Downloaded from www.Manualslib.com manuals search engine
--
Benllcy Publishers, a division ol Robcrt Bcnlley, In=. 1734 M~SB~CIIUP~IIS Avenue Cumbitdge. MA02138 USA Information lhat makes 800-423-4885 / 61 7.547.4170 the diiierence"
BentleyPublishe~
Technical contact inlormation I
We :.€ c3me ,o.lr leeooaca. Pieasc. ;Jam 1 cllriecl 00s an0 zoo ions lo our BhFLt/ recnns? o rcdss'un lor~m a1 http://~~~.BentleyPublishere.com
Errata information
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 information for 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
Do not use this manual unless vou are familiar with basic automotive reoair orocedures and safe
workshoo oracfices. This manual illustrates
the workshop procedures requked formoslservice work. It is not a subsiituti for full and up-to-date information from thevehiclemanufaciurer
or for proper training as an automotive technician. Note that it is not possible for us 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.
The vehicle manufacturer will continue to issue service information updates and parls retrofits
after the editorial closing of this manual. Some
of lhese updates and retrofits will apply lo procedures and specifications in this manual. We regret that we cannot supply updates to
purchasers of this manual.
We have endeavored to ensure the accuracy
of the information in this manual. Please note, however, that considering the vast quantity and
the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information contained in this
manual.
FOR
THESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAICES ANY WARRANTIES, EXPRESS OR IMPLIED, THATTHE INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS. AND WE EXPRESSLY DISCLAIM THE IMPLIED WARRANTIES OF MERCHANTABILTTY AN0 OF FITNESS FOR A PARTICULAR PURPOSE, EVEN IFTHE PUBLISHER OR AUTHOR HAVE BEEN ADVISED 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 CONSEQUENTIAL DAMAGES THAT RESULT FROM ANY USE OFTHE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION INTHIS BOOK. IN NO EVENT 1
I Your common sense and oood iudoment are crucial to safe and successful service work. Read orocedures throuoh before startino them. I . -- - -~ ~ ---~. - ~ ~~ Think about whether the condition of your car, &r level of mechanical skill, or your level of reading compreh&sion might resill in or
contribute in some way to an occurrence which might cause you injuly, damage your car, or result in an unsafe repair. If you have doubts
for these or other reasons about your ability to pelform safe repair work on your car, have the work done at an authorized BMW dealer or
other qualified shop.
Part numbers listed in this manual are for identification purposes only, not for ordering. Always check wilh your authorized BMW dealer to
verify part numbers and availability before beginning service work lhat may require new
park.
Before anempting any work on your BMW, read the 001 General Warnings and Cautions, and any WARNING or CAUTION that
accompanies a procedure in the service manual. Review the WARNINGS and CAUTIONS each time you prepare to work on your BMW.
I Spec a too s req.1 red to perlorm cena n service operations arc oenl fed n the manLa an0 arc recomrnenoeo lor JSC Jse ol loo s olner than those recommended In lh s serv ce manual may be oelnmcnlal lo lrlc car's sale open1 on as rvec as lne salely 01 lne person servcng I the car. I
Copies of this manual may be purchased from most automotive accessories and 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 procedures described 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
~Acludes index.
ISBN 0-8376-0317-X (obi<) ,, , 1. BMW 5 series automobiles--Maintenance and repair--Handbooks manuals, etc. 1.
Robert Bentley, Inc.
TL215.8258623 2003 629.28'722--dc23 2003052231
Bentley Stock No. 8502
Editorial closing 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 Printed Library Materials. @
OCopyright 2007 Robert Bentley. Inc. Bentiey Publishers is a trademark of Robert Bentley, Inc.
All rights reserved. All information contained in this manual is based on the information available to the publisher at 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
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
ofhenvise, without the
prior written consent of the publisher. This includes text, figures, and tables. All rights reserved under Berne and Pan-American Copyright
conventions.
Cover photos of car exteriors by Jonathan Richard for
Bentley Publishers @ Robert Bentley, Inc. Cover design and use of blue band on
spine and back cover are trademarks
of Bentley Publishers. All rights reserved.
