BMW 5251 User manual

Service Manua
5251, 5281, 530i, 540i
Sedan, Sport Wagon
1997,1998,1999,2000,2001,2002
www.bmwclub.pro - BMW PRO FORUM!

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Erratainformation
We will evaluate submissions and post appropriate editorial
changes online as text errata or tech discussion. Appropriate
errata will be incorporated with the boolc text in future printings.
Read errata informationfor this book before beginning work on
your vehicle. See the following web address tor additional
information:
http://unw.BentleyPublishers.com/errata/
WARNING-important safety notice
Donotusethis manualunlessvouarefamiliarwith basic automotivereoairoroceduresandsafeworkshoooracfices.This manualillustrates
the workshopprocedures
requkedformoslservicework. Itisnotasubsiituti forfullandup-to-dateinformationfromthevehiclemanufaciurer
or for propertrainingas an automotivetechnician. Note that it is not possiblefor us to anticipate all of the ways or conditionsunderwhich
vehicles maybeservicedor to providecautionsas to all of the possiblehazardsthat mayresult.
Thevehiclemanufacturerwillcontinuetoissueserviceinformationupdatesandparlsretrofitsaftertheeditorialclosingofthismanual.Some
of lhese updates and retrofits will apply lo proceduresand specifications in this manual. We regret that we cannot supply updates to
purchasersof this manual.
We haveendeavoredto ensure the accuracyof the informationinthis manual. Pleasenote,however,that consideringthevast quantityand
the complexityof the service information involved, we cannot warrant the accuracy or completeness of the informationcontained inthis
manual.
FOR
THESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAICES ANY WARRANTIES, EXPRESSOR IMPLIED, THATTHE INFORMATION IN
THIS BOOK IS FREE OF ERRORS OR OMISSIONS. AND WE EXPRESSLY DISCLAIMTHE IMPLIED WARRANTIES OF MERCHANTABILTTYAN0 OF FITNESS
FOR A PARTICULAR PURPOSE,EVENIFTHEPUBLISHER OR AUTHOR HAVE BEENADVISED OFA PARTICULAR PURPOSE,AND EVEN IF A PARTICULAR
1
PURPOSE IS INDICATED IN THE MANUAL. THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LlABlLrrY FOR DIRECT. INDIRECT. INCIDENTAL OR
1
I
CONSEQUENTIALDAMAGESTHAT RESULT FROM ANY USE OFTHE EXAMPLES,INSTRUCTIONS OR OTHER INFORMATIONINTHISBOOK. INNO EVENT
1
I Your common sense and oood iudomentare crucial to safe and successful service work. Readorocedures throuoh before startinothem. I
. -- - -~ ~
---~. - ~ ~~
Think about whether the condition of your car, &r level ofmechanical skill, or your level of reading compreh&sion might resill in or
contributeinsomeway to an occurrencewhich mightcause you injuly, damage your car, or result inan unsafe repair.
If you have doubts
for theseor other reasonsaboutyour ability to pelformsafe repairwork on your car,havethe work done at an authorizedBMW dealer or
other qualifiedshop.
Part numberslistedin this manual are for identificationpurposesonly, not forordering. Always check wilh your authorized BMW dealerto
verify part numbersandavailabilitybeforebeginningservicework lhatmayrequirenewpark.
Before anempting any work on your BMW, read the 001 General Warnings and Cautions, and any WARNING or CAUTION that
accompanies a procedureinthe service manual. Reviewthe WARNINGS and CAUTIONSeach time you preparetowork onyour BMW.
I
Spec a toos req.1 redto perlormcenan service operations arc oenlfed n the manLa an0 arc recomrnenoeolor JSC Jse ol loosolner
than those recommendedIn lhs serv ce manualmay beoelnmcnlallolrlc car's sale open1on as rvec as lnesalely 01 lnepersonservcng
I the car.
I
Copies of this manual may be purchased from most automotive accessoriesand parts dealers specializing in BMW automobiles, from
selected booksellers, or directly from the publisher.
This manual was published by Robert Bentley, Inc., Publishers. BMW has not reviewed and does not vouch for the accuracy of the
technical specifications and proceduresdescribed in this manuai.
Libratv of Conaress Cataloaino-in-Publication Data
" " -
BMW 5 Series (E39) : service manual : 523. 528i,530i. 540i, sedan, sport wagon, 1997,
1998, 1999,2000,2001,2002
~Acludesindex.
ISBN0-8376-0317-X (obi<)
,, ,
1. BMW 5 series automobiles--Maintenanceand repair--Handbooks manuals, etc. 1.
Robert Bentley, Inc.
TL215.8258623 2003
629.28'722--dc23 2003052231
BentleyStock No. 8502
Editorialclosing 08/03
090807 10987654
The paper used in this publication is acid free and meets the requirements of the National Standard for Information Sciences-
Permanence of Paper for PrintedLibrary Materials. @
OCopyright2007 Robert Bentley. Inc. Bentiey Publishersis a trademark of Robert Bentley, Inc.
All rights reserved. All informationcontainedinthis manual is based on the informationavailable to the publisherat the time of editorial
closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced,stored in a
retrievalsystem, or transmittedin any form or by any means, electronic, mechanical,photocopying,recording,or ofhenvise, without the
prior written consent of the publisher.Thisincludestext,figures,andtables.All rightsreservedunderBerneandPan-AmericanCopyright
conventions.
Cover photos of car exteriors by Jonathan Richardfor Bentley Publishers
@ Robert Bentley, Inc. Cover design and use of blue band on
spine and back cover are trademarksof Bentley Publishers. All rights reserved.
Manufactured inthe United States ofAmerica

