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BMW Manuals
Automobile
5251
Service manual
BMW 5251 Service Manual
Sedan/sport wagon 1997-2002 5 series e39
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page
of
1002
Go
page 1
page 2
page 3
page 4
page 5
page 6
page 7
page 8
page 9
page 10
page 11 - Table of Contents
page 12 - General
page 13 - Warnings. cautions and notes
page 14
page 15 - Safety
page 16 - Working under car
page 17 - Advice for the Beginner
page 18 - Tightening fasteners
page 19 - Gaskets and seals
page 20 - Electrical testing
page 21 - Genuine BMW parts
page 22 - Information you need to know
page 23
page 24 - Basic tool requirements
page 25
page 26 - Jack stands
page 27 - Torque wrench
page 28 - Changing a tire
page 29 - Jump starting
page 30 - Towing
page 31 - Spare parts kit
page 32
page 33
page 34 - Maintenance
page 35 - Service Interval Indicator (Sll)
page 36
page 37
page 38 - Maintenance Tables
page 39
page 40
page 41 - Fluid and Lubricant Specifications
page 42 - Fluids and lubricants
page 43
page 44 - Engine oil. checking level
page 45 - Engine oil and filter. changing
page 46 - Accelerator and linkage
page 47
page 48
page 49
page 50
page 51 - Idlespeed
page 52 - Power steering fluid, checking level
page 53 - Spark plugs, replacing
page 54 - Interior ventilation microfilter, replac...
page 55
page 56 - Brake fluid. replacing
page 57 - Brake system, inspecting
page 58 - Clutch fluid. checking
page 59 - Drive axle joint (CV joint) boots. inspe...
page 60 - Fuel tank and fuel lines. inspecting
page 61 - Suspension. front. inspecting
page 62 - Transmission service. manual
page 63 - Body and Interior Maintenance
page 64 - Polishing
page 65 - Windshield wiper blade maintenance
page 66
page 67
page 68
page 69
page 70
page 71
page 72
page 73
page 74
page 75
page 76
page 77
page 78
page 79
page 80
page 81
page 82
page 83
page 84
page 85
page 86
page 87
page 88
page 89
page 90
page 91
page 92
page 93
page 94
page 95
page 96
page 97 - Cylinder Head Removal and Installation (...
page 98
page 99 - Cylinder compression, checking
page 100
page 101 - Wet compression test
page 102 - Cylinder leak-down test
page 103
page 104
page 105
page 106
page 107
page 108
page 109
page 110
page 111 - Cylinder head, installing, M52 engine
page 112 - Cylinder Head Removal and Installation (...
page 113
page 114
page 115
page 116 - Cylinder head, removing, M52 TU and M54 ...
page 117
page 118
page 119
page 120
page 121
page 122
page 123
page 124
page 125
page 126
page 127
page 128
page 129
page 130
page 131
page 132
page 133 - Cylinder head, installing, M52 TU and M5...
page 134
page 135
page 136
page 137
page 138
page 139
page 140 - Double VANOS Timing
page 141
page 142
page 143
page 144
page 145
page 146
page 147
page 148
page 149
page 150 - Intake manifold, removal and installatio...
page 151
page 152
page 153
page 154
page 155 - Left cylinder head, removing, M62 engine
page 156
page 157
page 158
page 159
page 160 - Left cylinder head, installing, M62 engi...
page 161
page 162
page 163
page 164
page 165
page 166 - Right cylinder head, removing, M62 engin...
page 167
page 168
page 169
page 170
page 171 - Right cylinder head, installing, M62 eng...
page 172
page 173
page 174
page 175
page 176
page 177
page 178 - Special Tools
page 179
page 180
page 181 - Cylinder Head
page 182 - Valves. leak test
page 183 - Hydraulic lifters, checking and replacin...
page 184
page 185
page 186
page 187
page 188 - Camshaft andLifter Removal and Installat...
page 189
page 190
page 191
page 192
page 193
page 194
page 195 - Camshaft and lifter. removal and install...
page 196
page 197
page 198
page 199
page 200
page 201
page 202
page 203
page 204 - Double VANOS timing chain components
page 205
page 206
page 207
page 208
page 209
page 210
page 211
page 212
page 213
page 214
page 215 - Camshaft removal and installation (M62 e...
page 216 - Valves
page 217
page 218
page 219
page 220
page 221
page 222
page 223
page 224
page 225
page 226
page 227
page 228
page 229
page 230
page 231
page 232 - Valves. leak test
page 233 - Valve guides
page 234 - Valve stem oil seals
page 235
page 236
page 237
page 238 - Special tools
page 239
page 240
page 241
page 242 - Crankshaft Oil Seal, Front
page 243
page 244
page 245 - Crankshaft oil seal, replacing (M52 TU a...
page 246
page 247 - Crankshaft oil seal, replacing (M62 and ...