Manufactured in the United States of America
Downloaded from www.Manualslib.com manuals search engine
Selected Boolcs and Repair Information from Bentley Publishers
MINI Cooper
MINI Cooper Service Manual: 2002-2004 Bc,illc!! Pirl~lisl!~~ ISBN 0-8376-1068-0 AlexZanardi - My Swectest Victory rllex Zmmrdi itjill! Ginrz11,cn Gns~x~ri,,i ISBN (1-8376-1249-7
BMW 3 Series IE36) Scrvire Manual: 1992-1998,318ilisliC. 323is/iC, 3?5i/is/iC, 328ilisliC, M3 Be~iili.!~ Pirl?lisliers ISBN 0-8376-0326-9
BMW
5 Series Scrvicc Manual: 1997-2002 525i, 528i. 530i. 540i, Sedan, Sport Wagon Bcrrlluy P~rlilishens ISBN 0-8376-0317-X
Porsclze Tl~c Unfair Advantage hlirrk Do,~ult,re ISBN 0-8376-0073-Iilrcj; Porsche: Excellcncc Was Expected I
Porschc 911 Enthusiast's CompanionT3' Aiirinri Slr~,tzlli~~r ISBN 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 French I
Bosch 1-landbook for Automotive Elcctrics and Elcchonics Rillrcr I Bwcli, GrjilrH ISBN 0-8376-1050-8
Bosch Handbook for Diesel-Engine Managcmcnt Ril1iei.t Bosdl, ClrrbH ISBN 0-8376-1051-6
Bosch Handbook for
Gasolinc-Engine Management Robcrf Bosclr, G~ribH ISBN 0-8376-1052-4
'7
Battle for lhe Bcelle I
Jells, Golf, GTI Scrvicc Manual: 1999-2005 1.8L lurbo, 1.9LTDI diesel, PD dicscl, 2.0L ga5aline. 2.81 VRG B~.!iIlcy Pt,blislicrs ISBN 0-8376-125-9
New Bcctle ServiceManual:1998-20021.8L turbo, 1.91 TDI diesel, 2.0L gasoline Bailicy P~irirlishers ISBN 0-8376-0376-5
New Bcctle 1998-2005, New Beetle Convcrtible2003-2005 Official Factory
Rcpair Manual an CD-ROM
I~olkiatgurr ~JAriicricn ISBN 9784-8376-1265-2
Boscll Fuel Injection and Enginc Management Clml-Its 0. Pmbsi, SAE ISBN 0-8376-0300-5 Clzevrolet
Corvctlc Illustralcd Encyclopedia Torn Beifurli ISBN 0-8376-0928-3
Racc Car Aerodynamics losupli Kntz ISBN 0-8376-014>8
Road &Track Illustrated Automotive
Dictionary
Joltri Dilrkl ISBN 0-8376-11143-6
Scientific Design of Exl~aust and Intake Systems I'lrililr H. S,sillr 0-8376-0309-9 Corvette Fuel
Injection &Electronic Enginc Managcment 1982-2001: Clmrlcs 0. I1rol,sl, SAE ISBN 0-8376-0861-9
I'acrat Ser\,irc hl.>nu.~l: 1998-2004.1.81. lurbu, 2.RL Vb, .l.IIL \\'8, inrludinl: tv.~gc>n and 4blOTION Giiitlc!/ P~iiblislicrs ISBN 0-8376-0360-2 Zora Arkus-Duntov:Thc Lcgcnd Behind corvt.ttc Je1.q Birl-1011 ISBN 0-8376-0858-9
Ci~evmlcl by the Numbers 1965-1969: The
Essential Chcvrolct Paris Refcrcncc illn,i Cnl2i11 ISBN 0-8376-0956-9
Passat. Passat Waron 1998-2005 Official
Gnlf,
GTI, Jctta 1993-1999, Cabrio 199% 2002 Official Factory Repair Manual on
CD-ROM
Volhsiraigu>t oJA,rtrricn ISBN 978-0-8376-1263-8
Jetta, Golf, GTI: 1993-1999,
Cabtio: 1995- 2002 Scrvicc Manual ll~iillcy I'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~'~' 1'1~1 Bmrlul! 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
Tbc Official Ford Mustang 5.0 Technical
Reference & I'crformancc Handbook:
1979-1993
A1 l
1998-2004, Avant 1999- 2004, allroad quallro 2001-2005, 56 Avant 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~l ISBN 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 autornohilcboolissinrc 1950. Plcasc write to us at 1734 Mniincliusctts Ave..Cnmbridge, kIA02138,i~isit ourivcb sitc, ol-c,lll 1-800-12345'15 ini a free copy ofnurcolaiog.
