steering BMW 525i 2001 E39 Workshop Manual

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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

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01 0-2
General
This section is intended to help the do-it-yourselfer get start-
ed. Tips on workshop practices, basic tools, and a quick refer-
ence guide to emergencies can be found here.
WARNING-
Do not use this manual unless you are familiar with basic
automotive repair procedures and safe workshop
practices.
0 This manual illustrates the worl quired for most service work; it is not a substitute for full
and up-to-date information from the vehicle manufac-
turer or for proper training as an automotive technician.
Note that it is not possible to anticipate all of the ways
or conditions under which vehicles may be serviced or
to provide cautions as to all of the possible hazards that
may result.
MOW TO USE THIS MANUAL
WARNING -
Your common sense and goodjudgement are crucial to safe
and successful service
work. Read procedures through be-
fore starting them. Think about whether the condition of your
cac your level of mechanical skill, or pour level of reading
comprehension might result in or contribute in some way to
an occurrence that might cause you injury, damage your car;
or result in an unsafe repair. If you have doubts for these or
other reasons about your ability to perform safe repair work
on your car; have the work done at an authorized
BMW deal-
er or other qualified shop.
The manual is divided into ten sections:
0 GENERAL, MAINTENANCE
0 I ENGINE
2 TRANSMISSION
3 SUSPENSION, STEERING AND BRAKES
4 BODY
5 BODY EQUIPMENT
6 ELECTRICAL SYSTEM
7 EQUIPMENT AND ACCESSORIES
- ELE ELECTRICAL WIRING DIAGRAMS
OBD ON-BOARD DIAGNOSTICS

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020 Maintenance
General ........................... .02 0.2
Special tools ........................ .02 0.2
Service Interval Indicator (Sll) ........... .02 0.3
Service Interval Indicator (Sll), resetting ... .02 0.3
Inspection I, Inspection 11 ............... .02 0.5
Maintenance Tables ................ .02 0.6
Fluid and Lubricant Specifications .. .02 0.9
Fluids and lubricants ................. .02 0.10
Engine Oil Service ................ .02 0.1 I
Engine oil. checking level ............. .02 0.12
Engine oil and filter. changing .......... .02 0-13
Engine Compartment Maintenance . .02 0.14
Accelerator and linkage ............... .02 0.14
Air filter. replacing ................... .02 0.1 4
Cooling system service ............... .02 0.15
Engine drive belt service .............. .02 0.16
Idlespeed .......................... 020-19
Catalytic converter and oxygen sensors .. .02 0.19
Power steering fluid, checking level ..... .02 0.20
Spark plugs ........................ .02 0.20
Spark plugs, replacing ................ .02 0.21
Interior ventilation microfilter, replacing ... .02 0.22
Other Mechanical Maintenance ..... .02 0.22
Battery, checking. cleaning. and replacing .02 0-22
Brake fluid. replacing ................. .02 0-24
Brake pad 1 rotor wear. checking ........ .02 0.24
Brake system, inspecting ............. .02 0.25
Parking brake. checking ............... 020-25
Clutch fluid. checking ................. 020-26
Differential oil level. checking ........... 020-26
Drive axle joint (CV joint) boots. inspecting 020-27
Exhaust system. inspecting ............ 020-27
Fuel filter. replacing .................. 020-27
Fuel tank and fuel lines. inspecting ...... 020-28
Suspension. front. inspecting ........... 020-29
Suspension. rear. inspecting ........... 020-29
Tires. checking inflation pressure ........ 020-29
Tires. rotating ....................... 020-29
Transmission service. automatic ........ 020-29
Transmission service. manual .......... 020-30
Transmission fluid. checking and filling
(manual transmission)
................ 020-30
Wheels. aligning ..................... 020-30
Body and Interior Maintenance ..... 020-31
Body and hinges. lubricating ........... 020-31
Exterior washing ..................... 020-31
Interior care ........................ 020-31
Leather upholstery and trim ............ 020-31
Polishing ........................... 020-32
Seat belts .......................... 020-32
Special cleaning ..................... 020-32
Washing chassis ..................... 020-32
Waxing ............................ 020-32
Windshield wiper blade maintenance ..... 020-33