page 248
page 249
page 250 - VANOS control unit, removing (M52 engine...
page 251
page 252
page 253
page 254
page 255 - VANOS control unit, installing (M52engin...
page 256
page 257
page 258 - VANOS timing, checking and adjusting (M5...
page 259
page 260
page 261
page 262 - Timing chains, removing (M52 engine)
page 263
page 264
page 265
page 266 - Timing chain, installing (M52 engine)
page 267
page 268
page 269
page 270 - (M52 TU and M54 engines)
page 271
page 272 - Double VANOS control unit
page 273 - VANOS control unit, removing (M52 TU and...
page 274
page 275
page 276
page 277 - VANOS control unit, installing (M52 TU a...
page 278
page 279 - VANOS timing, checking and adjusting (M5...
page 280
page 281
page 282
page 283
page 284
page 285
page 286 - Timing chains assembly (M52 TU and M54 e...
page 287 - Timing chains, removing (M52 TU and M54 ...
page 288
page 289
page 290
page 291
page 292
page 293 - Timing chains, installing (M52 TU and M5...
page 294
page 295
page 296
page 297
page 298
page 299
page 300
page 301
page 302 - Timing Chain (M62 engine to 9/98)
page 303
page 304
page 305
page 306
page 307
page 308
page 309
page 310 - Timing chains, installing (M62 engine to...
page 311
page 312
page 313
page 314
page 315 - Camshaft timing, checking and adjusting ...
page 316
page 317
page 318
page 319
page 320
page 321
page 322 - Special tools
page 323 - Engine lubrication
page 324 - Oil pressure. checking
page 325 - Oil pressure warning system. testing
page 326
page 327
page 328 - Crankshaft rear main seal. replacing (V-...
page 329
page 330 - Oil pan. removing and installing (6-cyli...
page 331
page 332
page 333 - Lower oil pan. removing and installing (...
page 334
page 335 - Upper oil pan. removing and installing (...
page 336
page 337
page 338
page 339
page 340 - Oil pressure warning switch. replacing
page 341 - (6-cylinder and V-8)
page 342 - Oil pump. removing and installing (6-cyl...
page 343
page 344 - Oil pump. removing and installing (V-8)
page 345
page 346 - Oil pressure relief valve (6-cylinder)
page 347 - Oil pressure relief valve (V-8)
page 348
page 349
page 350
page 351 - Warnings and cautions
page 352
page 353
page 354 - Lgnition system
page 355
page 356
page 357 - Ignition firing order
page 358 - Disabling ignition system
page 359
page 360 - Crankshaftspeedsensor
page 361
page 362 - Camshaft position sensors 120-1
page 363
page 364 - Knocksensors
page 365
page 366
page 367
page 368 - Battery. Starter. Alternator
page 369 - Battery Safety Terminal
page 370 - Warnings and cautions
page 371 - Battery testing
page 372 - Battery open-circuit voltage test
page 373 - Closed-circuit current measurement
page 374
page 375 - Battery charging
page 376
page 377 - Alternator (generator
page 378 - Water-cooled alternator
page 379 - Charging system quick-check
page 380
page 381 - Alternator. removing and installing (6-c...
page 382 - Alternator. removing and installing (M62...
page 383
page 384 - Alternator. removing and installing (M62...
page 385 - Starter
page 386 - Starter. removing and installing (6-cyli...
page 387 - Starter. removing and installing (V-8 en...
page 388
page 389 - Solenoid switch. removing and installing
page 390
page 391
page 392
page 393 - Tools and test equipment
page 394
page 395 - Warnings and cautions
page 396 - Fuel Supply
page 397 - ECM relay. testing
page 398
page 399 - Mass air flow (MAF) sensor
page 400 - Engine coolant temperature (ECT) sensor
page 401 - Testing and replacing
page 402 - Throttle position sensor (TPS)
page 403 - Ldle speed control valve
page 404
page 405 - Fuel injectors. checking and replacing
page 406 - Evaporative emissions. overview
page 407 - Secondary air injection. overview
page 408 - Engine control module (ECM)
page 409 - Siemens MS 41.1 ECM pin assignments
page 410
page 411
page 412
page 413
page 414
page 415
page 416
page 417 - ECM relay. testing
page 418
page 419
page 420 - Engine coolant temperature (ECT) sensor
page 421 - Intake air temperature (IAT) sensor
page 422 - MS 42.0 throttle valve assembly. replaci...
page 423
page 424
page 425 - MS 43.0 throttle valve assembly. replaci...
page 426
page 427
page 428 - Throttle cable. adjusting (MS 42.0
page 429 - Evaporative emissions control diagrams
page 430 - Engine control module (ECM)
page 431 - Siemens MS 42.0 and MS 43.0
page 432
page 433
page 434
page 435
page 436
page 437 - M5.2 system features
page 438
page 439 - ECM relay. testing
page 440
page 441 - Oxygen sensors. checking
page 442 - Fuel injectors. checking and replacing
page 443 - Mass air flow (MAF) sensor. replacing
page 444 - Ldle speed control valve. testing and re...