YOU are now in Volume
I
I
Foreword ................... .. .................................................................................. v
Index
........................ .. ................................................................ rearofmanual
General,
001 General Warnings and Cautions
002 Vehicle Identificationand VIN Decoder
Maintenance OiO
020 Maintenance
Engine
100 Engine-General
110 EngineRemovaland Installation
113 Cylinder HeadRemovaland
Installation
116 Cyiinder HeadandValvetrain
117 CamshaftTiming Chain
119 LubricationSystem
200 Transmission-General
2 Transmission 210 clutch
230 ManualTransmission
I20 IgnitionSystem
121 Battery,Starter,Alternator
130 Fuel Injection
160 FuelTank andFuel Pump
170 Radiatorand Cooling System
180 ExhaustSystem
240 AutomaticTransmission
250 GearshiftLinkage
260 Driveshaft
Suspension, 300 Suspension,Steering and 330 RearSuspension
Brakes-General
331 FinalDrive
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 ExteriorTrim, Bumpers
512 DoorWindows
Equipment
513 InteriorTrim
7
Equipmentand 720 seat Belts
Accessories
721 Airbag System (SRS)
OBD On-BoardDiagnostics
. ............ ..
515 Central Locitingand
Anti-Theft
520 Seats
540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rearof manual
Electrical
6 system
600 ElectricalSystem-General 620 Instruments
610 ElectricalComoonent Locations 630 Liohts
611 wipersandwashers
612 Switches
eati in^ andAir Conditioning
Radio
. ........... ........ .........................
ElectricalWiring Diagrams

SelectedBoolcs andRepairInformationfromBentleyPublishers
MINI Cooper
MINI Cooper Service Manual: 2002-2004
Bc,illc!! Pirl~lisl!~~ISBN 0-8376-1068-0
AlexZanardi - MySwectest Victory
rllex Zmmrdiitjill! Ginrz11,cnGns~x~ri,,i
ISBN (1-8376-1249-7
BMW3 Series IE36)ScrvireManual:
1992-1998,318ilisliC. 323is/iC, 3?5i/is/iC,
328ilisliC, M3
Be~iili.!~Pirl?lisliersISBN 0-8376-0326-9
BMW
5 Series ScrviccManual: 1997-2002
525i, 528i. 530i. 540i, Sedan, SportWagon
Bcrrlluy P~rlilishensISBN 0-8376-0317-X
Porsclze
Tl~cUnfair Advantage
hlirrk Do,~ult,reISBN 0-8376-0073-Iilrcj; Porsche: Excellcncc Was Expected
I<iirlLcldui,~sse!tISBN 0-8371,-0235-1
0-8376-0069-3(~1bJ
GoingFaster! Mastering the Art of Race Porsche 911Carrcm Service Manual:
198G1989
B~.~iile!/Pllblislters ISBN 0-8376-0291-2
Porschc 911Enthusiast's CompanionT3'
AiirinriSlr~,tzlli~~rISBN 0-8376-0293-9
BMW 6 Scries Enthusiasl's CompanionTh1
Jc~.li'iil!/liV0l10li ISBN 0-8376-0193-2
Driving
Tlw Skip Bizl.bul-Riicing Sclaiol
ISBN 0-8376-0227-0 BMW 7 Series Servicc Manual:1988-1994,
735i,735iL, 74%. 740iL. 750iL
Beritlc!/ I'irblislrens ISBN 0-8376-0328-5
A FrenchI<issWith Dcalh: SteveMcQuecn
and theMaking of LC M,!r~s
hliclael i(ei/scr ISBN 0-8376-0234-3 Porschc911SCCoupc,Targo,and Cabriolet
Scrvict. Manual: 1978-1983
Br>illu!yPtibiishersISBN 0-8376-0290-4
Bosclz
SoortsCarandComoctition Drivins
P;url ~ri'rp ~vilhforc&rd I)!/ Phil Hill "
ISBN 0-8376-0202-5 Boscl~AulomativcHandbook 6th Edition
Robul.1 Boscli, CIII~HISBN 0-8376-1243-8
Bosch 1-landbookfor Automotive Elcctrics
and Elcchonics
Rillrcr I Bwcli, GrjilrHISBN 0-8376-1050-8
Bosch Handbook forDiesel-Engine
Managcmcnt
Ril1iei.t Bosdl, ClrrbH ISBN 0-8376-1051-6
Bosch Handbook for Gasolinc-Engine
Management
Robcrf Bosclr, G~ribHISBN 0-8376-1052-4
'7
Battle forlheBcelle
I<iir.lLiid~,igsc>tISBN 0-8376-0071-5
Jells, Golf, GTI Scrvicc Manual: 1999-2005
1.8L lurbo, 1.9LTDIdiesel, PD dicscl,
2.0L ga5aline. 2.81VRG
B~.!iIlcyPt,blislicrs ISBN 0-8376-125-9
New Bcctle ServiceManual:1998-20021.8L
turbo, 1.91TDIdiesel, 2.0L gasoline
Bailicy P~irirlishersISBN 0-8376-0376-5
New Bcctle 1998-2005, New Beetle
Convcrtible2003-2005 Official Factory
Rcpair Manual anCD-ROM
I~olkiatgurr~JAriicricnISBN 9784-8376-1265-2
Boscll Fuel Injection and Enginc
Management
Clml-Its 0. Pmbsi, SAE ISBN 0-8376-0300-5
Clzevrolet
CorvctlcIllustralcd Encyclopedia
Torn Beifurli ISBN 0-8376-0928-3
Racc CarAerodynamics
losupli Kntz ISBN 0-8376-014>8
Road &Track Illustrated Automotive
Dictionary
JoltriDilrkl ISBN 0-8376-11143-6
Scientific Design of Exl~austand Intake
Systems
I'lrililr H. S,sillr 0-8376-0309-9
CorvetteFuel Injection &Electronic
EngincManagcment 1982-2001:
Clmrlcs 0. I1rol,sl, SAE ISBN 0-8376-0861-9
I'acrat Ser\,irchl.>nu.~l:1998-2004.1.81.
lurbu, 2.RL Vb, .l.IIL \\'8, inrludinl: tv.~gc>n
and 4blOTION
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Zora Arkus-Duntov:Thc Lcgcnd Behind
corvt.ttc
Je1.qBirl-1011ISBN 0-8376-0858-9
Ci~evmlclby the Numbers 1965-1969:
TheEssential Chcvrolct Paris Refcrcncc
illn,i Cnl2i11ISBN 0-8376-0956-9
Passat. Passat Waron 1998-2005 Official
Gnlf, GTI, Jctta1993-1999, Cabrio 199%
2002Official Factory Repair Manual on
CD-ROM
Volhsiraigu>toJA,rtrricn ISBN 978-0-8376-1263-8
Jetta, Golf,GTI: 1993-1999, Cabtio: 1995-
2002Scrvicc Manual
ll~iillcyI'trblisln.~~~ISBN 0-8376-0366-8
Alfa Romco All-Alloy Twin Cam
Companion
195G1994
1'nl Bncdulr ISBN 0-8376.0275-0
Alfa Romco Owner's Bibl~'~'
1'1~1Bmrlul! ISBN 0-8376-0707-8
Ford
Ford Fuel Injection and Electronic Engine
Control: 1988-1993
Clinrlcs 0. Pmirsl, SrlE ISBN 0-8376-03Lll-3
Arldi
Audi A4 Repair Manual: 1996-2001.1.8L
lurbo, 2.8L. including Avant and quatlro
Buirile!/ Ptrhlislters ISBN 0-8376-0371-.I
EuroVan Official Factory Rcp.,ir Manual:
1992-1999
I/~llhio~sar,ifAii!wicn ISBN 0-8376-0335-8
TbcOfficial Ford Mustang 5.0 Technical
Reference
& I'crformancc Handbook:
1979-1993
A1 l<inci~u~ihrirri,iISBN 0-8376-0210-6
Audi A6 Sedan
1998-2004, Avant 1999-
2004, allroad quallro 2001-2005,
56Avant 2002-2004, RS6 2003-2004 Official
Factory Rcpair Manual on CD-ROM
Ai!dioJ/in,er.ini ISBN 978-0-8376-1257-7
Jccp CJ Rubuildcr's Manual: 1972-1986
MOSI~S Lltii~lISBN 0-8376-0151-7
Jccp Owner's Biblen', Third Edition
Moscs Lzrdel ISBN 0-8376-1117-2
Automotive Reference
Bcnlluy Publishers has published iewicc
manualsand autornohilcboolissinrc1950.
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BMW 23SarviccManual: 1996-2002.
including 23Roadster, 23Coupe, M
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Be~illqPi,blislicis ISBN 0-8376-1250-0
BMW 3 Scrics (Ed61Scrvicc Manual:
Mcrcedes-Bcnz Technical C~mpanion'~~'
Bu,rllu!! P,rlilislio.i ISBN 11-8376-1033-8
Mcrccdcs-Bcnz E-Class (W124)O~vner's
BibleT>' : 1986-1995
llu~tilc!~Pi~lriisiieisISBN 11-8376-0230-(1
Urlilii-!~P~~Blisi~~rsISBN 11-8376-11772

