2001 BMW 525i fuel control

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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
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5 Series Scrvicc Manual: 1997-2002 525i, 528i. 530i. 540i, Sedan, Sport Wagon Bcrrlluy P~rlilishens ISBN 0-8376-0317-X
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Foreword
For the BMW owner with basic mechanical skills and for independent auto service professionals.
this manual includes many of the specifications and procedures that were available to an
authorized BMW dealer service deoartment as this manual went to
Dress. The BMW owner with , no intention of working on his or her car will find that owning and referring to this manual makes it
possible to be better informed and to more
Itnowledgeably discuss repairs with a professional
automotive technician.
If you are a BMW owner intending to do maintenance and repair work, make sure you have
screwdrivers, a set of metric wrenches and sockets and metric Allen and
Torx wrenches, since
these basic hand tools are needed for most of the work described in
this manual. Many procedures
also require a torque wrench to ensure that fasteners are tightened properly and in accordance
with specifications. Additional information on basic tools and other tips are in
010 General. In
some cases, the text refers to special tools that are recommended or required to accomplish
adjustments or repairs. These tools are usually identified by their
BMW special tool number and
illustrated.
Disclaimer
We have endeavored to ensure the accuracy of the information in this manual. When the vast
array of data presented in the manual is
talten into account, however, no claim to infallibility can
be made. We therefore cannot be responsible for the result of any errors that may have crept into
the text. Please also read the Important Safety Notice on the copyright page at the beginning of
this book.
Prior to starting a repair procedure, read the procedure,
001 General Warnings and Cautions
and the warnigns and cautions that accompany the procedure. Reading a procedure before
beginning
work will help you determine in advance the need for specific skills, identify hazards,
prepare for appropriate capture and handling of hazardous materials, and the need for particular
tools and replacement parts such as gasltets.
Bentley Publishers encourages comments from the readers of this manual with regard to errors,
and/or suggestions for improvement of our product. These communications have been and will be
carefully considered in the preparation of this and other manuals. If you identify inconsistencies in
the manual, you may have found an error. Please contact the publisher and we will endeavor to
post applicable corrections on our
website. Posted corrections (errata) should be reviewed before
beginning
worlc. Please see the following web address:
BMW offers extensive warranties, especially on components of the fuel delivery and emission
control systems. Therefore, before deciding to repair a BMW that may be covered wholly or in part
by any warranties issued by
BMW of North America, LLC, consult your authorized BMW dealer.
You may find that the dealer can
make the repair either free or at minimum cost. Regardless of its
age, or whether it is under warranty, your BMW
Is both an easy car to service and an easy car to
get serviced. So
if at any time a repair is needed that you feel is too difficult to do yourself, a trained
BMW technician is ready to do the job for you.
Bentley Publishers

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Maintenance
Service Interval lndicator (Sll)
The BMW Service Interval lndicator (SII) notifies the driver
when oil change and other service is required. The
Sll dis-
plays the phrase "OIL SERVICE"
or"INSPECTI0N" and 7
light emitting diodes (LEDs) in the Instrumentcluster: 5green,
one yellow and one red.
For the
1997 and later 5 Series, BMW introduced an oil
change interval based on fuel consumption. The advantages
of this system are:
Fuel consumption is an accurate method of determining
engine load and the need for service.
The processing electronics are simple.
Resetting of indicator before the scheduled time will not
affect the time to the next service.
4 The Sll is programmed to measure a set volume of con-
sumed fuel. This volume varies between models, dependent
on vehicle and engine size. The
Sil control unit receives a
signal from the engine control module (ECM) when the vehi-
cle is in use. As
20% of the programmed fuel volume is con-
sumed, one of the green LEDs will go out. Each successive
20% of fuel consumption will cause the next LED to go out
until
100% of the measured volume has been consumed. At
this point the yellow LED will come on, indicating that service
is due. When
108% of the measured volume has been con-
sumed, the red LED will illuminate, indicating that service is
overdue.
Service Interval Indicator (SII), resetting
After the specified maintenance has been carried out, the Sll
memory should be reset.
NOTE-
For reference, the BMW oil service requirements are approx-
imately equivalent to the maintenance tliat other European
manufacturers specify at intervals with a maximum of every
15.000 miles or I2 months.

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Table b. Inspection I Service (continued)
Checlt transmission and differential for
external lealts.
Check CV joint boots for damage or leaks.
Visually
check fuel tank, fuel lines, and
connections for
leaks.
New parts
Tools Required required
Check condition, position, and mounting
ol
exhaust system. Visually check and adjusl
if necessary.
Check power steering system for lealts.
Check power steering
fluid level and adjust
if necessary.
Check steering racidbox and tie rods for
tightness. Checit condition of front axle
joints, steering
linkage, and steering shaft
joints.
Check overall thickness of front and rear
bralte pads using
BMW special tool. If
replacement is necessary:
Examine brake disc surface.
Clean brake pad contact points in calipers
Grease wheel centering hubs.
Checlt thickness of parking brake linings
only when replacing rear brake shoes.
Checit operation of pariting brake and
adjust as necessary.
Checlt front control arm bushings for
damage or wear.
Check brake system connections and
lines
for leaks, damage, and incorrect
positioning Warm
engine
(~ealer service Irepair , required recommended lnformat~on
Check parking braite actuator. Adjust if
necessary
Check ail tire pressure (including spare)
and correct if necessary.
Checlt condition of tires (outer tread
surface), tread wear pattern: in case of
uneven wear, perform wheel alignment.
inspect entire body according to terms of
rust oerforation limited warrantv. (Must be
*:
4:
2 ~ perfdrmed at least every two years). I
Read out on-board diagnostic (OBD 11) fault
codes.
Checkengine coolant
system1 heater hose
connections for
leaks.
Checit coolant level and antifreeze
protection level. Add coolant as necessary.
* 100113010BD
I
170

