK.
WARNINGS-
See also CAUTIONS
- Some repairs may be beyond your capability. If you lack the skills, - Catch draining fuel, oil, or brake fluid in suitable containers. Do
tools and equipment, or a suitable workplace for any procedure
not use
foodor beverage containers that might mislead someone
described in this manual, we suggest you leave such repairs to
into
drinking from them. Store flammable fluids away from fire
an authorized BMW dealer service department or other qualified
hazards. Wipe up spills at once, but do not store the oily rags,
shop. which can ignite and burn spontaneously.
. Do not reuse any fasteners that are worn or deformed. Many fas- Always observe good worRshop practices. Wear qoqqles when
teners are designed to be used only once and become
unreliable you operate machine tools or work with battery acid:kloves or
and mav fail when used a second time. This includes, but is not other
~rotective clothino should be worn whenever the iob re-
limited io, nuts, bolts, washers, self-locking nuts or bolts, clrclips yires' working with harmful substances.
and cotter pins. Always replace these fasteners with new parts.
Greases, lubricants and other automotive chemicals contain toxic
. Never work under a lifted car unless it is solidly supported on
substances, many of which are absorbed directly through the
stands
desiqned for the purpose. Do not supeort a car on cinder
skin. Read the manufacturer's instructions and warninos careful-
blochs, hollow tiles orotherbrops that may drurnbie undercontin-
uous toad. Never work under a car that is supported solely by a
iack. Never work under the car
while the enqine is runninq. - -
If you aregoing to work underacaron the ground, makesure that
the ground is level. Block the wheels to
keep the car from rolling.
Disconnect the battery negative
(-) terminal to prevent others
from starting the car while you are under it.
- Never run the engine unless the work area is well ventilated. Car-
bon monoxide kills.
Rings, bracelets and other jewelry should be removed so that
they cannot cause electrical shorts, get caught in running ma-
chinery, or be crushed by heavy parts.
- Tie long hair behind your head. Do not wear a necktie, a scarf.
loose clothing, or a necklace when you work near machine tools
or running engines. if your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
DO not attempt to
work on your car if you do not feel well. You in-
crease the
danger of injuryto yourseliand others if you are tired,
uDset or have taken medication or anv other substance that mav
keep you from being fully alert.
Illuminate your work area adequately but safely. Use a portable
iy. Use hand and eye protection. Avoid direct skin conGct.
Disconnect the battery negative (-) terminal whenever you work
on the fuel system
orthe electrical system. Do not smokeorwork
near heaters or other fire hazards. Keep an approved fire extin-
guisher handy.
. Friction materials (such as brake pads or shoes or clutch discs)
contain asbestos fibers or other friction materials. Do not create
dust by grinding, sanding, or by cleaning with compressed air.
Avoid breathing dust. Breathing any
friclion material dust can
lead to serious diseases and may result in death.
Batteries
giveoff explosive hydrogen gas during charging. Keep
sparks, lighted matches and open flame away from the top of the
battery. If hydrogen gas escaping from the cap vents is ignited, it
will ignite gas trapped in the cells and cause the battery to ex-
plode.
Connect and disconnect battery cables, jumper cables or a bat-
tery charger only wilh the ignition switched off. Do not disconnect
the battery while the engine is running.
Do not quick-charge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the
battery a second time.
. . safety lighiforworking lnsideor under the car. Make sure the bulb - Do not allow battery charging vollage to exceed 16.5 volts. If the
is enclosed bv a wire caoe. The hot filament of an accidentallv
batten! beoins ~roducina oas or boilino violentiv, reduce the
broken bulb can ignite spilled
fuel, vapors or oil. , - - - charglng rate. ~oostlng a sutfaled battery at a igh charging rate
can cause an
explosion.
-
Continued on next page