Foreword
For the BMW owner with basic mechanical skills and for independent auto serviceprofessionals.
this manual includes many of the specifications and procedures that were available to an
authorized BMW dealer service deoartment as this manual went to Dress. The BMW owner with
,
no intention of working on hisor hercar will find that owning and referring to this manual makes it
possible to bebetterinformedand to moreItnowledgeably discuss repairs with a professional
automotive technician.
Ifyou are a BMW owner intending to do maintenance and repair work, make sure you have
screwdrivers, a set of metric wrenches and sockets and metric Allen and Torx wrenches, since
these basic handtoolsare neededfor mostof the work describedin
this manual.Manyprocedures
also require a torque wrench to ensure that fasteners are tightened properly and in accordance
with specifications. Additional informationon basic tools and other tips are in
010 General. In
some cases, the text refers to special tools that are recommended or required to accomplish
adjustments or repairs.These tools are usually identified by their BMW special tool number and
illustrated.
Disclaimer
We have endeavored to ensure the accuracy of the information inthis manual.When the vast
array of data presented in the manual is talten into account, however, noclaim to infallibilitycan
be made. We therefore cannot beresponsiblefor the resultofany errors that may have crept into
the text. Please also readthe Important Safety Noticeonthe copyright page at the beginningof
this book.
Prior to starting a repair procedure, read the procedure,
001 General Warnings and Cautions
and the warnigns and cautions that accompany the procedure. Reading a procedure before
beginning work will help you determine inadvance the needfor specific skills, identify hazards,
preparefor appropriate capture and handling of hazardous materials, and the need for particular
tools and replacement parts such as gasltets.
Bentley Publishers encourages comments from the readers of this manual with regardto errors,
and/or suggestionsforimprovement ofour product.These communications have beenandwill be
carefully considered in the preparation of this and other manuals. If you identify inconsistenciesin
the manual, you may have found an error. Pleasecontact the publisher and we will endeavor to
post applicable corrections onour website. Postedcorrections (errata) should be reviewedbefore
beginning worlc. Please see the following web address:
BMW offers extensive warranties, especially on components of the fuel delivery and emission
control systems.Therefore, beforedeciding to repaira BMW that maybecovered wholly or in part
by any warranties issued by BMW of North America,
LLC, consult your authorized BMW dealer.
You mayfindthat the dealer can make the repair either free or at minimum cost. Regardlessof its
age, orwhether it is under warranty, your BMW Is both an easy car to service and an easy car to
getserviced. So
if atany timea repair isneededthat you feel istoodifficultto doyourself, atrained
BMW technician is ready to do the job for you.
Bentley Publishers