page 445 - Throttle position sensor (TPS)
page 446
page 447 - Testing and replacing
page 448
page 449 - Bosch 5.2 ECM pin assignments UP to 911 ...
page 450
page 451
page 452
page 453
page 454
page 455
page 456
page 457 - ME 7.2 system overview
page 458
page 459 - EDK adaptation
page 460
page 461 - Engine coolant temperature (ECT) sensor....
page 462 - Oxygen sensors. replacing
page 463 - Mass air flow (MAF) sensor
page 464 - Evaporative system pressure leak diagnos...
page 465 - Secondary air injection. overview
page 466 - Bosch ME 7.2 ECM pin assignments
page 467
page 468
page 469
page 470
page 471
page 472
page 473 - Fuel Tank and Fuel Pump
page 474 - Evaporative system troubleshooting
page 475 - Warnings and cautions
page 476 - Fuel pump fuse and relay
page 477 - Fuel pump electrical circuit, testing
page 478
page 479 - Fuel pump power consumption, testing
page 480 - Fuel pressure gauge, installing (6-cylin...
page 481 - (V-8 models
page 482 - Fuel delivery, testing
page 483
page 484
page 485 - FUELPUMP AND FUELLEVELSENDER
page 486
page 487 - Fuel level sender (left side). removing ...
page 488
page 489 - Siphon pump. removing and installing
page 490 - Fuel tank. draining
page 491 - Fuel tank. removing and installing
page 492
page 493 - Fuel expansion tank. removing and instal...
page 494 - Activated carbon canister I fuel tank le...
page 495
page 496
page 497
page 498 - Special tools
page 499 - Cooling system overview (M52 TU shown. o...
page 500 - Mechanical thermostat (M52 engine
page 501 - Transmission fluid heat exchanger
page 502
page 503 - Warnings and cautions
page 504 - Cooling system inspection
page 505 - Cooling system pressure test
page 506 - Combustion chamber leak test
page 507
page 508 - Coolant. draining and filling (V-8 model...
page 509
page 510 - Cooling system. bleeding
page 511
page 512 - Thermostat. removing and installing (M52...
page 513 - Thermostat. removing and installing (M52...
page 514 - Thermostat. removing and installing (V-8...
page 515 - Coolant pump. replacing (6-cylinder mode...
page 516 - Coolant pump. replacing (V-8 models)
page 517
page 518 - Radiator. removing and installing
page 519
page 520 - Expansion tank. removing and installing
page 521
page 522
page 523
page 524 - Exhaust System
page 525
page 526 - Muffler, replacing
page 527 - Exhaust manifolds, removing and installi...
page 528 - Exhaust manifolds, removing and installi...
page 529
page 530
page 531 - Oxygen Sensors
page 532 - Oxygen sensor, replacing (M52 and M62 en...
page 533 - M52 engine (528i 1997-1 998)
page 534 - M52 TU and M54 engines
page 535
page 536 - M62 engine (540i 1997-1 998)
page 537 - M62 TU engine
page 538
page 539
page 540
page 541
page 542
page 543
page 544 - Clutch
page 545
page 546 - Clutch hydraulic system
page 547
page 548 - Clutch master cylinder. replacing
page 549
page 550 - Clutch slave cylinder. replacing
page 551 - Clutch variations
page 552
page 553 - Clutch. removing
page 554 - Flywheel. removing and installing (6 cyl...
page 555 - Flywheel. removing and installing (V-8 e...
page 556
page 557
page 558
page 559 - Clutch. installing (new SAC components)
page 560
page 561
page 562
page 563
page 564
page 565
page 566 - Special tools
page 567
page 568
page 569
page 570 - Transmission fluid level. checking
page 571 - Back-up light switch, replacing
page 572 - (transmission installed)
page 573
page 574 - Put shaft seal. replacing
page 575
page 576
page 577
page 578
page 579
page 580
page 581
page 582
page 583
page 584
page 585 - Transmission Removal
page 586 - Special tools
page 587
page 588 - Automatic transmission applications
page 589
page 590 - ATF level, checking
page 591 - ATF, draining and filling
page 592
page 593 - Automatic transmission fluid pan and str...
page 594 - Transmission Removal and Installation
page 595
page 596
page 597
page 598
page 599
page 600 - Special tools
page 601 - Gearshift lever, removing (manual transm...
page 602 - Gearshift lever, installing (manual tran...
page 603
page 604 - Automatic Transmission Gearshift
page 605 - Automatic shiftlock, checking function (...
page 606 - Shift interlock, checking function (auto...
