1999 BMW 525i Remove starter

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Camshaft Timing chain1
Timing chains, removing
(M52 TU and M54 engines)
Camshaft timing chain removal requires that the oil pan be re-
moved. See
119 Lubrication System. Also required is re-
moval of the VANOS control
unit and disassembly of the
intake and exhaust camshaft sprocket assemblies as de-
scribed earlier in this repair group.
Special BMW
service tools are needed for timing chain re-
moval and installation. The special tools assure proper timing
of the valvetrain. Precise
marlts to set the timing on the cam:
shafts are not provided for reassembly. Read the procedures
through before beginning the job.
CA
UTION-
If the camshafts are not properly timed, the pistons can con-
tact the valves.
- D~sconnect negative (-) cable from battery.
CAUTION-
* Disconnecting the battery may erase fault code@) stored in
control module memory. Check for fault codes using spe-
cial
BMW diagnostic equipment.
Prior to disconnecting the battery, read the battery dis-
connection
cautfons given in 001 General Cautions
and
Warninqs.
- Remove VANOS control unit. See VANOS control unit, re-
moving
(M52 TU and M54 engines).
Remove sealing plug from crankcase below starter and se-
cure crankshaft with
BMW special tool ll 2 300.
Drain engine cooling system. See 170 Radiator and Cool-
ing System.
Remove belt driven cooling fan, fan shroud, and thermostat
housing. See
170 Radiator and Cooling System.
Remove drive belts. See
020 Maintenance.
NOTE-
Mark direction of belt rotation if reusing belt.
- Remove water pump pulley fasteners and pulley.
- Drain engine oil and remove oil pan as described in 119
Lubrication System.

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I Camshaft Timins Chain
4 Using special tool 11 2 450, rotate engine clocltwise to TDC
with number one cylinder cam lobes facing each other (ar-
rows)
as shown.
4 Lock crankshaft in TDC position with BMW special tool 11 3
200 (arrow).
- Remove BMW special tool 11 2 450 and remove hub.
- Remove upper engine oil pan. See 119 Lubrication.
- Remove alternator. See 121 Battery, Starter, Alternator.
- Remove retaining bolt for oil dipstick tube from upper timing
chain cover on right side.
- Remove camshaft position sensor from right upper timing
chain cover.
< Remove right upper timing chain cover:
Remove chain tensioner
(A).
CAUTIOG
Tensioner is under spring tension. Release slowly. 1
Release fasteners (arrows) and remove cover

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120-1 2
ignition System
Crankshaftspeedsensor
Crankshaft speed sensor, replacing (M52, M52 TU and
M54 engines)
4 Crankshaft speed sensor for 6-cylinder engine is mounted in
the left rear side of the cylinder block below the starter (ar-
row). The sensor reads a toothed pulse wheel mounted to
the end of the crankshaft.
- if the Engine Control Module (ECM) does not receive a signal
from the crankshaft speed sensor during cranking, the en-
gine will not start.
- If the OBD II svstem misfire detection ~rotocol detects a cat- - - ~~
alysr oarnagin; faLlt oJe to a ma I-nclion in crandshafi speeo
sensor components. Ine Check Engine
lignr (Malfuncrion In-
dicator Light or MIL) will be illuminated.
NOTE-
If the crankshaft speed sensor pulse wheel is damaged, the
engine will have to be disassembled down to the crankshaft
to
reolace the wheel.
- Make certain ignition has been turned off.
- Raise car and support in a safe manner.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive lift orjacltstands designed for
the ouroose.
A floor iaclc is not adequate support.
- Remove under engine splash guard
4 Working underneath starter:
Cut off wire tie securing crankshaft speed sensor harness
connector (arrow) to sensor.
* Disconnect harness connector.
4 Remove sensor mounting fastener (arrow) and remove sen-
sor from cylinder block.
- Installation is reverse of removal, noting the following:
Use a new O-ring when installing sensor.
Be sure wiring is routed in same orientation.
Secure sensor using new wire ties.
Use scan tool to read out and clear ECM fault memory.