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01 0-1
010 General
General ........................... .01 0.2
How to Use this Manual ............ .01 0.2
Warnings. cautions and notes ........... .0l 0.3
Getting Started .................... .0i 0.5
Safety ............................. .O1 0.5
Lifting the car ........................ .O1 0.5
Raising car ......................... .O1 0.5
Working under car .................... .O1 0.6
Advice for the Beginner ............ .O1 0.7
Planning ahead ...................... .O1 0.7
Workshop practices ................... .O1 0.7
Non-reusable fasteners ................ .O1 0.7
Tightening fasteners .................. .O1 0.8
Gaskets and seals .................... .O1 0.9
Electrical testing .................... .O1 0.10
Wire repairs ........................ .O1 0.10
Buying Parts ..................... .01 0.11
Genuine BMW parts ................. .O1 0.11
Non-returnable parts ................. .O1 0.11
Information you need to know .......... .0l 0.12
Service ........................... 01 0-1 3
TOOIS ............................. 010-13
Basic tool requirements ............... 01 0-1 4
Jack stands ......................... 01 0-1 6
Oil change equipment ................. 01 0-1 6
Torque wrench ...................... 01 0-17
Digital multimeter .................... 010-17
BMW special tools ................... 01 0-1 8
Emergencies ...................... 01 0-1 8
Changing a tire ...................... 01 0-1 8
Jump starting ....................... 01 0-1 9
Indicator and warning lights ............ 01 0-1 9
Towing ............................ 010-20
Spare parts kit ...................... 010-21

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01 0-1 0
General
Electrical testing
Many electrical problems can be understood and solved with
only a little fundamental knowledge of how electrical circuits
function.
Electrical current
only flows in a complete circuit. To operate.
every electrical device in the car requires a complete circuit
including a voltage source and a path to ground. The positive
(+) side of the battery is the original voltage source, and
ground is any return path to the negative
(-) side of the bat-
tery, whether through the wiring harness or the car body. Ex-
cept for portions of the charging system, all electrical current
in the car is direct current (DC) and flows from positive
(+) to
negative
(-).
4 Switches are used to turn components on or off by complet-
ing or interrupting the circuit.
A switch is "open" when the cir-
cuit is interrupted, and "closed" when the circuit is completed.
See
600 Electrical System-General for electrical trouble-
(LW, 1 shooting
Wire repairs
Light bulb
(consumer) ' - Repairs to a wiring harness require special care to make the
repair permanent. The wire ends must be clean.
if frayed or
Car body otherwise damaged, cut off the end and remove enough insu- (ground) i Battery lation to complete the repair. if the wire is too short, splice in a BOZLiEL new piece of wire of the same size and make two connec-
tions.
Use connectors that are designed for the purpose. Crimped
on orsoldered-on connectors are best. Crimp connectors and
special crimping pliers are widely available. If soldering, use
needle nose pliers to hold the wire near the solder joint and
create a "heat dam". This keeps the heat and the solder from
traveling up the wire. Always use a solder made specifically
for electrical
work (rosin core).
NOJE-
Twisting wires together to make a repair is not recommend-
ed. Corrosion and vibration will eventually spoil the connec-
tion and may lead to irreparable damage to sensitive
electronic components.
Insulate the finished connection. Electronics stores can sup-
ply heat-shrinkable insulating tubing that can be placed on to
the wire before connecting, slid over the finished joint, and
shrunic to a tight fit with a heat gun or hair dryer. The next best
alternative is electrical tape. Make sure the wire is clean and
free of
solder flux or other contamination. Wrap the joint tight-
ly to seal out moisture. See
600 Electrical System-General
for more information.