page 607
page 608 - Special tools
page 609 - Driveshaft description
page 610
page 611
page 612
page 613 - Driveshaft. aligning
page 614 - Driveshaft. removing
page 615
page 616 - Driveshaft. installing
page 617 - Flex.disc. replacing
page 618 - Center bearing assembly. replacing
page 619 - Front centering guide. replacing
page 620 - Constant velocity (CV) joint. replacing
page 621
page 622 - General
page 623 - Front suspension 6-cylinder models
page 624 - Front suspension V-8 models (540i)
page 625
page 626 - Rear suspension sedan models
page 627 - Rear suspension Sport Wagon (with coil s...
page 628 - Rear suspension Sport Wagon (EHC with ai...
page 629 - EHC operational diagram
page 630 - Rack-and-pinion steering
page 631 - Rim and tire sizes table
page 632 - E39 electronic brake and stability contr...
page 633
page 634 - Dynamic Stability Control (DSC)
page 635 - Front ride height specifications
page 636 - Rear ride height specifications
page 637
page 638 - Front Suspension
page 639
page 640 - Front suspension variations
page 641 - Front strut assembly, removing and insta...
page 642
page 643
page 644
page 645 - Front strut assembly components (6-cylin...
page 646
page 647
page 648 - Front Suspension Arms
page 649
page 650
page 651
page 652 - Tension strut, removing and installing
page 653
page 654 - Tension strut bushing, replacing
page 655
page 656
page 657
page 658 - Stabilizer bar, removing and installing
page 659
page 660 - Steering and Wheel Alignment
page 661
page 662 - Steering system
page 663 - Steering system variations
page 664 - Steering system warnings and cautions
page 665 - Steering Wheel
page 666
page 667
page 668 - Steering Column
page 669 - Removing and installing
page 670 - Steering column lock. removing and insta...
page 671
page 672 - (models with automatic transmission)
page 673
page 674 - Steering column adjustment motors
page 675 - Power steering pump. removing and instal...
page 676
page 677 - (6-cylinder models)
page 678
page 679
page 680 - Steering rack boot. replacing
page 681 - Tie rod (inner). replacing
page 682 - Steering Gearbox (V-8 models)
page 683 - Steering gearbox, removing and installin...
page 684
page 685
page 686 - Pitman arm. removing and installing
page 687 - Pitman arm. adjusting
page 688 - Steering idler arm. removing and install...
page 689
page 690 - Center tie rod. replacing
page 691 - Camber
page 692 - Front toe and toe difference angle
page 693 - Preparing for alignment
page 694
page 695
page 696
page 697
page 698 - Special tools
page 699
page 700 - Rear suspension variations
page 701 - Rear Struts and Springs (sedan models)
page 702
page 703 - Rear strut assembly, disassembling and a...
page 704
page 705 - Springs (Sport Wagon models)
page 706
page 707 - Coil spring, removing and installing
page 708 - Air spring, removing and installing
page 709 - Rear Suspension Arms, Subframe and Bushi...
page 710 - Swing arm, removing and installing (seda...
page 711
page 712 - Swing arm, removing and installing (Spor...
page 713
page 714
page 715 - Swing arm ball joint, replacing
page 716
page 717
page 718 - Upper rear control arm, removing and ins...
page 719 - Upper rear control arm, removing and ins...
page 720
page 721 - Upper front control arm (traction strut)...
page 722 - Rear axle assembly, removing and install...
page 723
page 724 - Rear axle assembly, removing and install...
page 725
page 726
page 727 - Rear subframe mounting bushings, removin...
page 728
page 729
page 730
page 731
page 732
page 733
page 734
page 735
page 736
page 737
page 738
page 739
page 740
page 741
page 742
page 743
page 744
page 745
page 746 - Special tools
page 747
page 748
page 749 - Final drive, removing and installing
page 750 - Differential oil level, checking
page 751 - Final drive i n ~ u t shaft seal, replac...
page 752
page 753
page 754
page 755
page 756 - Final drive cover, removing and installi...
