2001 BMW 525i Air sensor

Downloaded from www.Manualslib.com manuals search engine
Fuel Injection I
Connector X60004 (continued)
8 10
11
12
13
14
15
16
9
Output 0
Input
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
39
llnput lsignal l~oolant outlet temperature sensor
Output
Output
Ground
Input
Output
I I - I
40 /output Istart signal Istarter relay
Pedal position sensor (PWG), signal
Output Input
Output
input
Input
Input
Input
Input
Input
input
Input
Output
Input/-output
Input/-output
37
Connector X60003
Pedal position sensor
Fuel pump relay, activation
Oil pressure indicator Pedal position sensor (PWG), ground
Pedal position sensor (PWG), signal
Pedal position sensor (PWG), power supply
Not used
Not used Fuel
pump relay
Instrument cluster
Pedal position sensor
Pedal position sensor
Pedal position sensor
Engine speed signal output (TD)
Not used
Signal
back-up light
DM-TL (diagnostic module,
tank leakage)
Signal oil level sensor
Right rear wheel speed, signal
Clutch pedal position switch, signal
Brake light switch, signal
Not used
Voltage supply, terminal
15
Data link, MFL (multi-function steering wheel)
Brake light test signal
AJC compressor signal
DM-TL (diagnostic module, tank
leakage)
Not used
Diagnosis signal
TxD
Communication link (EWS)
Not used
Not used
CAN-BUS hiqh
38 1 Ground l~round I Coolant outlet temperature sensor
OED II plug
Integrated instrument cluster control module (IKE)
Light module
ABSIDSC control module
Clutch pedal position switch
Brake light switch
Fuse
F14
Airbag contact coil spring
Brake light switch
Heating and
A/C control module
OBD
II plug
Electronic immobilizer (EWS)
CAN-Bus link
CAN-Bus link
Input/-output CAN-Bus low

Downloaded from www.Manualslib.com manuals search engine
/ ~uel Tank and Fuel Pump
4 Remove tank sending unit:
Disconnect electrical harness connector.
Disconnect hose (arrow).
- Unscrew threaded collar from fuel level sender.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may
result if the special tool is not used.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CA UTIOW-
Do not bend fuel level sender arm.
4 Once level sensor unit has been lifted partially out of tank,
disconnect tank siphon hose by pressing tabs (arrows).
- Installation is reverse of removal
Attach tank siphon hose to sender unit firmly.
Use new sealing ring at tank collar.
. Be sure that fuel sender float points in same direction as
during removal.
- Reconnect harness connector.
Fill tank and
check for leaks by running engine.
CAUTION-
After finishing repairs but before starting engine, be sure
there is at least
5 liters (1.5gallons) of fuel in tan/(. The fuel
pump will be damaged if run without fuel.
Tightening
torque
Tank collar loclting rlng to tanlt 35 Nm (26 lb-ft) -

Downloaded from www.Manualslib.com manuals search engine
7 .- A Fuel Tank and Fuel Pump
Siphon pump, removing and installing
The fuel compensating siphon pump equalizes fuel level
between the two fuel tank lobes.
- Drain fuel tank as described later,
WARNING -
Fuel may be spilled. Do not smoke or work near heaters or
other fire hazards.
- Remove left and right fuel level sensors and fuel pump as
described earlier.
4 Once left side level sensor unit has been lifted partially out
of tank, disconnect tank siphon hose by pressing tabs
(arrows).
- The tank lobe siphon pump is held to baffle in bottom of right
tank lobe. Release retainer and lift out pump.
- Installation is reverse of removal.
Attach siphon pump to right side baffle.
Attach tank siphon hose to left sender unit firmly.
Use new sealing ring at tank collars
Be sure that fuel sender floats point in same direction as
during removal.
Reconnect harness connectors.
. Before starting engine, fill fuel tank with at least 5 liters
(1.5 gallons) of fuel.
Check for
leaks by running engine.
Afler finishing repairs but before starting engine, be sure

Downloaded from www.Manualslib.com manuals search engine
Radiator and Cooling System
Remove rubber trim strip between top of shroud and radiator.
Using 32 mm wrench
(BMW special tool 11 5 040) on fan
clutch nut (arrow), turn wrench in a clockwise direction
(working from front of car) while counterholding pulley with
BMW special tool
11 5 030. Spin fan off coolant pump.
NOTE-
The radiator cooling fan nut (32 mm wrench) has left-hand
threads.
Unclip AUC (air quality) sensor from shroud,
M54 engine: Disconnect auxiliary coolant pump from base of
fan shroud.
Lift fan and shroud together out of engine compartment.
To replace fan clutch, remove fan mounting bolts and sepa-
rate viscous clutch from fan.
Installation is reverse of removal.
Tightening
torques
Clutch nut to pump
Without
BMW tool 11 5 040 40 Nm (29 ft-lb)
With BMW tool 11 5 040 30 Nm
(22 ft-lb)
Fan to viscous clutch 10 Nm (89 in-lb)
Electric cooling fan, removing and
installing
The electric cooling fan is mounted behind the front bumper,
in front of the
A/C condenser.
- Remove front bumper. See 510 Exterior Trim, Bumpers.
- Remove left and right headlights. See 630 Lights,
- Where applicable, detach horizontal air ducts behind front
bumper and fold to side.
- Disconnect fan electrical connector on right side of radiator
shroud and lay aside.
- Detach wire loom from air duct in front of cooling fan
- Pry out expansion rivets holding air duct. Slide air duct down-
ward to remove.