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Table b. Inspection I Service (continued)
Checlt transmission and differential for
external lealts.
Check CV joint boots for damage or leaks.
Visually
check fuel tank, fuel lines, and
connections for
leaks.
New parts
Tools Required required
Check condition, position, and mounting
ol
exhaust system. Visually check and adjusl
if necessary.
Check power steering system for lealts.
Check power steering
fluid level and adjust
if necessary.
Check steering racidbox and tie rods for
tightness. Checit condition of front axle
joints, steering
linkage, and steering shaft
joints.
Check overall thickness of front and rear
bralte pads using
BMW special tool. If
replacement is necessary:
Examine brake disc surface.
Clean brake pad contact points in calipers
Grease wheel centering hubs.
Checlt thickness of parking brake linings
only when replacing rear brake shoes.
Checit operation of pariting brake and
adjust as necessary.
Checlt front control arm bushings for
damage or wear.
Check brake system connections and
lines
for leaks, damage, and incorrect
positioning Warm
engine
(~ealer service Irepair , required recommended lnformat~on
Check parking braite actuator. Adjust if
necessary
Check ail tire pressure (including spare)
and correct if necessary.
Checlt condition of tires (outer tread
surface), tread wear pattern: in case of
uneven wear, perform wheel alignment.
inspect entire body according to terms of
rust oerforation limited warrantv. (Must be
*:
4:
2 ~ perfdrmed at least every two years). I
Read out on-board diagnostic (OBD 11) fault
codes.
Checkengine coolant
system1 heater hose
connections for
leaks.
Checit coolant level and antifreeze
protection level. Add coolant as necessary.
* 100113010BD
I
170

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--- -
Maintenance
Table b. Inspection I Service (continued)
I I I I
Warm engine Dealer service
required recommended
Check windshield
washer fluid level and
antifreeze protection.
Add washer fluid as necessary.
Replace ventilation
microfilter. (Note:
reduce replacement intervals in dusty
operation conditions)
Reset Service interval Indicator
(Sil).
Additional
repair
information
Tools Required
*
eck aim of washer jets and adjust if
necessary.
covers, obvious damage or attachment o
s or accessories.
Road test
Check braking performance, steering,
heating and air conditioner operation.
Check manual transmission and clutch
operation or automatic transmission
operation. New
parts
required
*
Bodylelectrical
121
630
630
Checic battery state of charge
Check operation of:
headlights,
parking iights, back-up lights.
license plate lights, interior lights,
glove box
illumination, engine compartment light,
trunk light, turn signals, emergency
flashers, stop iights.
Check operation of horn and headlight
dimmer switch
:i:

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020-1 6
Maintenance
loose, hose is damaged, or connection is dirty or corroded.
Dried coolant has achalky appearance. Hoses should be firm
and springy. Replace any hose that is cracked, has become
soft and limp, or has been contaminated by oil.
4 As a preventive measure, replacement of the cooling system
hoses every four years is recommended. The illustration
shows examples of damage to coolant hoses. Any of these
conditions is cause for replacement (illustration courtesy of
/ Abrasion Damaged Hose Heat Damaged Hose 1 Gates Rubber Company, I~c.).
Engine drive belt, replacing
Drive belts and pulleys transfer power from the engine crank-
shaft to various accessories.
E39 models use two polyribbed
(serpentine) belts:
The outer belt turns the
NC compressor.
0 The inner, longer belt turns the alternator (generator), cool-
ant pump and power steering pump.
Inspect drive belts with the engine off. If the belt shows signs
of wear, cracking, glazing, or missing sections, it should be
replaced
immediately. To reduce the chance of belt failure
while driving, replacement of the belts every four years is
recommended.
WARNING -
Observe care when replacing belts. Personal injury could
result if a tensioner springs back into position uncontrolled.
CA UTIOI\C
Mark drive belt rotation direction if removing and reusing an
old belt.
NOTE-
When belts are replaced with new ones, store the old set in
the trunk for emergency use.
All models, use
BMW special tools 11 5 030 and 11 5 040 to
loosen and remove cooling fan and clutch from coolant
pump.
NOTE-
32 mm cooling fan nut has left-hand threads
If necessary, remove fan cowl from radiator.

