2001 BMW 525i engine wire

Downloaded from www.Manualslib.com manuals search engine
Engine Removal and lnstallationl
< Remove positive battery cable and intake manifold cover:
Remove protective cover from positive (+)jump start post
(4.
Loosen and remove battery lead mounting nut.
Remove lead and push down through intake manifold
Remove trim covers
(arrows) from fuel injector cover.
Remove cover hold down bolts and lift off cover.
Working above engine, disconnect the following:
Vent line from cylinder head cover (A).
M52 engine: Oxygen sensor connectors (8).
Electrical harness connector from intalte camshaft VANOS
solenoid valve
(C).
M52 engine: Disconnect electrical harness connectors at
throttle valve position switch
(D), ASC valve position switch
(E), fuel injector harness (F) and vent valve (G).
CAUTION-
Be sure to mark oxygen sensor harness connectors so that
they can be reassembled correctly Do not interchange con-
nectors.
4 M52 TU, M54 engine: Disconnect fuel injector electrical con-
nectors from injectors.
Use small screwdriverto pry one corner of wire lock clip on
fuel injector
1 connector.
Repeat for all injectors.
Lifl off connector loom and lay aside.

Downloaded from www.Manualslib.com manuals search engine
110-12
Engine Removal and Installation
4 Remove hoses from thermostat housing by releasing locks
(arrows). If applicable, detach electrical harness connector
for thermostat housing.
NOTE-
Two different types of hose fasteners are used on the E39
car; lock clamp type as shown above or standard band
clamps.
- On vehicles equipped with mechanical cooling fan: Remove
belt-driven cooling fan and radiator as described in
170 Ra-
diator and Cooling
System.
CAUTION-
32 mm radiator fan mounting nut has left hand threads.
4 Disconnect coolant hose (arrow) at rear left side of engine
above starter.
4 Disconnect coolant hose (arrow) at front left side of engine
mount.
- Unbolt power steering fluid reservoir and pull aside without
detaching hoses. Secure to fender with cord or stiff wire.

Downloaded from www.Manualslib.com manuals search engine
Engine Removal and Installation
4 Working at E-box at right rear of engine compartment:
Disconnect engine electrical harness connectors
(arrows).
Lift off harness looms and lay over engine.
- Remove polyribbed drive belts. Mark direction of rotation if
belts will be reused. See 020 Maintenance.
- Remove exhaust system and transmission from car. See 180
Exhaust System, 230 Manual Transmission or 240 Auto-
matic Transmission.
NOJE-
Detach automatic transmission cooler lines from radiator, re-
move brackets holding lines to side of engine, andstore lines
in a clean environment.
- Remove power steering pump:
If necessary, remove steering pump pulley.
Remove front and rear pump mounting bolts.
Suspend pump from body using stiff wire.
4 Remove A/C compressor mounting bolts (arrows) and AIC
compressor from its mounting bracketwithoutdisconnecting,
distorting, or deforming any refrigerant lines. Suspend from
body using stiff wire.
4 If applicable, remove secondary air pump:
Remove hose at one-way valve
(A).
Remove bolts at support bracket on strut tower (arrows).
- Disconnect electrical harness from bottom of secondary
air pump.
Remove bracket from strut tower.

Downloaded from www.Manualslib.com manuals search engine
110-16
Engine Removal and Installation
ENGINE, REMOVAL AND
INSTALLATION (V-8 MODELS)
NOTE-
Engine removal procedures are similar for all V-8 models.
When differences exist, they are noted at the beginning of
each step. Engine are referred to by engine code. If neces-
sary, See
100 Engine-General for engine code andappli-
cation information.
Be sure to cover all painted surfaces before beginning the
removal procedure. As an aid to installation, label all com-
ponents, wires and hoses before removing them. Do not
reuse gaskets, O-rings or seals during reassembly
WARNING
-
Due to risk ofpersonal injury, be sure the engine is cold be-
fore beginning the
removal procedure.
- Disconnect negative (-) cable from battery.
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove engine hood or place hood in service position. See
410 Fenders, Engine Hood.
Remove
intake manifold cover, version 1:
Remove plastic trim caps (arrows).
Remove cover mounting fasteners and
lift off cover.
Remove intake manifold cover, version
2:
Press down on locking pins (arrows) to release locks
Lifl cover straight
up to remove.