Downloaded from www.Manualslib.com manuals search engine
Tightening torques Block drain plug to block
25 Nm (18 ft-lb)
Radiator drain plug to radiator 2 - 3 Nm (18 - 27 in-lb)
Thermostat housing to
cylinder head 10 Nm (89 in-lb)
Thermostat, removing and installing
(V-8 models)
The electrically-heated thermostat is an integral parl of the
thermostat housing. The operation of the thermostat is moni-
tored by the engine control module (ECM).
- If a faulty thermostat is suspected, use appropriate scan tool
to interrogate ECM for stored fault codes.
- Drain radiator and engine block. See Coolant, draining and
filling
(V-8 models).
WARNING -
Allow cooling system to cool before opening or draining the
system.
- Disconnect mass air flow (MAF) sensor electrical harness
connector. Remove air intake duct together with MAF sensor.
- Remove mechanical cooltng fan and fan shroud. See Me-
chanical (viscous clutch) cooling fan, removing and
in-
stalling.
Disconnect electrical harness connector (arrow) from ther-
mostat housing.
Remove coolant hose from thermostat housing.
NOTE-
M62 engine: Hose is clamped on.
M62 TU engine: Hose is attached with quick-disconnect fit.
ting. Remove clip to disconnect hose.

Downloaded from www.Manualslib.com manuals search engine
.," --
Radiator and Cooling System --- 1
insert two M6 screws (arrows) in tapped bores and tighten
uniformly until pump is free from timing chain cover (thermo-
stat and hoses have been removed for purposes of visual
clarity).
Installation is reverse of removal, noting the following:
Be sure to replace sealing O-ring and gaskets.
Coat O-ring with water-based lubricant during installation.
Refill with coolant. See Coolant, draining and filling
(6-
cylinder models).
Tightening torques
-
Coolant pump to timing chain 10 Nm (89 in-lb)
cover
Coolant pump pulley to coolant
10 Nm (89 in-lb
pump
Engine block drain plug to block 25 Nm (1 8 It-lb)
Radiator drain plug to radiator 2 - 3 Nm (I8 - 27 in-lb)
Coolant pump, replacing (V-8 models)
I 1 < The engine coolant pump is mounted in the front of the en-
gine in ;he timing chain cover.
1. Thermostat housing
2. Thermostat
3. Thermostat sealing O-ring
4. Water pump
5. Water pump gasket
- Drain cooling system. See Coolant, draining and filling (V-
8 models).
- Remove cooling fan and fan shroud. See Mechanical (vis-
cous clutch) cooling fan, removing and installing.
- Remove engine drive belts: See 020 Maintenance.
NOTE-
Mark direction of drive belt rotation if reusing belt,
- Remove vibration dampener. See 117 Camshaft and Tim-
ing Chain.
- Disconnect mass air flow (MAF) sensor electrical harness
connector. Remove air intake duct together with
MAF sensor.
- Disconnect coolant hoses from thermostat housing and cool-
ant pump housing.

Downloaded from www.Manualslib.com manuals search engine
.. - --
Radiator and Cooling System
Tightening torques
Coolant pump to timing chain 10
Nm (89 in-lb)
cover
Coolant pump
pulley to coolant
pump
10 Nm (89 in-lb
Engine
blocic drain plug to block 25 Nm (18 ft-lb)
Radiator drain plug to radiator
2-3Nm(18-27in-lb)
Thermostat cover to coolant
pump assembly 10 Nm (89 in-lb)
Radiator, removing and installing
Removal of the radiator is similar for V-8 and 6-cylinder mod-
els.
- Raise front of car and support safely.
WARNING -
Make sure the car is stable and well supported at aN times.
Use a professional automotive liff
orjaclc stands designed for
- Remove splash shield from under engine.
- Drain radiator and engine block. See Coolant, draining and
filling
(V-8 models).
WARNING -
Allow cooling system to cool before opening or draining sys-
tem.
< Remove air filter housing:
Disconnect electrical harness connectors
(A and B).
Loosen clamps (C and D).
Remove mounting fastener (arrow) and remove air filter
housing together with mass air flow
(MAF) sensor.

Downloaded from www.Manualslib.com manuals search engine
. --
Radiator and Cooling system/
4 Pry out expansion rivets (A) on left and right side of fan
shroud. Loosen hose clamp
(6) and remove hose from ex-
pansion tank.
Remove expansion tank: Remove expansion tanlc cap, vent plug
(A) and tank retain-
ing clips (arrows).
Lift expansion
tanlc upward and off lower retaining lugs.
Push shroud back to expose expansion tank vent line. Re-
move line.
Using 32 mm wrench
(BMW special tool 11 5 040) on fan
clutch nut (arrow), turn wrench in a clockwise direction
(working from front of car) while counterholding pulley with
BMW special tool 11 5 030. Spin fan off coolant pump.
NOTE-
The radiator cooling fan nut (32 mrn wrench) has left-hand
threads.
Disconnect electrical harnesses from
AUC (air quality) sen-
sor and coolant level sensor.