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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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7 Maintenance
< Unbolt caliper from steering arm to properly inspect:
Brake pad thickness
(A)
Brake rotor
Condition of caliper seal
(B)
Condition of caliper slider bolts (C)
NOTE-
Brake caliper removal and installation procedures are given
in
340 Brakes.
Brake pad lining minimum thickness
Dimension
A 3.0 mm (0.12 in)
Brake system, inspecting
Routine maintenance of the brake system includes maintain-
ing the brake fluid in the reservoir,
checking bralte pads for
wear, checking parking brake function, and inspecting the
system for fluid lealts or other damage:
- Check that bralte hoses are correctly routed to avoid chafing
or
Itinking.
- lnspect unions and brake calipers for signs of fluid leaks.
- lnspect rigid lines for corrosion, dents, or other damage.
- Inspect flexible hoses for cracking
- Replace faulty hoses or lines as described in 340 Brakes.
WARNING-
Incorrect installation or overtightening hoses, lines, and
unions may cause chafing
orlealage. This can lead to partial
Parking brake, checking
The parking brake system is independent of the main braking
system and may require periodic adjustment depending on
use. Adjust the parking brake if the brake lever can be pulled
up more than
8 clicks. Check that the cable moves freely. A
description of the parking brake and
parlting bralte adjust-
ment can be found in
340 Brakes.

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Maintenance
Suspension, front, inspecting
Inspection of the front suspension and steering includes a
check of all moving parts
forwear and excessive play. Inspect
ball joint and tie-rod rubber seals and boots for cracks
ortears
that could allow the entry of dirt, water, and other
contaminants. See
310 Front Suspension.
Suspension, rear, inspecting
Differential and rear drive axle service consists of checking
and changing the gear oil, inspecting for leaks, and checking
the drive axle
CV joint boots for damage.
The areas where
lealts are most likely to occurare around the
drive shaft and drive axle mounting flanges. For more infor-
mation on identifying oil leaks and theircauses, see
330 Rear
Suspension and
331 Final Drive.
Tires, checking inflation pressure
Correct tire pressures are important to handling and stability,
fuel economy, and tire wear. Tire pressures change with tem-
perature. Pressures should be
checked oRen during season-
al temperature changes. Correct inflation pressures can be
found on the driver's door pillar and in the owner's manual.
Note that tire pressures should be higher when the car is
more heavily loaded.
WARNING-
Do not inflate any tire to a pressure higher than the tire's max-
imum inflation pressure listedon the sidewall. Use care when
adding air to warm tires. Warm tire pressures can increase as
much as
4 psi (0.3 bar) over their coldpressures.
Tires, rotating
BMW does not recommend tire rotation. Due to the car's sus-
pension design, the front tires begin to wear first at the outer
shoulder and the reartires begin to wearfirst at the middle of
the tread or inner shoulder. Rotating the tires may adversely
affect road handling and tire grip.
Transmission service, automatic
The automatic transmissions installed in E39 models are
filled with special automatic transmission fluid. The transmis-
sion lubricant type can be found on the "type-plate" on the
side of the transmission. The recommended lubricants are
listed earlier in this repair group. See Fluids and lubricants.
If in doubt, consult an authorized BMW dealer for alternate

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020-30
Maintenance
fluid use and the most-up-to-date information regarding
transmission operating fluids.
The automatic transmission is not equipped with a dipstick.
Therefore, checking the ATF level is an involved procedure
which includes measuring and maintaining a specified ATF
temperature during the checking procedure.
For more complete
ATF service information, including
checking
ATF level and ATF filter replacement procedures,
see
240 Automatic Transmission.
Transmission service, manual
Manual transmission service consists of inspecting for leaks
and checking the fluid. Evidence of transmission leaks is
like-
ly to be seen around the driveshaft mounting flange and at the
bottom of the bellhousing.
NOTE-
For more information on identifying oil
leaks and their
causes, see 230 Manual Transmission and210 Clutch.
Transmission fluid, checking and filling
(manual transmission)
Tne manual transmss'on inslalleo 'n rne E39 models s f;lled
with a special liierime iluid (ivlTF-LT-I). oi. ordinarily
does
not need to be changed.
< Check manual transmission oil level at transmission filler plug
(A). Make sure car is on level surface.
NOTE- Transmission fluid level
checking and replacement
procedures are covered in 230 Manual Transmission.
Wheels, aligning
BMW recommends checking the front and rear alignment
once a year and whenever new tires are installed.
NOTE-
See 320 Steering and Wheel Alignment for a more detailed
discussion of alignment requirements and specifications.