Downloaded from www.Manualslib.com manuals search engine
I Engine Removal and Installation
WARNING -
Use extreme caution when draining and disposing of engine
coolant. Coolant is poisonous andlethal to humans andpets.
Pets are attracted to coolant because of its sweet smell and
taste. Seek medical attention immediately if coolant is ingest-
---
Working at rear of intake manifold:
Disconnect brake booster vacuum line (A).
Disconnect fuel tank vent line
(6).
Disconnect hoses (C and D) at coolant manifold
- Remove transmission harness support (E).
- Remove oil filter housing assembly from fender:
- Remove oil filter housing mounting fasteners.
Use stiff wire to secure oil filter housing to engine.
NOTE-
Do not disconnect oil lines from filter housing.
4 Disconnect supply and return fuel lines (where applicable) at
or near fuel rail. Plug open fuel lines.
NOTE-
BMW uses three styles of fuel line connections; a slngle use
clamp, a locking fitting that uses special tool
16 7 050 to re-
lease, and a
quiclc release sleeve (arrows) that disconnects
the line when depressed.
WARNING-
Fuel In fuel line is under pressure (approx. 3 - 5 bar or45 -
75 psi) and may be expelled. Do not smoke or worlc near
heaters or other fire hazards. Keep a fire extinguisher
handy. Before disconnecting fuel hoses, wrap a cloth
around fuel hoses to absorb any lealcing fuel. Catch and
dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before worlcing on the tank or lines.
< Remove air filter housing and mass air flow sensor:
Disconnect mass air flow sensor (A) and
intalte air temper-
ature sensor
(6) electrical harness connectors.
. Remove air filter housing mounting fastener (arrow).
Loosen intake hose clamp (C).
M62 engine: Remove hose at idle air stabilizer.
Remove air filter housing with mass air flow sensor.
Remove intalte hose from throttle body.

Downloaded from www.Manualslib.com manuals search engine
--
-- Engine Removal and installation' -
Remove polyribbed A/C compressor belt:
Mark direction of belt travel if belts are to be reused.
Loosen bolts
(A).
Turn adjusting lug (B) clocltwise to release belt tension.
Working beneath car, remove power steering pump and air
conditioner compressor. Suspend from body using stiff wire.
Remove exhaust manifolds. See
180 Exhaust System.
< lnstall engine lifting device (BMW 11 0 000 or equivalent) to
front and rear engine supports and raise engine until it's
weight is supported. Detach engine mounts.
a Watch carefully for hoses and electrical wires that might
snag.
- installation is reverse of removal:
Replace all gaskets, O-rings and seals.
V-8 engine mounts have two sets of mounting holes. E39
cars use front most mounting holes.
* On cars with automatic transmission, use new O-rings at
ATF cooler lines.
Use new alignment sleeves when installing transmission.
Be sure engine drive belts properly engage pulley grooves.
When installing belt, preload tensioner to stop (toward
belt), then tighten tensioner clamping nut.
lnstall front exhaust pipes using new gasltets and copper
paste and new mounting hardware. See
180 Exhaust
System.
Change engine oil and filter. Check all other fluid levels as
described in
020 Maintenance.
Refill and bleed cooling system as described in
170 Radi-
ator and Cooling System.
CAUTION-
Do not interchange knoclc sensor harness connectors. Seri-
ous engine damage may result

Downloaded from www.Manualslib.com manuals search engine
. .- . --
Lr -- - - - -- Cylinder Head Removal and Installation I -
- Release pressure at compression gauge valve, then remove
gauge from spark plug hole. Repeat test for each cylinder
and compare results with values given in Table a.
Table a. Compression testing specifications
Minimum compression
6-cylinder
10-1 1 bar (142-156 psi)
V-8 12-14 bar (174-203 psi)
Maximum difference between
cylinders (all engines)
0.5 bar (7 psi)
- Compression readings may be interpreted as follows:
Low compression indicates a poorly sealed combustion
chamber.
0 Relatively even pressures that are below specification nor-
mally indicate worn piston rings
andlor cylinder walls.
Erratic values tend to indicate valve leakage.
Dramatic differences between cylinders are often a sign of
a failed head
gasket, burned valve, or broken piston ring.
- If readings are within specifications, reinstall spark plugs and
ignition coils.
NOTE-
Used spark plugs should be reinstalled in the same cylinder
from which they were removed.
Tightening torque Spark plug to cylinder head 25 Nm
(18 ft-lb)
lanition coils to cylinder head 10 Nm (7.5 ft-lb)
- Remainder of installation is reverse of removal. Be sure to re-
install all wires disconnected during test, especially ground
wires at coils and cylinder head cover (where applicable).
Wet compression test
To further help analyze the source of poorcompression,awet
compression test is the next step.
- Repeat compression test, this time squirt a teaspoon of oil
into each cylinder. The oil will temporarily help seal between
piston rings and cylinder wall, practically eliminating leakage
past rings for a short time.
- If this test yields a higher reading than "dry" compression
test, there is probably leakage between piston rings and
cylinder walls, due either to wear or to broken piston rings.
- Little or no change in compression reading indicates other
leakage, probably from valves.

Downloaded from www.Manualslib.com manuals search engine
-
Cylinder Head Removal and Installation c
q Remove secondary air inject~on check valve (arrow).
4 Remove cylinder head top cover:
Remove plastic trim caps (arrows).
Remove engine oil filler cap.
Remove cover hold down fasteners and lift off cover.
4 Remove ignition coils:
Disconnect ignition coil harness connectors.
. Remove coil mounting fasteners.
Remove coils.
Remove ground straps.
NOTE-
Make note of ground wire at mounting studs arrangement
during removal.
- Remove sparlc plugs.
- Remove cylinder head cover mounting fasteners and remove
cylinder head cover.
NOTE-
The cylinder head cover mounting bolt insulators and gas-
lets should be reinstalled in their original locations. Make
note of their arrangement during removal.