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Maintenance
continue to operate as designed. Extending the replacement
interval may void the emission control warranty coverage.
See
180 Exhaust System for information on replacing the
oxygen sensors.
Tightening torque
Oxvoen sensor to exhaust
manifold 50 Nrn (37 ft-lb)
NOTE-
A special soclet for replacing the oxygen sensor is available
from most automotive parts stores. The soclet has
a groove
cut down one side to allow the sensor to be installed without
damaging the wire harness.
Power steering fluid, checking level
The power steering system is permanently filled and does not
have a drain. Routinely adding ATF is not required unless the
system is leaking.
4 To check power steering fluid level in fluid reservoir:
Park car on level ground with engine off.
Level is correct
if it is between MlN and MAX marks on
dipstick.
If level is below
MlN mark, add fluid to reservoir to bring
level up.
* Hand-tighten reservoir cap.
Power steering fluid
Dexron
1iiO ATF or equivalent
Spark plugs
E39 models through model year 1998 were equipped with
spark plugs with two electrodes. These are gapped to
0.7 mm
(0.028 in) by the manufacturer and are not adjustable.
Starting with 1999 models, long life spark plugs with
3 or four
electrodes were used. These can be retroactively fitted to
earlier
models. The recommended spark plug replacement
interval
forthese is 100,000 miles.The electrode gap in these
spark plugs is not adjustable.
Spark plug applications
M52 Bosch FBLDCR
M52 TU, M54 Bosch FGR7DQP or NGK BKRBEQUP
M62 to 7/97 Bosch F7LDCR or NGK BKR6EK
M62 from 7/97 Bosch F9LDCR
M62 TU Bosch FGR7DQP or NGK BKRGEQUP

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020-22 Maintenance
1
- Installation is reverse of removal, bearing in mind the
following:
Lightly lubricate new
spark plug threads with
copper-based anti-seize compound.
Thread plugs into cylinder head by hand to prevent
cross-threading.
. Be sure to reinstall and tighten coil grounds.
Tightening torque Spark plug
to cylinder head 25 Nm (18 It-lb)
Interior ventilation microfilter, replacing
Two interior ventilation microfilters are used, one on each
side of the engine compartment at the fire wall.
< To replace the microfilter, unclip the wire fastener and
remove the cover.
Lift out the filter, and replace. Left side shown; right is
similar.
Replace cover and clip wire fastener to retain cover.
Battery, checking, cleaning, and replacing
The battery Is located in the right side of the luggage compart-
ment. Simple maintenance of the battery and its terminal
connections will ensure maximum starting periormance,
especially in winter when colder temperatures reduce battery
power.
Battery cables should be tight. The terminals, cable clamps
and battery case should be free of the white deposits that
indicate corrosion and acid salts. Even a thin layer of dust
containing conductive acid salts can cause battery discharge.

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Maintenance
- To remove battery corrosion:
Disconnect battery cables. Disconnect negative (-)cable
first.
* Remove battery from trunk
Clean terminal posts and cable clamps with a wire brush.
Clean main chassis ground terminal next to battery.
Corrosion can be washed away with a
baking soda and
water solution that will neutralize acid.
Reinstall battery and reconnect cable clamps, positive
(+)
cable first.
Lightly coat outside of terminals, hold down screws, and
clamps with petroleum jelly, grease, or a commercial
battery terminal corrosion inhibitor.
WARNING
-
Battery acid is extremely dangerous. Take care to keep it
from contacting eyes, skin, or clothing. Wear eye protection.
Extinguish all
smolihg materials and do not work near any
oaen flames.
CAUTION-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
NOTE-
The original equipment battery in E39 models is mainte-
nance free. The original electrolyte will normally last the
entire service life of the battery under moderate climate con-
ditions.
Battery electrolyte should be maintained at the correct level
just above the battery plates and theirseparators. The correct
level is approximately
5 mm ('14 in.) above the top of battery
plates or to the top of the indicator
marks (if applicable). The
battery plates and the indicator marks can be seen once the
fillercaps are removed.
if theelectrolyte level is low, replenish
it by adding distilled water only.
4 The original equipment BMW battery is equipped with a
built-in hydrometer "magic eye"
(arrow). Battery condition is
determined by the color of the eye:
Green: Adequate charge
* Black: Inadequate charge, recharge
Yellow: Defective battery, replace
Batteries are rated by ampere hours (Ah), the number of
hours a specific current drain can be sustained before com-
plete discharge, or by cold cranking amps (CCA), the number
of amps available to crank the engine in cold weather
condi-