page 757
page 758 - Drive axle assembly
page 759
page 760
page 761
page 762
page 763
page 764 - Special Tools
page 765
page 766 - E39 brake system
page 767 - Troubleshooting
page 768
page 769 - Warnings and cautions
page 770
page 771 - Brakes, bleeding
page 772
page 773 - Brake Pads, Calipers and Rotors
page 774 - Brake pads, checking and replacing
page 775
page 776
page 777 - Brake rotors, removing and installing
page 778
page 779 - Master cylinder, removing and installing
page 780
page 781 - Brake booster check valve
page 782 - Brake booster, removing and installing
page 783
page 784 - Parking Brake
page 785
page 786 - Parking brake cable, replacing
page 787
page 788 - ABS Component Replacement
page 789 - ABS impulse wheel
page 790
page 791
page 792 - DSC pressure sensor
page 793 - (1 999 - 2002 models)
page 794
page 795
page 796 - Body dimensions (in inches)
page 797 - Bodyshell
page 798
page 799 - Tailgate
page 800 - Rear wiper system
page 801 - Safety and Security Features
page 802 - Airbags
page 803 - Battery safety terminal (BST)
page 804 - Seats
page 805 - Central body electronics
page 806
page 807
page 808
page 809
page 810
page 811
page 812
page 813
page 814
page 815
page 816
page 817
page 818
page 819
page 820 - Doors
page 821
page 822 - Door check. replacing
page 823 - Door hinge adjustment
page 824 - Door hinge assembly
page 825 - Door trim panel. removing and installing
page 826
page 827
page 828 - Sill trim panels
page 829
page 830
page 831
page 832
page 833
page 834
page 835
page 836
page 837
page 838
page 839
page 840
page 841
page 842
page 843
page 844
page 845
page 846
page 847
page 848
page 849
page 850
page 851
page 852 - Outside mirror glass. replacing
page 853 - Outside mirror housing
page 854
page 855 - Bumpers
page 856 - Front bumper assembly
page 857 - Front bumper, removing and installing
page 858 - Front bumper impact absorber. replacing
page 859 - Rear bumper assembly
page 860 - Rear bumper. removing and installing
page 861 - Rear bumper impact absorber. replacing
page 862 - Front bumper height. adjusting
page 863 - BMW emblem. removing and installing
page 864 - Radiator grill. removing and installing
page 865
page 866 - Special tools
page 867 - Window switches
page 868 - Power window motors
page 869 - Window motor limit stop function
page 870 - Window anti-trap strip, testing
page 871 - Rear window anti-trap strip, removing
page 872 - Door window. adjusting
page 873 - Door window. removing and installing
page 874
page 875 - Front window regulator removing and inst...
page 876
page 877 - Rear window regulator. removing and inst...
page 878
page 879
page 880 - Lnterior Trim
page 881
page 882
page 883
page 884
page 885 - Lower dash panel assembly, removing and ...
page 886
page 887
page 888
page 889 - Upper dash assembly, removing and instal...
page 890 - Window and door post trim panels, removi...
page 891
page 892
page 893 - Dash panel support, removing and install...
page 894 - Glove compartment, removing and installi...
page 895
page 896 - Central Locking
page 897 - Central locking inputs and outputs
page 898
page 899
page 900
page 901 - Remote entry (FZV)
page 902 - Remote entry (FZV) inputs and outputs
page 903
page 904
page 905
page 906
page 907 - Trunk lid soft close (SCA)
page 908 - SCA subsystem
page 909 - Sport Wagon tailgate and rear window loc...
page 910 - Door Handles and Locks
page 911 - Door latch, removing and installing
page 912 - Outer door lock cylinder, removing and i...
page 913 - Trunk lock. removing and installing
page 914 - Trunk lock striker plate. removing and i...
page 915 - Tailgate lock. emergency release
page 916 - EWS variations
page 917 - EWS control module. replacing
page 918 - Anti-theft System (DWA)
page 919 - Interior protection
page 920 - Glass breakage sensors
page 921
page 922 - SeatIMirrorlSteering Column Memory
page 923
page 924 - Seat switch and memory module
page 925
page 926
page 927 - Rear seat cushion and backrest, removing...
page 928 - Headrest. removing and installing
page 929
page 930 - Sunroof
page 931 - Sunroof, normalization
page 932 - Sunroof panel, emergency closing
page 933
page 934
page 935 - Sunroof with glass roof panel, adjusting
page 936 - Sunroof panel, removing and installing (...
page 937 - Sunroof panel gasket, replacing (steel o...
page 938 - Sunroof motor, replacing
page 939
page 940 - Troubleshooting
page 941
page 942 - Front seat belt tensioner
page 943
page 944
page 945
page 946 - Rear Seat Belt Assembly
page 947 - Rear seat belts (sedan)
page 948 - Rear seat belts (Sport Wagon)
page 949
page 950
page 951
page 952 - Two-stage airbag (MRS 111)
page 953
page 954 - MRS airbag system diagram
page 955 - MRS control module. replacing
page 956 - Driver airbag. removing and installing
page 957 - Passenger airbag. removing and installin...