001 General Warnings and Cautions
PLEASE READ THESE WARNINGS AND CAUTIONS
BEFORE PROCEEDING WITH MAINTENANCE AND REPAIR WORK.
WARNINGS-
See also CAUTIONS
- Some repairs maybebeyondyour capability. If youlacktheskills, - Catch draining fuel, oil, or brakefluid in suitable containers. Do
tools andequipment, or a suitable workplace for any procedure notusefoodor beveragecontainersthat mightmisleadsomeone
described in this manual, we suggestyou leave such repairsto into drinking from them. Store flammablefluids away from fire
anauthorized BMW dealerservice department or other qualified hazards. Wipe up spills at once, but do not store the oily rags,
shop. which can ignite and burnspontaneously.
. Do not reuse any fasteners that are worn or deformed. Manyfas- Always observe goodworRshop practices.Wear qoqqles when
teners are designed to be usedonly onceandbecome unreliable you operate machinetools or work with batteryacid:kloves or
and mav fail when used a second time. This includes,but is not other ~rotectiveclothino should be worn whenever the iob re-
limited io, nuts, bolts, washers,self-lockingnuts or bolts,clrclips yires'working with harmfulsubstances.
andcotter pins. Always replacethese fastenerswith new parts. Greases, lubricantsandotherautomotivechemicalscontaintoxic
. Neverwork under a liftedcar unless it is solidly supported on substances, many of which are absorbeddirectly through the
stands desiqned for the purpose. Do not supeort a car on cinder skin. Readthe manufacturer's instructionsandwarninos careful-
blochs, hollowtiles orotherbrops that maydrurnbie undercontin-
uous toad. Neverwork under a car that issupported solely by a
iack. Neverwork under the car while the enqine is runninq.
- -
If youaregoingtowork underacaronthe ground, makesurethat
the ground is level. Blockthe wheels to keep the car from rolling.
Disconnect the battery negative
(-) terminalto prevent others
from starting the car while you are under it.
- Neverrunthe engine unlessthe work areais well ventilated.Car-
bonmonoxide kills.
Rings, bracelets and otherjewelry should be removedso that
they cannot cause electrical shorts, get caught inrunning 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 necklacewhen you work nearmachinetools
or running engines. if your hair,clothing,or jewelry were to get
caught inthe machinery, severe injurycould result.
DOnot attempt to work on your car if you do not feel well. You in-
crease the danger of injuryto yourseliand others
if you aretired,
uDsetor have taken medicationor anv other substance that mav
keep you from being fully alert.
Illuminate your work area adequatelybut safely. Use a portable
iy. Use hand and eye protection.Avoid direct skin conGct.
Disconnectthe battery negative (-) terminalwhenever you work
onthe fuelsystemortheelectricalsystem. Do notsmokeorwork
near heatersor other fire hazards. Keep an approvedfire extin-
guisherhandy.
. Frictionmaterials (such as brakepads or shoes or clutch discs)
containasbestosfibers or other friction materials. Do notcreate
dust by grinding, sanding, or by cleaningwith compressedair.
Avoid breathingdust. Breathingany friclion materialdust can
lead to serious diseases and may result in death.
Batteriesgiveoff explosivehydrogengas during charging. Keep
sparks, lightedmatchesandopenflameaway from the top of the
battery. If hydrogengas escapingfromthe cap vents is ignited,it
will ignitegas trapped in the cells and cause the batteryto ex-
plode.
Connectand disconnect battery cables,jumper cables or a bat-
terychargeronlywilh the ignitionswitchedoff. Donot disconnect
the battery while the engine is running.
Do not quick-chargethe battery (forbooststarting) for longer
than one minute.Wait at least one minutebefore boostingthe
battery a second time.
. .
safety lighiforworking lnsideor underthe car. Makesurethe bulb - Donot allow battery charging vollage to exceed 16.5 volts. Ifthe
is enclosed bv a wire caoe. The hot filament of an accidentallv batten! beoins ~roducinaoas or boilinoviolentiv, reducethe
brokenbulb can ignitespilled fuel, vapors or oil.
, - - -
charglngrate.~oostlngasutfaledbattery at a ighchargingrate
can cause an
explosion.
-
Continuedon nextpage

