2001 BMW 525i 260

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11 9-2
Lubrication System
This repair group covers lubrication system troubleshooting
as well as oil pan removal and oil pump replacement.
In 6-cylinder models, removal of the oil pan requires the re-
moval of the exhaust system and some front suspension
components. Those procedures are fully covered in:
180 Exhaust System
210 Clutch
230 Manual Transmission
0 240 Automatic Transmission
310 Front Suspension
320 Steering and Wheel Alignment
NOTE-
Oil change procedure and oil filter replacement are covered
in
020 Maintenance.
CAUTIOG
V8 engines: The oil pump fasteners (including the sprocket
retaining nut) are known to vibrate loose. This can result in oil
starvation and engine failure. Be sure to check oil bolts and
nut tightness whenever the
oilpump is accessible. If any fas-
teners are found to be loose, remove them and reinstall with
Loctite
Band torque to specifications.
Special tools
The engine needs to be properly supported while the front
suspension
subframe is lowered to access the oil pan.
A standard oil pressure gauge may be used for measuring oil
pressure.
Engine support bracket
(Tool No, BMW 00 0 20012011202~2041208)
4 6-cylinder crankshalt rear main seal tools
(Tool No. BMW 00 5 50011
1 1 260)

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Lubrication stern/
Remove remaining seal carrier bolts (arrows) and carefully
remove seal carrier without damaging the oil pan
gasltet.
CAUTION-
After removing seal carrier, checlc oilpan gasket for damage.
If gasket is damaged during removal, remove oil pan (as de-
scribed later) and replace
gasket.
< Remove old seal and install new seal into seal carrier using
BMW special tools
11 1 260 and 00 5 500.
NOTE-
A new radial seal is used from 4/98 production, and is the
only version available from
BMW as a replacement. The
new
sealno longer uses a spring to support the sealing lip.
Do not
lcinlc or damage the sealing lip. Do not touch with
fingers.
* BMW offers the rear main seal carrier and seal in a lit A
plastic support bushing, required for sliding the seal over
the crankshaft, is included with the
lcit.
I CAUTION- 1
Do not use BMW special tool 1 I 2 213 (mstallation guide)
with the new style seal. Use only the special tool
supphed
with the seal lcit.
When reinstalling seal carrier to crankcase:
Check locating sleeves for damage.
Replace
gasltet between rear main seal carrier and crank-
case.
Apply thin coat of
3 Bond 8 1209 or equivalent sealant to
oil pan gasket sealing surfaces.
* Lubricate crankshaft seal contact surface.
Use plastic support bushing
(A) that comes with seal ltit as
an installation
quide, fittina seal over end of crankshaft. Use - -
care to push seal carrier and support bushing on straight,
without tilting sideways. Remove support bushing.
- lnstall seal carrier bolts and torque to specifications.
4 Use new bolts (arrows) at base of seal carrier. Coat threads
with sealing compound before installing.
- Install and tighten oil pan bolts.

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Fuel Tank and Fuel pump/
- Remove suction hose from tank filler neck carefully to avoid
damaging filler neck baffle plate.
CAUTION-
After finishing repairs but before starling engine, be sure
there is at least
5 liters (1.5 gallons) of fuel in tanlc. The fuel
pump will be damaged if run without fuel.
Fuel tank, removing and installing
- Remove fuel tank filler cap and drain tank as described
earlier.
- Disconnect negative cable from battery.
CAUTION-
Prior to disconnecting the battea read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove rear seat bottom cushion. Peel forward lip of carpet
from beneath seat cushion and carefully peel back insulation
to expose fuel tank access cover on left and right sides. Re-
move covers.
Disconnect right side supply hose and
electr~cal harness
connector (arrows).
D~sconnect left side return hose and electrical harness
connector.
Working inside car, disconnect parking
bralte cable ends
from parking brake lever. See
340 Brakes.
Lift car and support safely.
Make sure the car is stable and
we/ supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose. A floorjaclc is not adequate support.
- Remove complete exhaust system and heat shield. See 180
Exhaust System.
- Remove drive shaft. See 260 Driveshaft

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Manual Transmission Selector shaft seal, replacing
(transmission installed)
- Put transmission into second gear.
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floorjack is not adequate support
- 6-speed transmission: Remove rear engine splash shield
- Remove exhaust system and heat shields. See 180 Exhaust
System.
- Support transmission with transmission jack.
- Disconnect driveshaft at transmission and tie to side. See
260 Driveshaft.
4 Remove transmission crossmember:
Where applicable, release electrical harnesses from
transmission crossmember.
. Remove transmission mounting bolts (A).
Remove transmission crossmember bolts (B).
Where applicable, remove bolts
(C).
NOTE-
5-speed transmission shown in illustration. 6-speed trans-
mission is similar.
- Tilt down rear of transmission.
CAUTION-
Jilting the engine to lower the transmission can lead to
damaae to various components due to lack of clearance.
-
4 Pry sprlng locking rlng (A) out of groove and press pin
of
sh~fl rod.
Detach
sh~ft rod from selector shafl and tie as~de.
(B) out