BMW
BMW 23 Sarvicc Manual: 1996-2002. including 23 Roadster, 23 Coupe, M
Roadster, M Coupe
Be~illq Pi,blislicis ISBN 0-8376-1250-0
BMW 3 Scrics (Ed61 Scrvicc 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~lriisiieis ISBN 11-8376-0230-(1
Urlilii-!~ P~~Blisi~~rs ISBN 11-8376-11772
Downloaded from www.Manualslib.com manuals search engine
120-7
Ignition System
Spark plug electrode gap /Too small /TOO big
Table
b. Ignition secondary voltage diagnostics
Secondary
voltage low
Fuel air mixture
I I Too lean
Secondary
voltage high
Spark plug electrode
Worniburnt
4 The illustration shows normal scope trace of spark at idle.
1. Start of ignition voltage peak
2 Level of ignition voltage
3. Level of combustion voltage
4. Period of combustion
5. Combustion curve characteristics
6. Start of decay process
7. Termination oscillations
Spark plug electrode
temperature
Engine compression
Spark plug wires
4 Short combustion period (indicates large spark plug gap).
Too
high
Too
low
I"" 9, 10 I" to I!, r) i" 21 10 il bW,rn?7G
Too low
Too high
Faulty
4 Ignition spark at idle speed.
A - Normal ignition voltage peak (spark plug is good).
B - Low voltage peak is an indication of a closed plug gap.
C
- High voltage peak indicates an open plug gap.
< Long combustion period (indicates small spark plug gap).
~i,+i!,~,i~tiii~iit~~,t1!lc,',l~~4~l~,~,l,~+~{+',,l 1W W Sl ,@ 10 :o 9 20 21 10 0
Downloaded from www.Manualslib.com manuals search engine
I lgnition System
4 Normal combustion period at idle.
4 Normal oscilloscope pattern for ignition system at idle.
15. 15
4 lgnition voltage peaks at idle.
1. Normal ignition peaks.
2. Downward peak (arrow) is shortened (ignition coil is
defective).
3. Downward peak (arrow) is missing completely (ignition
coil is defective).
4 Defective ignition coil.
1. Short spark period.
2. The spark voltage line (arrow) is very slight
< Defective ignition coil.
1. Normal combustion period.
2. Absence of spark voltage line (arrow).
(r+~+~+~(.~i+~/.~~itlt~~(tit~lii~~jt~~~i~ittiii~l IW 10 ED 10 (0 ID U 10 11 70 0 sa,ma,
2 . 15 - .
5 - - - 0
30
.
.
20 .
I0 - -
0
iiiCi;kiW*huiMwiritil~tiii 110 10 00 ro w M A, 30 2" *:,:mu
Downloaded from www.Manualslib.com manuals search engine
Fuel Injection
4 Remove electrical harness connector (arrow) from IAT sen-
sor.
CAUTION-
Be sure the ignition switch is in the off position before repiac-
ins the intake temperature sensor.
- Depress loclting clip on side of temperature sensor and pull
straight out of intake manifold.
- Installation is reverse of removal
- Use a new sealing O-ring at base of sensor and lubricate with
assembly lubricant for
ease of installation
MS 42.0 throttle valve assembly, replacing
< The motor driven throttle valve for the MS 42.0 system is re-
- ferred to as MDK (motor driven throttle valve). The MDK unit
is electronically operated to regulate intake air flow by the
ECM.
The
MS 42.0 system uses a throttle cable from the accelera-
tor pedal to the MDK unit. The throttle cable is connected di-
rectly to the integral pedal position sensor
(PWG) in the MDK
unit. This sensor communicates pedal position to the ECM,
which in turn electronically regulates throttle plate position.
The MDK pulley is linked to the throttle shaft by springs to al-
low ASC intervention to override the driver's pedal position.
NO TE -
The MDIC unit is non-adjustable and must be replaced as
a complete unit if found to be faulty.
if replacing the
MDK unit, the adaptation values stored in
the ECM must be clearedand the new unit initialized using
BMW special service tools.
CAUTION-
If the adaptation process is not completed correct& the en-
gine wiii
not start.
- Disconnect battery negative (-) cable in luggage compart-
ment.
CAUTION-
Prior to disconnecting the battern read the battely discon-
nection cautions in
001 General Warnings and Cautions.
Downloaded from www.Manualslib.com manuals search engine
31 0-2
I Front Suspension
This repair group covers the repair and replacement of com-
ponents that make up the front suspension of E39 cars.
Two different types of steering systems are used in the E39
series. 6-cylinder
(5251,5281 and 530i) models are equipped
with a rack and pinion type steering system mounted to an
aluminum subframe.
V-8 (540i) models use a steering gear-
box type system mounted to a steel subframe.