I General Warnings and Cautions
WARNINGS (continued)
. The air conditioning system is filled with chemical refrigerant,
which ishazardous.The AIC system should beserviced only by
trained technicians usingapprovedrefrigerantrecoverylrecycling
equipment, trainedinrelatedsafetyprecautions,andfamiliarwith
regulationsgoverningthedischarginganddisposalof automotive
chemical refrigerants.
. Do not expose any part of the AIC system to high temperatures
such as open flame. Excessiveheat will increase system pres-
sure and may cause the system to burst.
Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairinga tire that may have been inflated using
anaerosol tire inflator.Keep sparks, openflameor othersources
of ignition away from the tire repairarea. Inflate and deflate the
tire at least four times before breaking the bead from the rim.
Completely removethe tirefrom the rimbeforeattemptingany re-
pair.
Cars covered by this manualare equipped with a supplemental
restraint system (SRS),that automaticallydeploys airbags and
pyrotechnic seat belt tensioners Inthe event oia frontal or side
impact.These are explosive devices. Handledimproperlyor with-
out adequate safeguards,they can be accidently activated and
cause serious injury.
- The ignition system produces highvoltages that can be fatal.
Avoidcontact with exposedterminalsanduseextremecarewhen
working ona car with the engine runningor the ignition switched
on.
. Placejack standsonly at locationsspecifiedbythe manufacturer.
Thevehicle illtino iacksu~oliedwiththevehicleisintendedfortire
-. , .
changesonly.A heavydutyfloorjack shouldbeusedloliftvehicle
before installing jacl( stands. See
010 General.
- Battery acid (electrolyte)can cause severe burns. Flushcontact
area with water, seek medicalattention.
Aerosol cleaners and solventsmay containhazardousor deadly
vapors andare highlyflammable.Useonly inawell ventilatedar-
ea. Do not use on hot surfaces (engines,brakes, etc.).
Do not remove coolant reservoiror radiator cap with the engine
hot. Danger of burns andengine damage.
CAUTIONS-
See also WARNINGS
- if you lack the slqills, toolsandequipment,or asuitableworl(shop
forany procedure describedin this manual,leavesuch repairsto
an authorized BMW dealer or other qualifiedshop.
BMW is constantly improvingitscars andsometimes these
changes, both inpartsandspecifications,aremadeapplicableto
earlier models.Therefore,part numberslisted in this manualare
for reference only. Always check with your authorized BMW deal-
er parts department for the latestinformation.
Beforestarting ajob, make certain that you have allthe neces-
sary tools and parts onhand. Readailthe instructionsthorough-
ly, and do not attempt shortcuts. Use tools appropriate to the
work and use only replacementparts meetingBMWspecifica-
tions.
Usepneumaticand electric tools only to loosenthreaded parts
and fasteners.Never use these tools to tighten fasteners,espe-
cially on light alloy parts. Always use a torque wrench to tighten
fastenersto the tighteningtorque specificationlisted.
Be mindfulof the environmentand ecology.Beforeyou drain the
crankcase,find out the proper way to disposeof the oil. Do not
pouroil onto the ground, down a drain, or into a stream, pondor
lake. Disposeof waste inaccordancewith Federal, State and
Locallaws.
The control modulefor the anti-lock brakesystem (ABS) cannot
withstandtemperaturesfroma paint-dryingboothoraheatlamp
inexcess of 203" F (95°C) and should not be subjected to tem-
peraturesinexcess of 185°F (8S°C)for more than two hours.
- Beforedoing any electricalwelding on cars equippedwith ABS,
disconnect the battery negative
(-) terminal (groundstrap) and
the ABS control module connector.
- Always makesure ignition is off beforedisconnectingbattery.
Labelbatterycablesbeforedisconnecting.Onsome models, bat-
tery cablesare not color coded.
Disconnectingthe battery may erase fault code@)storedincontrol
modulememory. Usingspecial BMW diagnoslicequipment, check
loriauitcodes priorto disconnectingthe batterycables. Ifthe mal-
I.mct on ndicatorIgnt (MIL) s I. ..minaled. see OBDOn-Board
Diaanostics Tl11siant is iuenlftedas lneCheck Ena~neoht
(1997-2000modelsjor~ervlceEngineSoonlight(2061andlater
models). If any other systemiaults havebeendetected(indicated
by an illuminatedwarning light),see an authorizedBMW dealer.
Ifa normalor rapidcharger is usedto chargebattery,the battery
must be disconnected and removed from the vehicle inorder to
avoid damagingthe vehicle.
- Do not quick-chargethe battery (for boost starting) forlonger
than one minute. Wait at least one minute before boostingthe
battery a second time.
* Connectand disconnecta battery charger onlywith the battery
chargerswitched off.
- Sealedor "maintenancefree" batteries should be slow-charged
only, at anamperage rate that is approximately10%of the bat-
tery's ampere-hour (Ah)rating.
. Do notallow battery chargingvoltageto exceed 16.5volts. Ifthe
battery begins producinggas or boilingviolently, reducethe
charging rate. Boostingasulfatedbattery at a highcharging rate
can cause an explosion.

002 Vehicie identification and
VlN Decoder
Vehicle identification Number (VIN), decoding
Some of the information inthis manual applies only to cars of a parlicuiar modelyear or range
of vears. For examole. 1999refers to the 1999 modelvear but does not necessarilv malchthe
caiendsr year in which the car was manufacturedor sold. To besure of the modelyearof a
particular car, checic the Vehicle ldentification Number (VIN)on the car.
The VIN is a unique sequence of 17characters assigned by BMW loidentify each individual
car. Whendecoded, the VIN tellsthe country andyear of manufacture; make, modeland serial
number: assembly plant and some equipment specifications.
The BMW VIN is on a plate mountedontop ofthe dashboard, on the driver's side where the
number can be seen through the windshield, The 10thcharacter is the modelyear code. The
letters
I. 0, Q and U arenot usedfor modelyear designation. Examples: X for 1999, Y for 2000,
1 for 2001,2 for 2002, etc. Thetable below explains some of the codes inthe VIN for 1997
through 2002 BMW
E39 5 Series BMWscovered by this manual.
Sample
VIN: ~~Iz~o~w~B~w~ 13 8 9 1
lposition 1 2 3 zi 5 6 7 8 9 10 11 12-17
VIN
position Description Decodinginformation
1-3 Countrv of WBA B
I J 1 znan~+q ;BT BMW Molorsporl.Gmon,~;nchGerrn;!n,
Linc 525 (2UU1 - 2003) 528 (2000-2003. 530; 540 i
5
1
Manual beltswith dual airbags
Manualbeltswith advancedairbaos
Series
Body type
i
engine lype
. ..
D 5251(2001 - 2002),528i (1997 - 2000)
E MS. 530i,540i (1997 - 1998)
J 5251Wagon
M 528i (1999
- 2000)
N 5401Sedan (1999 - 2003)540i wagon (2001)
P 528i wagon (1999
- 2000)
R 540i waaon 12002 - 20031
6,4 Aulomatic
5,3 Manual
Vehicle type 3.4.7 Passenger vehicle
Checlr digit
Model year
Restraintsystem
1 0 Manualbelts
3 Manual belts wilh driver
& passengerairbags
4 Manualbeltswith advanced passenger
B driver airbags
0 - 9or X, calculatedby NHTSA
V 1997
W 1RRR
Assembly plant A, F, K Munich,Germany
B,C,
D, G Dingolfing.Germany
E, J. P Reqensburq. Germany
.
Serialnumber Sequentialproduclion number lorspecificvehicle