page 958 - Door mounted side-impact airbag
page 959 - Head protection airbag components
page 960
page 961
page 962
page 963
page 964
page 965
page 966
page 967
page 968
page 969
page 970
page 971
page 972
page 973
page 974
page 975
page 976
page 977
page 978
page 979
page 980
page 981
page 982
page 983
page 984
page 985
page 986
page 987
page 988
page 989
page 990
page 991
page 992
page 993
page 994
page 995
page 996
page 997
page 998
page 999
page 1000
page 1001
page 1002
/
1002
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General
Warnings. Cautions and Notes
Safety
Lifting the Car
Raising Car
Working under Car
Advice for the Beginner
Planning Ahead
Workshop Practices
Non-Reusable Fasteners
Tightening Fasteners
Gaskets and Seals
Electrical Testing
Wire Repairs
Genuine BMW Parts
Non-Returnable Parts
Information You Need to Know
Basic Tool Requirements
Jack Stands
Oil Change Equipment
Torque Wrench
Digital Multimeter
Changing a Tire
Jump Starting
Indicator and Warning Lights
Towing
Spare Parts Kit
Maintenance
Special Tools
Service Interval Indicator (Sll)
Service Interval Indicator (Sll), Resetting
Maintenance Tables
Fluid and Lubricant Specifications
Fluids and Lubricants
Engine Oil. Checking Level
Engine Oil and Filter. Changing
Accelerator and Linkage
Air Filter. Replacing
Idlespeed
Catalytic Converter and Oxygen Sensors
Power Steering Fluid, Checking Level
Spark Plugs
Spark Plugs, Replacing
Interior Ventilation Microfilter, Replacing
Brake Fluid. Replacing
Brake Pad 1 Rotor Wear. Checking
Brake System, Inspecting
Parking Brake. Checking
Clutch Fluid. Checking
Differential Oil Level. Checking
Drive Axle Joint (CV Joint) Boots. Inspecting
Exhaust System. Inspecting
Fuel Filter. Replacing
Fuel Tank and Fuel Lines. Inspecting
Suspension. Front. Inspecting
Suspension. Rear. Inspecting
Tires. Checking Inflation Pressure
Tires. Rotating
Transmission Service. Automatic
Transmission Service. Manual
Transmission Fluid. Checking and Filling (Manual Transmission)
Wheels. Aligning
Body and Interior Maintenance
Body and Hinges. Lubricating
Exterior Washing
Interior Care
Leather Upholstery and Trim
Polishing
Seat Belts
Special Cleaning
Washing Chassis
Waxing
Windshield Wiper Blade Maintenance
Cylinder Head Removal and Installation (M52 Engine)
Cylinder Compression, Checking
Wet Compression Test
Cylinder Leak-Down Test
Cylinder Head, Removing, M52 Engine
Cylinder Head, Installing, M52 Engine
Cylinder Head Removal and Installation (M52 TU and M54 Engines)
Cylinder Head, Removing, M52 TU and M54 Engines
Cylinder Head, Installing, M52 TU and M54 Engine
Double VANOS Timing
Chain Components
Double VANOS Timing Chain Components, Installing, M52 TU and M54 Engines
Cylinder Head Removal and Installation (M62 Engine)
Intake Manifold, Removal and Installation, M62 Engine
Left Cylinder Head, Removing, M62 Engine
Left Cylinder Head, Installing, M62 Engine
Right Cylinder Head, Removing, M62 Engine
Right Cylinder Head, Installing, M62 Engine
Special Tools
Cylinder Head
Valves. Leak Test
Hydraulic Lifters, Checking and Replacing
Camshaft Andlifter Removal and Installation
Camshaft and Lifter. Removal and Installation (M52 TU and M54 Engine)
Double VANOS Timing Chain Components
Camshaft Removal and Installation (M62 Engine)
Valves
Valves. Leak Test
Valves. Removing and Installing
Valve Guides
Valve Stem Oil Seals
Special Tools
Crankshaft Oil Seal, Front
Crankshaft Oil Seal, Front, Replacing (M52 Engine
Crankshaft Oil Seal, Replacing (M52 TU and M54 Engines
Crankshaft Oil Seal, Replacing (M62 and M62 TU Engines)
VANOS Control Unit, Removing (M52 Engine)
VANOS Control Unit, Installing (M52Engine)
VANOS Timing, Checking and Adjusting (M52 Engine
Timing Chains, Removing (M52 Engine)
Timing Chain, Installing (M52 Engine)
(M52 TU and M54 Engines)
Double VANOS Control Unit
VANOS Control Unit, Removing (M52 TU and M54 Engines)
VANOS Control Unit, Installing (M52 TU and M54 Engines)
VANOS Timing, Checking and Adjusting (M52 TU and M54 Engines)
Timing Chains Assembly (M52 TU and M54 Engines)
Timing Chains, Removing (M52 TU and M54 Engines)
Timing Chains, Installing (M52 TU and M54 Engines)
Timing Chain (M62 Engine to 9/98)
