2001 BMW 525i Front

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- Removing left side exhaust manifolds (cylinder bank 5-8):
- Remove heat baffle plate on left side.
Remove oxygen sensor using
BMW special tool 11 7 030
or similar oxygen sensor socket.
Install
BMW special tools 00 0 200,OO 0 201,OO 0 202,OO 0
204, and 00 0 208 or other suitable engine lifting support
above engine and attach to lifting eye on left head.
NOTE-
The supports on special tool 00 0 208 must rest on the
screws on the fenders.
- Remove nut at top of engine support on left side
- Raise engine at front suspension lug a maximum of 25 mm
(I
.O in).
Release clamping bolt and nut
(arrow) and slide universal
joint off steering gear.
4 Remove nuts securing left exhaust manifold to head,
Raise front of manifold as high as possible past end posi-
tion of steering gear and feed out towards bottom.
- Installation is reverse of removal.
Coat exhaust mounting studs with CRC or equivalent
copper paste.
Use new exhaust gaskets and self-locking nuts.
Install new self-locking nuts on engine mount and steering
shaft bolt.

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-- -
Exhaust System
Oxygen sensors (precatalyst), replacing
(M52 TU and M54)
The precatalyst oxygen sensors are installed at the top of the
exhaust manifolds.
WARNING-
Allow components to cool before servicing.
- Using BMW scan tool DlSplus (Diagnostic Information Sys-
tem) or equivalent, read out and clear ECM fault codes.
Working at right side of engine above exhaust manifolds,
remove front or rear oxygen sensor harness connector
(arrows) from bracket, then separate plug.
NOTE-
In photo, secondary air pump has been removed for clarity.
Remove oxygen sensor using special oxygen sensor
removal socket.
Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing a sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
- -.
Oxygen sensor to manifold 50 Nm (37 ft-lb)
Oxygen sensors (post-catalyst), replacing
(M52 TU and M54)
The post-catalyst oxygen sensors are installed at the rear of
the catalytic converters.
WARNING-
Allow components to cool before servicing
- Using BMW scan tool DlSplus or equivalent, read out and
clear ECM fault codes.
- Remove large cover from above fuel raillintake manifold.

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Exhaust System
Label and disconnect sensor harness connectors (arrows).
CAUTlOI\C
Label connectors so that front and rear connectors are not
mixed up.
- Detach harness from guides and brackets.
- Remove oxygen sensor from exhaust manifold using special
tool
11 7 030 or equivalent.
- Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing old sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
Oxygen sensor to manifold 50 Nm (37 ft-lb)
Oxygen sensor, replacing
(M52 and M62 engine)
The sensors are installed at the front and rear of the catalytic
converters.
I WARNING- I
I Allow components to cool before servicing. I
Using BMW scan tool DlSplus or equivalent, read out and
clear
ECM fault codes.
Detach harness from guides and brackets.
Remove oxygen sensors (arrows) from exhaust using spe-
cial tool
ll 7 030 or equivalent.
Installation is reverse of removal
New sensor threads come coated with anti-seize paste.
If reusing a sensor, apply thin coat of anti-seize paste to
threads only. Do not contaminate tip of sensor with paste
or lubricants of any sort.
Install harness and connector in original location.
Tightening torque
Oxvaen sensor to manifold 50 Nm (37 it-lb)

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Exhaust System
M52 engine
(5281 1997-1 998)
1. Exhaust manifolds
2. Sealing washer
3. Plug
4. Gasket (manifold to cylinder
head)
5. Clamping sleeve
6. Post-catalytic converter oxygen sensor
7. Pre-catalytic converter oxygen
sensor
8. Hanger
9. Rear muffler
10. Vibration dampener
11. Center support bracket
12. Clamping sleeve
13. Front pipe with catalytic
converters
14. Hanger
15. Center muffler
16. Gasket (front pipe to manifold)

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I Exhaust System
M52 TU and M54 engines
(528i 1999-2000
and 525i 2001-2003)
1. Transmission bracket
2. Center support bracket
3. Front muffler
4. Clamping sleeve
5. Vibration dampener
6. Hanger
7. Rear muffler
8. Hanger
9. Center muffler
10. Oxygen sensors, post-catalytic
converter
11. Oxygen sensors, pre-catalytic
converter
12. Exhaust manifoldlcatalytic
converter assemblies

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Exhaust systeml
M54 engine
(5301 2001-2003)
Clamping sleeve
Front muffler Rear muffler
Hanger
Vibration dampener
Clamping sleeve
Center muffler
Hanger
Gasket (front pipe to manifold)
10. Exhaust
manifold/catalytic
converter assemblies
11. Oxygen sensors, post-catalytic converter
12. Oxygen sensors, pre-catalytic converter

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I Exhaust System
M62 engine
(540i 1997-1 998)
1. Right side catalytic converters
2. Support bracket
3. Support bracket
4. Center muffler
5. Hanger
6. Rear muffler
7. Clamping sleeve
8. Oxygen sensors, post-catalytic
converter
9. Oxygen sensors, pre-catalytic
converter
10. Left side catalytic converter
11. Sealing rings
12. Left front exhaust manifold
13. Left rear exhaust manifold
14. Gasket
15. Exhaust manifold, right front
16. Exhaust manifold, right rear

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--.
- - Manual Transmission
- V-8 engine: Remove heat shield from left front axle support.
< V-8 engine: Remove engine speed reference sensor from
transmission.
- Where applicable, remove brackets for transmission under-
body protection (adjacent to transmission).
4 Support transmission with transmission jack.
- Where applicable, remove reinforcing cross brace from
below driveshaft at transmission.
- Disconnect harness connector from back-up light switch
on transmission.
- Free harnesses for oxygen sensors and back-up lights
from crossmember and transmission.
Remove transmission crossmember: Remove transmission mount bolts
(A).
Remove transmission crossmember bolts (B)
Where applicable, remove bolts (C).
NOTE-
5-speed transmission shown in illustration. Crossmember
assembly for 6-speed transmission is similar.
Disconnect driveshaft from transmission and hang to one
side. See
260 Driveshaft.
I CAUTION- I
Do not damage constant velocity joint orprotective boot at
rear differential.
- 6-cylinder engine: Remove stabilizer bar links and swivel sta-
bilizer bar
u~wards.