01 0-1
010 General
General ........................... .010.2
Howto Use this Manual ............ .010.2
Warnings. cautions and notes ........... .0l0.3
Getting Started .................... .0i0.5
Safety ............................. .O10.5
Lifting the car ........................ .O10.5
Raisingcar ......................... .O10.5
Working undercar .................... .O10.6
Advice for the Beginner ............ .O10.7
Planningahead ...................... .O10.7
Workshop practices ................... .O10.7
Non-reusablefasteners ................ .O10.7
Tightening fasteners .................. .O10.8
Gaskets and seals .................... .O10.9
Electricaltesting .................... .O10.10
Wire repairs ........................ .O10.10
Buying Parts ..................... .010.11
Genuine BMW parts ................. .O10.11
Non-returnableparts ................. .O10.11
Informationyou needto know .......... .0l0.12
Service ........................... 010-13
TOOIS ............................. 010-13
Basic tool requirements ............... 010-1 4
Jack stands ......................... 01 0-16
Oil change equipment ................. 010-16
Torque wrench ...................... 010-17
Digitalmultimeter .................... 010-17
BMW specialtools ................... 010-18
Emergencies ...................... 010-18
Changing a tire ...................... 010-18
Jump starting ....................... 010-19
Indicatorand warning lights ............ 010-19
Towing ............................ 010-20
Spare parts kit ...................... 010-21

010-2
General
Thissection is intended to help the do-it-yourselfer get start-
ed.Tipson workshoppractices, basic tools,and aquick refer-
ence guide toemergencies can be found here.
WARNING-
Do not use this manual unlessyou are familiar with basic
automotiverepairprocedures and safe workshop
practices.
0 Thismanual illustrates the worl<shopprocedures re-
quiredformostservice work;it isnota substitute for full
and up-to-date information from the vehicle manufac-
turer or forproper 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
toprovide cautionsastoall of thepossible hazards that
may result.
MOW TO USE THIS MANUAL
WARNING -
Your commonsenseandgoodjudgementarecrucialtosafe
andsuccessful service work. Readprocedures throughbe-
forestarting them. Thinkabout whethertheconditionofyour
cac your level of mechanicalskill, or pour level of reading
comprehensionmight result in or contributein some way to
anoccurrencethatmight causeyou injury,damageyourcar;
or result in an unsafe repair. Ifyou have doubtsfor theseor
otherreasons aboutyour ability toperform safe repair work
onyour car; have theworkdoneatanauthorized
BMW deal-
er or other qualifiedshop.
Themanual is divided intoten 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

General
0 GENERAL,MAINTENANCEcoversgeneralvehicle infor-
mation
(010 General) as well as the recommendedmainte-
nanceschedulesand service proceduresto performBMW
scheduledmaintenancework
(020 Maintenance).
The nextseven sections
(1 through 7) are repairbasedand
organizedbythree digit repairgroups. Mostmajorsections
beginwith a GENERALrepairgroup, e.g.
100 Engine-Gen-
eral.These "00 (doublezero)groupscontaindescriptivethe-
oryof operationandsystemtroubleshootinginformation.The
remainderof the repairgroupswithina section containthe
serviceand repair information.The lasttwo sectionscontain
detailedelectricalwiringschematicsandOBDIIscantooland
diagnostic information.
Warnings,cautions and notes
Throughoutthis manualare many passageswith the head-
ingsWARNING, CAUTION,or NOTE.Thesevery important
headingshavedifferentmeanings.
WARNING-
The text underthis headingwarns ofunsafepracticesthat
areverylikelyto causeinjury, eitherbydirectthreatto theper-
son(~)performingtheworkorbyincreasedrisl(ofaccidentor
mechanicalfailure while drivinq.
CAUTION-
A CAUTIONcallsattentionto importantprecautionstobeob-
senfedduringthe repairwork that willhelppreventacciden-
tally damagingthecaroritsparts.
NOTE-
A NOTEcontainshelpfulinformation,tips that willhelpindo-
inga betterjobandcompletingitmore easily.
PleasereadeveryWARNING,CAUTION,AND NOTEin
001
GeneralWarningsandCautionsand asthey appear inre-
pairprocedures.They arevery important. Readthem before
you beginany maintenanceor repairjob.