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Engine identifying features
4 The M52 engine (MY97-98 528i) used a single on-off vari-
able intake valve timing system (called VANOS). The cylinder
block is cast iron and the cylinder head is aluminum. The en-
gine management system is Siemens MS 41
.I and features
NGK-type (0-5 volt) oxygen sensors.
NOTE-
VANOS is an acronym based on the German words Variable
Nocltenwellen Steuerung (variable camshaft timing).
4 The M52 TU engine (MY99-00 5281) and the M54 engines
(MY01-02 525il530i) are fitted with double VANOS. The en-
gine
blocits are constructed of aluminum alloy with cast iron
cylinder sleeves.
4 The double VANOS (variable camshaft control) system incor-
porates true variable control of both the
intake and exhaust
camshafts, as compared to the single VANOS system on the
M52 engine
(onloff control of the intaite camshaft only).
The M54 engines use a fully electronic throttle control (drive
by wire). There is no accelerator cable connecting the throttle
pedal to the throttle housing in these cars.

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110-3
Engine Removal and lnstallationl
Q Fuel line plugs
(Tool No.
BMW 13 5 281 / 13 5 282)
4 Fuel line removal tool
(Tool No.
BMW 16 1 050)
CAUTION-
Disconnecting the battery may erase fault code@) storedin
memoiy Check for fault codes prior to disconnecting the
battery cables.
If the MIL (Malfunction Indicator Light, also may be
called "Check Engine" or "Service Engine Soon" light)
is illuminated, see
OBD On-Board Diagnostics for
DME fault code information.
It orhersysrem faults have been detected, as indicated I
by an ~llum~nated ABS, SRS orASC/DSC ~arning light,
see the appropriate repair group in this manual or an
authorized BMW dealer for more information on fault
codes.
NOTE- Engine removal procedures are similar for all 6-cylinder
models. When differences
exist, they are noted at the be-
ginning of each step. Engine are referred to by engine
code. See
100 Engine-General for engine code and appli-
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.
The
intake manifold must be removed on &cylinder mod-
els before the engine can be removed.
WARNING-
Due to risk of personal injury, be sure the engine is cold be-
fore beginning the removal procedure.

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Engine Removal and lnstallationl
< Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jump start post
(4.
Loosen and remove battery lead mounting nut.
Remove lead and push down through intake manifold
Remove trim covers
(arrows) from fuel injector cover.
Remove cover hold down bolts and lift off cover.
Working above engine, disconnect the following:
Vent line from cylinder head cover (A).
M52 engine: Oxygen sensor connectors (8).
Electrical harness connector from intalte camshaft VANOS
solenoid valve
(C).
M52 engine: Disconnect electrical harness connectors at
throttle valve position switch
(D), ASC valve position switch
(E), fuel injector harness (F) and vent valve (G).
CAUTION-
Be sure to mark oxygen sensor harness connectors so that
they can be reassembled correctly Do not interchange con-
nectors.
4 M52 TU, M54 engine: Disconnect fuel injector electrical con-
nectors from injectors.
Use small screwdriverto pry one corner of wire lock clip on
fuel injector
1 connector.
Repeat for all injectors.
Lifl off connector loom and lay aside.

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110-12
Engine Removal and Installation
4 Remove hoses from thermostat housing by releasing locks
(arrows). If applicable, detach electrical harness connector
for thermostat housing.
NOTE-
Two different types of hose fasteners are used on the E39
car; lock clamp type as shown above or standard band
clamps.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator as described in
170 Ra-
diator and Cooling
System.
CAUTION-
32 mm radiator fan mounting nut has left hand threads.
4 Disconnect coolant hose (arrow) at rear left side of engine
above starter.
4 Disconnect coolant hose (arrow) at front left side of engine
mount.
- Unbolt power steering fluid reservoir and pull aside without
detaching hoses. Secure to fender with cord or stiff wire.