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Maintenance
< Remove NC compressor belt:
Loosen tensioner mounting fasteners (arrows)
Swing tensioner down to remove belt.
4 To reinstall compressor belt:
Route belt over pulleys.
* Pretension belt by turning adjuster clockwise (arrow) to
stop.
- Tighten tensioner mounting bolts (A).
Tightening torques
Fan clutch to coolant pump (left- hand thread)
with BMW tool
11 5 040
30 Nm (22 ft-lb)
without BMW tool 11 5 040
40 Nm (29 ft-lb)
Tensioner to engine block
8.8 grade
22 Nm (16 ft-lb)
10.9 grade (Ilquid-cooled alternator) 30 Nm (22 ft-lb)
Idle speed
Engine idle speed can change due to a number of factors, in-
cluding normal wear. The idle speed is electronically adaptive
and not adjustable. See
130 Fuel Injection for more informa-
tion.
Catalytic converter and oxygen sensors
OBD II enhanced emission standards require the engine
control module (ECM) to monitor the oxygen content in the
exhaust with oxygen sensors placed before and after the cat-
alytic converter. This allows for tighter control of tail pipe
emissions and also allows the ECM to diagnose converter
problems. If the ECM detects that catalytic converter or oxy-
gen sensor efficiency has degraded past a certain
prepro-
grammed limit, it will turn on the malfunction indicator light
(MIL), and store a diagnostic trouble code (DTC) in the ECM.
See OBD On-Board Diagnostics for more information on
OBD
ll systems.
Replacement of oxygen sensors at the specified intervals
he engine and emission control system will

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.-. -
Maintenance
Drive axle joint
(CV joint) boots, inspecting
CVjoint protective boots must be closely inspected forcracks
and any other damage that will allow contaminants to get into
the joint.
If the rubber boots fail, the water and dirt that enter
the joint will quickly damage it.
NOTE-
Replacement of the CVjoint boots and inspection of the
joints are described
in 331 Final Drive.
Exhaust system, inspecting
Exhaust system life varies widely according to driving habits
and environmental conditions. If short-distance driving pre-
dominates, the moisture and condensation in the system will
not fully dry out. This will lead to early corrosion damage and
more frequent replacement.
Scheduled maintenance of the exhaust system is limited to
inspection:
* Check to see that all the hangers (arrow) are in place and
properly supporting the system and that the system does
not strike the body.
Check for restrictions due to dents or
kinlts,
Check for weakness or perforation due to rust.
NOTE-
Alignment of the system and the location of the hangers are
described in
180 Exhaust System.
Fuel filter, replacing
The fuel filter is located beneath the center of the car, approx-
imately under the driver's seat.
A protective cover must be
removed to access the filter.
4 Fuel filter for M62 engine (arrow)
- Disconnect battery negative (-) cable
CAUTIOI\C
Disconnecting the battery cables may erase fault codes
stored
in engine control module memory.
WARNING -
Fuel will be expelled forcibly when the filter is removed. Do
notsmoke or work near heaters orother fire hazards. Keep a
fire extinguisher handy

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Engine Removal and lnstallationl
NOTE-
BMW uses three styles of fuel line connections; a one-time
single use clamp, a locking fitting that uses special tool
16 1
050 to release, and a quick release sleeve (arrow) that dis-
connects the line when depressed.
WARNING-
Fuel may be expelled under pressure. Do not smoke or work
near heaters or other fire hazards. Keep a fire extinguisher
handy Before disconnecting fuel hoses, wrap a cloth around
fuel hoses to absorb any leaking fuel. Plug all
oDen fuel lines.
< M52 engine: Remove throttle valve and ASC throttle
assemblies.
Disconnect ASC throttle cable
(A).
Remove ASC throttle housing mounting fasteners (El).
Clamp off, disconnect, and plug coolant hoses (C).
Disconnect throttle and cruise control cables (D).
Remove throttle housing mounting hardware and throttle
valve.
NOTE-
M52 TU, M54 engine: Throttle body is removed with intake
manifold.
< M52 TU engine: Pull throttle cable out of rubber retainer (A)
and unloclc ball end of cable (6) from throttle actuator.

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11 3-6
Cylinder Head Removal and Installation
- Disable ignition system by removing DME main relay. See
610 Component Locations for relay location.
WARNING-
. The ignition system produces high voltages that can be fa-
tal. Avoid contact with exposed terminals and use
exfreme
caution when working on a car with the ignition switched on
or the engine running.
Do not touch or disconnect ignition
components while
the engine is running or being cranked by the starter.
Failure to remove the DME main relay or attempting to
disa-
bie the fuel andignition systems by other methods may result
in damaoe to the enoine control module
(ECM).
- - Remove plastic cylinder head cover(s)
,,I . ,. .*,.,,&- - Remove coil grounding straps.
I CAUTION-
I nition system components. I
- Remove coils.
- Remove spark plugs from all cylinders.
NOTE-
Check the spark plugs for oil deposits that may indicate poor
cylinder sealing, then set them aside in order. Used spark
plugs should be reinstalled in the same cylinder from which
they were removed.
4 Install compression gauge in first cylinder spark plug hole,
tight enough to form a good seal.
- With parking brake set, transmission in PARK or NEUTRAL,
and accelerator pedal pressed to floor, crank engine with
starter. Record highest value indicated by gauge.
NOTE-
* The compression gauge reading should increase with
each compression stroke and reach near its maximum
reading in about
4-6 strokes.
All cylinders should reach maximum compression in the
same number of
strolces. If a cylinder needs significantly
more strokes to reach
maximum compression, there is a
problem.