.
General
WARNING-
Never run the enginein tile workareaunlessitis well-ven-
tilated. Theexhaustshould be vented to the outside. Car-
bonmonoxide (CO)in exhaust kills.
Remove all neckties, scarfs, loose clothing, orjewelry
when working near a running engine or power tools.
Tuck in shirts. Tielong hair and secure it under a cap.
Severeinjury canresult from thesethingsbeing caugiit
in rotating parts.
Removerings, watches,and bracelets.Aside from the
dangers of moving parts, metallicjewelry conducts
electricity and may cause shorts, sparks, burns, or
damage totheelectricalsystem whenaccidentally con-
tacting thebattery or other electrical terminals.
Disconnect the battery negative
(-) cable whenever
working on or near the fuel system or anything that is
electrically powered. Accidental electrical contact may
damage the electrical system or cause a fire.
Fuelishighly flammable.Whenworkingaround fuel,do
not smoke or work near heaters or other fire hazards.
Keep an approved fire extinguisherhandy.
Thefuel system is designed to retain pressure even
whentheignition is off Whenworlcing withthefuelsys-
tem, loosen the fuel lines slowly to allow the residual
pressure to dissipate gradually. Takeprecautions to
avoid spraying fuel.
. Illuminate the worlcarea adequately and safely Use a
portable safety light for worlcinginside orunder thecar.
A fluorescent typelight is best because it gives off less
heat. If using a light witha normal incandescent bulb,
use rough service bulbs to avoidbreakage. Thehot
fil-
ament of an accidentally broken bulb can ignite spilled
fuel or oil.
Keep sparks, lighted matches,and any open flame
away from thetopof thebattery. Hydrogen gas emitted
by the battery is highly flammable.Any nearby source
of ignition may cause the battery to explode.
Never lay tools orparts in the engine compartment or
on topof thebattery.Theymay fallintoconfinedspaces
andbe difficult to retrieve,become caught in belts or
other rotating parts when the engine is started, or
cause electrical shorts and damage to the electrical
system.

General
Muchof thenecessarymaintenanceand minorrepairthat an
automobilewill needcanbedonewith ordinarytools. Below
you'llfind importantinformationon howto work safely,adis-
cussionof whattools will be neededand how to usethem.
Safety
Although an automobilepresentsmany hazards, common
sense andgood equipmentcan helpensuresafety. Manyac-
cidents happen becauseof carelessness.Payattention and
stickto the safety rulesinthis manual.
Lifting the car
4 The properjacking points should be used to raise the car
safely and avoiddamage. The jack suppliedwith the car can
only be used at the four side points (arrows)just behindthe
front wheels orjust infront of the rear wheels.
WARNING-
. Neverwork undera liftedcarunlessitissolidlysupported
on
jack stands thatareintendedfor thatpurpose.
When raising the carusinga floorjackorhydrauliclift,
carefullypositionthejackpadtopreventdamagingthe
carbody.
* Watch thejack closely. Malesure itstays stable and
does notshift ortilt.
As the carisraised, itmayroll
sliahtlv andthe jack mavshift.
Raising car
-
Park car on flat, levelsurface.
-
If changing a tire, loosen lugbolts beforeraisingcar. See
Changing
a tire.
Placejack into position. Maltesure jack is restingon flat, sol-
idsurface. Usea boardor other supportto provideafirm sur-
face for jack, itnecessary.
-
Raise car slowly while constantlycheckingpositionofjack
and car.
-
Once car is raised,bloclc wheelthat is oppositeand farthest
from jack to prevent car from unexpectedly rolling.

(General
WARNING-
Do not rely on the transmission or the parking brake to
keepthecarfromrolling. Theyarenot
a substituteforpos-
itivelybloclcing theopposite wheel.
Never work underacar thatissupportedonlyby ajaclc.
Usejack stands designed to support the car. See
Tools.
Working under car
-
Disconnectnegative (-) cablefrom battery so that car cannot
be started. Let others know whatyou will be doing.
CAUTION--
Prior todisconnecting thebattery, read the battery discon-
nection cautionsgiven in
001 General Cautions and
Warnings.
-
Raise car slowly as described above.
-
Use at least twojack stands to support car. Usejack stands
designed for the purpose of supporting a car. See Tools.
WARNING-
* A jaclc is a temporaryliftingdeviceandshouldnot be used
alone tosupport the car whileyou are under it.
Do not use wood,concreteblocks, orbricks to support
a ca,: Woodmay split Blocksandbricks, whilestrong,
arenot designed for thatkind of load, andmay breakor
-
Place jaclc stands on firm,solid surface. If necessary,use a
flat board or similar solid object to provide a firm footing.
-
Lower car slowly until its weight is fully supported by jack
stands.Watchto make sure that thejack stands do not tip or
lean as the car settles on them.
-
Observe all jacking precautions again when raising car to re-
move jack stands.

General
ADVICE FOR THE BEGINNER
Thetips that follow are generaladviceto helpthe do-it-your-
self BMWownerperiorm repairsand maintenancetaslts
moreeasily and moreprofessionally.
Planning ahead
Knowwhat the wholejob requiresbeforestarting. Readthe
procedurethoroughly,frombeginningto end, inordertoknow
just what to expectandwhat partswill haveto be replaced.
Workshop practices
Keepingthings organized,neat,andclean isessentialto do-
ingagoodjob. Whenworkingunderthehood,iendercovers
willprotectthefinishfrom scratchesandotherdamage.Make
surethe carfinish isclean so that dirtunderthe coverdoes
notscratchtheiinish.
Any repairjob will be lesstroublesomeifthe partsareclean
Forcleaningold parts,there are manysolventsand parts
cleanerscommerciallyavailable.
Forcleaningparts priorto assembly, commerciallyavailable
aerosolcans of partscleaneror brakecleanerare handyto
use, andthe cleanerwill evaporatecompletely.
WARNING-
Mostsolvents usedforcleaningpartsarehighlyflammable
aswellastoxic, especiallyinaerosolform. Use withextreme
care. Donotsmoke. Donotusetheseproductsindoorsor
nearanysourceofheat, sparksorflame.
Non reusable fasteners
Manyfastenersusedon thecars coveredbythis manual
must be replacedwith newonesoncethey are removed.
These includebutarenotlimitedto: bolts,nuts(self-locking,
nylock,etc.), rollpins,clips andwashers. GenuineBMW
partsshouldbethe only replacementparts usedfor this pur-
pose.
Someboltsare designedto stretchduringassemblyand are
permanentlyaltered,renderingthem unreliableonce re-
moved.Theseare knownas torque-to-yieldfasteners. Al-
ways replacefastenerswhereinstructedtodoso. Failureto
replacethesefastenerscouldcause personalinjuryorvehi-
cle damage. Seean authorizedBMW dealerfor applications
and orderinginformation.