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Battery, Starter, Alternator
Warnings and cautions
WARNING -
Wear goggles, rubber gloves, and a rubber apron when
working around the battery or battery acid (electrolyte).
Battery acid contains sulfuric acid and can cause skin
irritation and burning.
If acid is spilled on your skin or
clothing, flush the area at once with large quantities of
water. If electrolyte gets into your eyes, flush them with
large quantities of clean water for several minutes and
call a physician.
Batteries that are being charged or are fully charged
give off explosive hydrogen gas. Keep sparks and open
flames away. Do not
smoke.
CA UTIOI\C
Only use a digital multimeter when testing automotive elec-
trical components.
. If a repair procedure specifies disconnecting the bat-
tery, follow the instruction for safety reasons.
Prior to disconnecting the battery, read the battery dis-
connection cautions in
001 General Cautions and
Warnings.
Models with MS43 engine management: Allow at least
3 minutes to elapse after turning ignition ley to OFFpo-
sition before disconnecting battery. This willallow sum-
cient tinie to complete the DMJL (fuel tank pressure)
test
* Disconnecting the battery cables may erase fault codes
stored in ECM memory.
Always disconnect the negative
(-) battery cable first
and reconnect it last. Cover the battery post with an in-
sulating material whenever the cable is removed.
Do not disconnect battery, alternator or starter wires
while the engine is running.
0 Never reverse the battery cables. Even a momentary
wrong connection can damage the alternator or other
electrical components.
Do not depend on the color of insulation to tell battery
positive and negative cables apart. Label cables before
removing.
The slide-tilt sunroof may fail to function properly
after
disconnecting and reconnecting the battery. Reinitial-
ize sunroof as described in 540 Sunroof.

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.
Battery, Starter, Alternator
Table b. Specific gravity of battery electrolyte at 27°C (80°F)
Specific gravity State of charge
1.265 Fully charged
1.225 75% charged
1.190 50% charged
1.155 25% charged
1.120 Fully discharged
if the specific gravity is at
orabove 1.225, butthe battery lacks
Dower for
startinq, determine the battew's service condition
with a load volta& test. if the average specific gravity of the
six cells is below 1.225, remove the battery from the luggage
compartment and recharge.
Battery open-circuit voltage test
Before testing, load battery with 15 amperes for one minute
with battery load-tester or turn on headlights for about one
minute without engine running. Connect digital voltmeter
across battery terminals. Open-circuit voltage levels are giv-
en in Table
c. Open-circuit voltage and battery charge.
If open-circuit voltage is
OK but battery still lacks power for
starting, perform a load voltage test.
If open-circuit voltage is
below 12.4 volts, recharge battery
and retest.
Table c. Open-circuit voltage and battery charge
Open-circuit voltage State of charge
12.6 V or more
12.4 V
12.2v
12.0 v
Fully charged
75% charged
50% charged
25% charged
11.7Vorless Fully discharged
Battery load voltage test
A battery load tester is required for a load voltage test. The
test is made by applying a high resistive load to the battery
terminals and then measuring battery voltage. The battery
should be
fully charged forthe most accurate results. The bat-
tery cables must be disconnected before
malting the test. Re-
place the battery if the voltage is below that listed in Table d.
Battery load test
- minimum voltage.