See
300 Suspension, Steering and Brakes-General for a
description of the front suspension and components, as well
as specifications for setting ride height.
CAUTION-
Some E39 models are equipped with aluminum suspen-
sion components. The foiiowing cautions apply:
Due to the chemical and corrosion characteristics of
aluminum, do not bring into contact with battery acid.
* Do not clean with wire brushes with brass or iron bris-
ties. Only use brushes with stainless steei bristles.
Do not expose to flying sparks from grinding/cutting op-
erations.
* Do not subject to steei welding splashes.
Do not expose to temperatures over 80°C (176°F).
even for short periods. Temperatures in painting faciii-
ties are not a problem.
Special tools
Special service tools are required for most of the work de-
scribed in this repair group. In addition to the tools depicted in
the illustrations, avariety of press tools are necessaryfor con-
trol arm bushing replacement. Read the procedures through
before beginning any job.
31 2 210 I < Strut nut socket
(Tool No. 31 2 210)
Downloaded from www.Manualslib.com manuals search engine
51 2-2
I Door Windows 1
This repair group covers door glass, window regulator and
power window motor repair information.
CA U JIO&
All E39 models are equipped with side-impact airbags in the
front doors. Some models are also equipped with
airbags in
the rear doors. Be sure to read the
airbag warnings and cau-
tions in 721
Airbag System (SRS).
Electric window switch replacement is covered in 612
Switches.
The windshield, rear window, fixed rear doorglass, and cargo
compartment glass (Sport Wagon only) are bonded using
special adhesives and tools. It is recommended that bonded
glass replacement be done by an authorized
BMW service fa-
cility or an automotive glass installer.
Special tools
Some window repair operations require special tools.
Power windows
- Power window features in E39 models include:
Control of the front and rear door window motors is carried
out directly by the General Module (GM
Ill).
One-touch operation in both directions on all four windows.
Cable type window regulator used for all door windows.
. Anti-trap protection provided by pressure sensitive finger
guard.
Right front and each rear door has a single window switch
located in door handle trim.
Rear door window switches can be deactivated by press-
ing child lock-out switch in the driver's window switch block.
Convenience closinglopening of the windows from driver's
loci( cylinder or convenience opening only from remote un-
lociting feature (FZV) remote key.
Window (FZV) operation can be owner customized with
Car Memory function. See 515 Central Locking and Anti-
Theft.
After ignition is switched off, electric windows can be oper-
ated until a door is opened or until
I6 minutes has elapsed.
The GM
IiI bases window motor end position on current
draw (load). There is a maximum window motor run time of
6 seconds. The motor is then switched off even if the end
position load sensor fails.
Downloaded from www.Manualslib.com manuals search engine
51 2-4
I Door Windows
/ Anti-trap strip
Power window motors
The window motors are mounted on cable regulators. The
window motor control circuit consists of two wires for operat-
ing the motor in both directions.
The motors are activated by relays in the GM
Ill. The relays
provide either power or ground depending on the direction of
window travel. The GM
Ill controls the polarity based on a re-
quest to run the window from a window switch or a conve-
nience
openinglclosing signal.
Convenience openinglclosing
The GM Iii provides the convenience openlclose feature, pro-
viding control of the power windows (and sunroof) from out-
side the vehicle with the key in the driver's door lock. The FZV
(remote key) provides the same function for window opening
only.
Anti-trap protection is active during convenience closing from
the driver's door lock.
If the GM receives a request to operate convenience closing
or opening for more than
110 seconds, the function is deacti-
vated and a
fault code is stored.
Window anti-trap protection
4 A rubber pressure guard is located at the top edge of each
door frame. It consists of two contact strips that close when
subjected to pressure. When the contact strip closes (for ex-
ample, a hand is trapped between the top of the window and
the door frame), an anti-trap signal is sent to the GM
Ill. The
window immediately (within
10 milliseconds) reverses direc-
tion. This feature does not require
initialization.
The E39 pressure sensor finger guard has a resistance of 3
Kw and it is monitored for open circuits. When pressed, the
monitored resistance changes to
< 1 Kw. if anti-trap protection
becomes faulty the one touch window closing will not func-
tion.
Window anti-trap protection is
only active in the one touch
and convenience close modes of operation. If the window
switch is pulled and held, anti-trap protection will not function.
The anti-trap contact strip has a resistance of
1.2 K Ohm and
it is monitored for open circuits. Faults with the anti-trap sys-
tem will cancel the one touch feature requiring the window
switch be held to close the window.