General
Tightening fasteners
Whentighteningtheboltsornuts onacomponent,itisalways
goodpracticeto tightenthe boltsgraduallyand evenly to
avoidmisalignmentor over-stressingany one portionofthe
component. Forcomponentssealed with gaskets, this meth-
od helpsto ensurethat the gasket will seal properly.
WARNING
-
Table a: Generalbolttighteningtorques in Nm(max.
permissible)is
a generalreferenceonly Thevalueslistedin
thetable are notintendedto beusedasa substitutefor tor-
quesspecificallycalledoutinthe textorinmanufacturer'sin-
formation.
4 Where there are severalfasteners, tighten them ina se-
NOTE-
* Metric boltclassesorgradesarernarlcedonthe bolthead.
* Donotconfuse wrenchsize withboltdiameter.Foralisting
ofthe common wrenches usedon various bolt diameters,
see Basictoolrequirements.
2
BOO~FNG
quence alternating betweenopposite sides of the compo-
nent. Repeatthe sequence until all the bolts are evenly
tightened to the proper specification.
Forsomerepairsaspecifictighteningsequence isneces-
sary,or particularorderof assemblyisrequired. Suchspecial
conditionsarenotedinthetext,andthe necessarysequence
isdescribedor illustrated.Where nospecifictorque is listed,
Table
a: General bolttighteningtorquesinNm(max. per-
missible)can beusedas a generalguidefor tighteningfas-
teners.

General
Table a. Generalbolttighteningtorques inNm
(max. permissible)
BoltClass (accordingto DIN
267)
Gaskets and seals
Gasket aredesignedto crush and becomethinner asthe mat-
ingpartsareboltedtogether. Onceagasket hasbeenused,it
is nolongercapable;f malting as good a seal as when new,
andis muchmore likely to leak. Forthisreason, gaskets
should not be reused.
Somegaskets andsealsared~rectional.Makesurethatthese
are ~nstalledcorrectly. Inplaceswhere ashaft must pass
through a housing,flex~blelipseals are usedto keepthe lubri-
cating
011 or grease from leaking out pastthe rotatlngshaft.
Sealsshould never bereusedoncethey havebeenremoved.
When rernovlnga seal, becareful not to damage the metal
surfaces.
Thelteytoseal installation istogetthesealinstraight without
damaging it. Useaseal driver that isthe same diameter as
the seal housingto gently andevenly install into place. Ifa
proper size seal driver isnot available, asocket of the right
size will do.
Someseals are directional and special installation instruc-
tions apply. Makesureaseal isinstalledwiththe lipfacingthe
correct way. Notethe installation direction of the old seal be-
fore removing it.

010-10
General
Electrical testing
Many electrical problems can be understoodandsolved with
only a littlefundamental knowledge of howelectricalcircuits
function.
Electricalcurrent onlyflows ina complete circuit.Tooperate.
every electrical device inthe car requires a complete circuit
includinga voltage sourceand apathto ground. The positive
(+) side of thebattery isthe original voltage source, and
groundisany return pathtothe negative
(-) sideof the bat-
tery, whether through thewiring harness or the car body. Ex-
cept for portions of the charging system, all electrical current
inthe car is direct current (DC) andflows from positive
(+) to
negative
(-).
4 Switches are usedto turn components on or off by complet-
ing or interrupting the circuit.
A switch is "open" when the cir-
cuit isinterrupted, and"closed"whenthecircuit iscompleted.
See
600 ElectricalSystem-General for electrical trouble-
(LW, 1 shooting
Wire repairs
Light bulb
(consumer)
' -
Repairstoa wiring harness require special careto makethe
repair permanent. Thewire ends must beclean. iffrayed or
Car body
otherwise damaged, cut off theendandremoveenoughinsu-
(ground) i
Battery
lationto complete the repair.ifthewire istooshort, spliceina
BOZLiEL
new pieceof wire of the same size and maketwo connec-
tions.
Useconnectors that are designed for the purpose. Crimped
onorsoldered-onconnectorsarebest.Crimpconnectorsand
special crimpingpliersare widely available. Ifsoldering, use
needlenose pliersto holdthewire nearthesolderjoint and
create a "heat dam". This keepsthe heat andthe solder from
traveling upthewire. Always usea solder made specifically
for electrical work (rosin core).
NOJE-
Twistingwires together to make a repairisnotrecommend-
ed. Corrosionandvibration will eventually spoilthe connec-
tion andmayleadto irreparable damage to sensitive
electronic components.
Insulatethe finished connection. Electronics stores can sup-
ply heat-shrinkable insulatingtubingthat can beplaced onto
the wire beforeconnecting, slid over the finishedjoint, and
shrunicto atight fit with a heatgun or hairdryer.Thenextbest
alternative iselectrical tape. Makesure thewire is cleanand
freeof solder flux or othercontamination. Wrap thejoint tight-
lytoseal out moisture. See
600 ElectricalSystem-General
for moreinformation.