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Battery, Starter, ~lternatorl
WARNING-
Always wear protective goggles and clothing when perform-
ing a load test.
Table
d. Battery load test - minimum voltage
Ambient temperature Voltage*
27
" C (80" F) 9.6 V
-I 8' C (0"
F) 8.5 V
* Measure
after applying a 200 amp load for 15 seconds.
Closed-circuit current measurement
If the vehicle battery is discharged for an unknown reason,
perform a closed-circuit current measurement as the first test.
For diagnostic purposes, it is important to not disconnect the
battery. Disconnecting the battery may reset a faulty control
unit, preventing proper diagnosis.
The following test is generally completed overnight using a
multimeterwith a closed circuitcurrent measurement adaptor
with a recording function
- Check that battery voltage is 12 volts or higher. If lower,
recharge battery.
- Switch off electrical consumers (interior lights, telephone,
aftermarket equipment, or others).
- Open luggage compartment and remove battery trim panel.
Use screwdriver to lock latch on trunk lid or hatch, simulating
closed luggage compartment. Close other doors.
- Open driver's door, then close it, simulating driver entering
vehicle.
- Switch ignition to RUN position for at least five seconds, then
turn ignition to OFF position. This simulates driving vehicle.
- Open and close driver's door, simulating driver leaving
vehicle.
- Lock car and arm alarm.
- Wait at least 16 minutes for consumer cut-off.

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121-9
Battery, Starter, ~lternatorl
Battery charging
Discharged batteries can be recharged using a batterycharg-
er. Remove the battery from the trunk during charging.
Prolonged charging causes electrolyte evaporation to a level
that can damage the battery. It is best to use a low-current
charger
(6 amperes or less) to prevent battery damage
caused by overheating.
WARNING -
Hydrogen gas given off by the battery during charging is ex-
plosive. Do not smoke.
Keep open flames away from the top
ofthe batte~ and prevent electrical sparks by turning off the
battery charger before connecting or disconnecting it.
Battery electrolyte (sulfuric acid) can damage the car. If
electrolyte is spilled, clean the area with a solution
ofbak-
ing soda and water.
Always allow a frozen battery to thaw before attempting
to recharge it.
Always disconnect both battery cables and remove bat-
tery from vehicle during battery charging. Do not ex-
ceed
16.5 charging voltage at the battery
Battery safety terminal, replacing
If the battery safety terminal has been triggered, investigate
and correct the cause prior to replacement.
- Working in right side of luggage compartment, remove bat-
tery trim panel.
- Disconnect negative (-) battery terminal and cover with
insulator.
- Disconnect positive (+) cable from battery.
- Release positive (+) cable from cable brackets on luggage
compartment wall. Lay new repair cable parallel to positive
cable.
- Mark off length of new cable on old cable. Allow 10 cm
(2.5 in) of slack.
- Saw through old cable.
Do not use bolt cutters or similar tools to cut through cable.
A cable end that has been squashed
flat will not fit into the

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Battery, Starter, ~lternatorl
Charging system quick-check
Use a digital multimeter to measure voltage across the bat-
tery terminals with key off and then again with engine running.
Battery voltage should be about 12.6 volts with key off and be-
tween 13.5 and 14.5 volts with engine running.
NOTE-
The regulated voltage (engine running) should be between
13.2 and 14.5, depending on temperature andoperating con-
ditions.
If the voltage is higher than 14.8, the voltage regula-
tor or
mulitfunction controller is most likely faulty
Check for clean and tight battery cables. Check ground cable
running from negative
(-) battery terminal to chassis and
ground cable running from engine to chassis. Check alterna-
tor drive belt condition and tension.
Charging system, checking
CAUTIOI\C
* Do not disconnect the battery while the engine is running.
Damage to the alternator and/or engine electronic systems
may result.
Only use a digital multimeter when testing charging
system components.
--7
4 Turn ignition key on. Check that battery warning light comes
on.
NOTE-
If the warning light does not come on, repair bulb or wiring
faults before continuing to checlc the charging system.
/ Charge indicator
502820805
4 6-cylinder engines only, remove complete air filter housing:
Loosen
intake duct hose clamp (A) at throttle assembly.
Loosen clamp and remove idle control hose from intake
duct
(B) and disconnect idle speed control valve electrical
harness connector.
Disconnect electrical harness connector
(C) from mass air
flow sensor.
Remove air filter housing mounting screw
(D).
Disconnect vent tube (E).
Loosen air intake duct clamp (F).
Carefully lift air filter housing out of engine bay.