Timing Chains, Removing (M62 Engine to 9/98)
Timing Chains, Installing (M62 Engine to 9/98)
Camshaft Timing, Checking and Adjusting (M62Engine)
Special Tools
Engine Lubrication
Oil Pressure. Checking
Oil Pressure Warning System. Testing
Crankshaft Rear Main Seal. Replacing (V-8)
Oil Pan. Removing and Installing (6-Cylinder
Lower Oil Pan. Removing and Installing (V-8)
Upper Oil Pan. Removing and Installing (V-8)
Oil Pressure Warning Switch. Replacing
(6-Cylinder and V-8)
Oil Level Warning Switch. Replacing
Oil Pump. Removing and Installing (6-Cylinder)
Oil Pump. Removing and Installing (V-8)
Oil Pressure Relief Valve (6-Cylinder)
Oil Pressure Relief Valve (V-8)
Warnings and Cautions
Engine Management
Lgnition System
Oscilloscope Diagnostic Diagrams
Misfire Detection
Ignition Firing Order
Disabling Ignition System
Checking for Spark
Crankshaftspeedsensor
Camshaft Position Sensors 120-1
Knocksensors
Battery. Starter. Alternator
Special Tools
Engine Electrical System
Battery Safety Terminal
Warnings and Cautions
Battery Testing
Hydrometer Testing
Battery Open-Circuit Voltage Test
Battery Load Voltage Test
Closed-Circuit Current Measurement
Battery Charging
Battery Safety Terminal, Replacing
Alternator (Generator
Alternator. Basic
Alternator with Multi-Function Control (MFR
Water-Cooled Alternator
Charging System Quick-Check
Charging System. Checking
Alternator. Removing and Installing (6-Cylinder Engine)
Alternator. Removing and Installing (M62 Engine. Air Cooled)
Alternator. Removing and Installing (M62 TU Engine. Water Cooled)
Starter
Starter Troubleshooting
Starter. Removing and Installing (6-Cylinder Engine)
Starter. Removing and Installing (V-8 Engine)
Solenoid Switch. Removing and Installing
Tools and Test Equipment
Warnings and Cautions
Fuel Supply
Relieving System Fuel Pressure
ECM Relay. Testing
Mass Air Flow (MAF) Sensor
Checking and Replacing
Engine Coolant Temperature (ECT) Sensor
Testing and Replacing
Testing and Replacing
Throttle Position Sensor (TPS)
Testing and Replacing
Ldle Speed Control Valve
Checking and Replacing
Fuel Injectors. Checking and Replacing
Evaporative Emissions. Overview
Secondary Air Injection. Overview
Engine Control Module (ECM)
Removing and Installing
Siemens MS 41.1 ECM Pin Assignments
ECM Relay. Testing
Engine Coolant Temperature (ECT) Sensor
Testing and Replacing
Intake Air Temperature (IAT) Sensor
Testing and Replacing
MS 42.0 Throttle Valve Assembly. Replacing
MS 43.0 Throttle Valve Assembly. Replacing
Throttle Cable. Adjusting (MS 42.0
Ldle Speed Control Valve. Checking and Replacing
Evaporative Emissions Control Diagrams
Evaporative Emissions Control
Engine Control Module (ECM)
Removing and Installing
Siemens MS 42.0 and MS 43.0
ECM Pin Assignments
M5.2 System Features
M5.2.1 System Features
ECM Relay. Testing
Oxygen Sensors. Checking
Fuel Injectors. Checking and Replacing
Mass Air Flow (MAF) Sensor. Replacing
Ldle Speed Control Valve. Testing and Replacing
Throttle Position Sensor (TPS)
Testing and Replacing
Engine Coolant Temperature (ECT) Sensor
Testing and Replacing
Auxiliary Throttle Valve (ADS) (M62 and M62 TU Engine). Replacing
Bosch 5.2 ECM Pin Assignments up to 911 997)
ME 7.2 System Overview
EDK Adaptation
Engine Coolant Temperature (ECT) Sensor. Testing
Engine Coolant Temperature (ECT) Sensor. Replacing
Oxygen Sensors. Replacing
Fuel Injectors. Removing and Installing
Mass Air Flow (MAF) Sensor
Removing and Installing
Evaporative System Pressure Leak Diagnosis. Overview
Secondary Air Injection. Overview
Bosch ME 7.2 ECM Pin Assignments
Fuel Tank and Fuel Pump
Fuel Tank Evaporative Control System
Evaporative System Troubleshooting
Warnings and Cautions
Fuel Pump Fuse and Relay
Operating Fuel Pump for Tests
Fuel Pump Electrical Circuit, Testing
Fuel Pump Power Consumption, Testing
Fuel Pressure Gauge, Installing (6-Cylinder Models
Fuel Pressure Gauge, Installing
(V-8 Models
Fuel Delivery, Testing
Fuelpump and Fuellevelsender
Fuel Level Sender (Right Side) and Fuel Pump. Removing and Installing
Fuel Level Sender (Left Side). Removing and Installing
Siphon Pump. Removing and Installing
Fuel Tank. Draining
Fuel Tank. Removing and Installing
Fuel Expansion Tank. Removing and Installing