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230-1 0
I Manual Transmission
Output shaft seal, replacing (5-speed
transmission) (transmission installed)
- Raise and safely support vehicle.
WARNING -
Make sure the car is stable and well supported at all times.
Use a professional automotive
lilt orjack stands designed
for the purpose.
A floorjack is not adequate support.
- Remove exhaust system and heat shields. See 180 Exhaust
System
Support transmission with transmission jack.
Disconnect driveshafi at transmission output flange, and
hang driveshaft to side. See
260 Driveshaft.
Remove transmission crossmember:
If applicable, release electrical harnesses from transmis-
sion crossmember.
Remove transmission mounting bolts
(A).
Remove transmission crossmember bolts (6).
Where applicable, remove bolts (C).
- Tilt down rear of transmission.
CAUTIOI\C
Tilting the engine to lower the transmission can lead to
damage to various components due to lack of clearance.
4 Remove collar nut with BMW special tool (see table below) or
suitable thin-walled deep
socltet. Use BMW special tool
23 0 020 or equivalent to counterhold output flange.
Collar nut sockets
Transmission
BMW special tool
Getrag S5D 250G 23 1 21 0 (27 mm)
ZF S5D 3202 23 2 320 (36 mm)
Use puller (BMW special tool 33 1 150 or equivalent) to
remove output flange.
Use BMW special tool
00 5 010 or other suitable seal puller
to remove seal from transmission housing.

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230-1 1
Manual ~ransmissionl
Coat new seal with transmission fluid. Use seal installation
drift (see table below) to drive seal into position until it is flush
with housing.
Output seal drives
Transmission
BMW special tool
Getrag S5D 250G 240110
ZF S5D 3202 23 2 300
inspect sealing surface on output flange. Replace if flange
surface is worn or damaged.
Heat output flange to about 176"
F (80" C) to aid in installa-
tion. This can be done by placing flange in hot water. Rein-
stall output flange to output shaft.
- Coat flange nut with LoctiteB243 and reinstall. Torque in two
stages.
Tightening torques Output flange to output shaft
Stage I 190 Nm (140 ft-lb)
Stage II (after loosening) 120
Nm (89 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Check transmission fluid level, topping up as necessary
Tightening torques Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
. MI0 (Torx bolt) 70
Nm (51 ft-lb)
. M8 (compression nut) 32
Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
- MI0 (8.8 grade) 48
Nm (35 ft-lb)
- MI0 (10.9 grade) 60
Nm (44 It-lb)
. MI2 (8.8 grade) 81 Nm (60 ft-lb)
. MI2 (10.9 grade) I00 Nm (74 It-lb)
M14 140 Nm (103 It-lb)
Transmission crossmember
- to transmission (ME) 21 Nm (15 It-lb)
- to chassis (M10) 42 Nm (30 It-lb)

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230-12
/ Manual Transmission
Output shaft seal, replacing (6-speed
transmission) (transmission installed)
- Raise and safely support vehicle.
WARNING-
Make sure the car is stable and well supported at all times.
Use a professional automotive lift
orjack stands designed for
the purpose.
A floorjack is not adequate support.
- Remove exhaust system and heat shields. See 180 Exhaust
System.
- Support transmission with transmission jack
- Disconnect driveshaft at transmission output flange, and
hang driveshaft to side. See
260 Driveshaft.
Remove transmission crassmember:
If applicable, release electrical harnesses from transmis-
sion crossmember.
Remove transmission and crossmember mounting bolts
(arrows).
5022305201 - Tilt down rear of transmission
CAUTION-
Tlting the engine to lower the transmission can lead to dam-
age to various components due to lack of clearance.
Use screwdriver to pry out output flange collar nut retaining
plate.
Remove collar nut with BMW special tool
23 2 320 or equiv-
alent thin-walled deep socltet
(36 mm). Use BMW special
tool
23 0 020 or equivalent to counterhold output flange.

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230-14
I Manual Transmission
If installing new output flange: Recalculate thickness of
shims based on difference in height between output shaft
surface and collar nut support surface. Shims must be within
the output flange preload specification below the collar nut
support surface.
Output flange preload Difference between heights of shaft and output 0.05
- 0.22 mm
flange sealing
suriace MINUS thickness of shims (0.002 - 0.009 in)
NOTE-
Shims are available in increasing sizes of 0.1 mm from
1.4 mm to 2.1 mm (0.055 in to 0.083 in) from BMWparts.
- Install shims. Install and torque flange collar nut.
Tightening torques Output flange to out put shaft
. Stage I 190 Nm (140 ft-lb)
. Stage II (after loosening) 120 Nm (89 it-lb)
- Use BMW special tool 23 2 470 to install flange nut retaining
plate.
- Remainder of installation is reverse of removal, noting the fol-
lowing:
Install driveshaft using new nuts. See
260 Driveshaft.
Checlc transmission fluid level, topping up as necessary.
Tightening torques
Aluminum driveshaft to flex-disc
- MI2 (use Dacromet-coated washers) 90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
MI0 (Tom bolt)
70 Nm (51 ft-lb)
M8 (compression nut) 32 Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
* MI0 (8.8 grade) 48 Nm (35 ft-lb)
- MI0 (10.9 grade) 60 Nm (44 ft-lb)
. MI2 (8.8 grade)
81 Nm (60 ft-lb)
MI2 (10.9 grade) 100 Nm (74 ft-lb)
- MI4 140 Nm (1 03 ft-lb)
Transmission
crossmembe~
to transmission (ME)
to chassis (M10)
21 Nm (15 ft-lb)
42 Nm (30 it-lb)