Activated Carbon Canister I Fuel Tank Leak Detection Unit (LDP or DMTL). Removing and Installing
Running Losses (312-Way) Valve
Removing and Installing
Special Tools
Cooling System Overview (M52 TU Shown. Others Similar
Coolant Pump
Thermostat
Mechanical Thermostat (M52 Engine
Electrically Heated Thermostat
Radiator and Expansion Tank
Mechanical Cooling Fan with Viscous Clutch
Electric (Auxiliary) Cooling Fan
Transmission Fluid Heat Exchanger
Warnings and Cautions
Cooling System Inspection
Cooling System Pressure Test
Combustion Chamber Leak Test
Thermostat
Coolant. Draining and Filling (6-Cylinder Models)
Coolant. Draining and Filling (V-8 Models)
Cooling System. Bleeding
Mechanical (Viscous Clutch) Cooling Fan
Removing and Installing
Thermostat. Removing and Installing (M52Engine)
Thermostat. Removing and Installing (M52 TU or M54 Engine)
Thermostat. Removing and Installing (V-8 Models)
Coolant Pump. Replacing (6-Cylinder Models)
Coolant Pump. Replacing (V-8 Models)
Radiator. Removing and Installing
Expansion Tank. Removing and Installing
Exhaust System
Muffler, Replacing
Exhaust Manifolds, Removing and Installing (M52 Engine)
Exhaust Manifolds, Removing and Installing (M52 TU and M54 Engines)
Exhaust Manifolds, Removing and Installing (M62 Engine)
Oxygen Sensors
Oxygen Sensors (Precatalyst), Replacing (M52 TU and M54)
Oxygen Sensors (Post-Catalyst), Replacing (M52 TU and M54)
Oxygen Sensor, Replacing (M52 and M62 Engine)
M52 Engine (528I 1997-1 998)
M52 TU and M54 Engines
M62 Engine (540I 1997-1 998)
M62 TU Engine
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www.bmwclub.pro - BMW PRO FORUM!
Service Manua
5251, 5281, 530i, 540i
Sedan, Sport Wagon
1997,1998,1999,2000,2001,2002
Table of
Contents
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2
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Chapters
010 General
11
020 Maintenance
33
11 3 Cylinder Head Removal and Installation
95
11 6 Cylinder Head and Valvetrain
177
11 7 Camshaft Timing Chain
237
11 9 Lubrication System
321
120 Lgnition System
349
121 Battery. Starter. Alternator
367
130 Fuel Injection
391
160 Fuel Tank and Fuel Pump
471
176 Radiator and Cooling System
497
180 Exhaust System
523
210 Clutch
543
230 Manual Transmission
565
240 Automatic Transmission
585
250 Gearshift Linkage
599
Table of Contents
607
. 300 Suspension. Steering and Brakes Genera8
621
031 Front Suspension
637
320 Steering and Wheel Alignment
659
330 Rear Suspension
697
33Ufinal Drive
745
Table of Contents
763
400 Body-General
795
Table of Contents
819
510 Exterior Trim. Bumpers
851
512 Door Windows
865
513 Lnterior Trim
879
51 5 Andcentral Locking Anti-Theft
895
Table of Contents
Troubleshooting
Starter
385
Evaporative system troubleshooting
474
Driveshaft description
609
Troubleshooting
767
Troubleshooting
940
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Summary of Contents for BMW 5251
Page 1
- BMW PRO FORUM! Service Manua 5251, 5281, 530i, 540i Sedan, Sport Wagon 1997,1998,1999,2000,2001,2002...
This manual is also suitable for:
530i
5281
540i
525i
Sport wagon
528i
...
Show all
Sedan
2002 530i sedan
2002 525i
2002 540i sedan
2002 528i
2001 530i sedan
2001 525i
2001 540i sedan
2001 528i
2000 530i sedan
2000 525i
2000 540i sedan
2000 528i
1999 530i sedan
1999 525i
1999 540i sedan
1999 528i
1998 530i sedan
1998 525i
1998 540i sedan
1998 528i
1997 530i sedan
1997 525i
1997 540i sedan
1997 528i
E39
5 series
1997 5251 sedan
1997 5251 sport wagon
1997 5281 sedan
1997 5281 sport wagon
1997 530i sport wagon
1997 540i sport wagon
1998 5251 sedan
1998 5251 sport wagon
1998 5281 sedan
1998 5281 sport wagon
1998 530i sport wagon
1998 540i sport wagon
1999 5251 sedan
1999 5251 sport wagon
1999 5281 sedan
1999 5281 sport wagon
1999 530i sport wagon
1999 540i sport wagon
2000 5251 sedan
2000 5251 sport wagon
2000 5281 sedan
2000 5281 sport wagon
2000 530i sport wagon
2000 540i sport wagon
2001 5251 sedan
2001 5251 sport wagon
2001 5281 sedan
2001 5281 sport wagon
2001 530i sport wagon
2001 540i sport wagon
2002 5251 sedan
2002 5251 sport wagon
2002 5281 sedan
2002 5281 sport wagon
2002 530i sport wagon
2002 540i sport wagon
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