BMW 5251 Bedienungsanleitung

Service

Manua

5251,

5281,

530i,

540i

Sedan,

Sport

Wagon

1997,1998,1999,2000,2001,2002

www.bmwclub.pro - BMW PRO FORUM!

Benllcy

Publishers,

division

Robcrt

Bcnlley,

In=.

1734

M~SB~CIIUP~IIS

Avenue

Cumbitdge.

MA02138

USA

Information

lhat

makes

800-423-4885

7.547.4170

the diiierence"

BentleyPublishe~

Technical contact inlormation

:.€

c3me ,o.lr leeooaca. Pieasc.

;Jam

cllriecl

00s

an0

zoo ions lo ourBhFLt/ recnns? o rcdss'unlor~ma1

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Erratainformation

We will evaluate submissions and post appropriate editorial

changes online as text errata or tech discussion. Appropriate

errata will be incorporated with the boolc text in future printings.

Read errata informationfor this book before beginning work on

your vehicle. See the following web address tor additional

information:

http://unw.BentleyPublishers.com/errata/

WARNING-important safety notice

Donotusethis manualunlessvouarefamiliarwith basic automotivereoairoroceduresandsafeworkshoooracfices.This manualillustrates

the workshopprocedures

requkedformoslservicework. Itisnotasubsiituti forfullandup-to-dateinformationfromthevehiclemanufaciurer

or for propertrainingas an automotivetechnician. Note that it is not possiblefor us to anticipate all of the ways or conditionsunderwhich

vehicles maybeservicedor to providecautionsas to all of the possiblehazardsthat mayresult.

Thevehiclemanufacturerwillcontinuetoissueserviceinformationupdatesandparlsretrofitsaftertheeditorialclosingofthismanual.Some

of lhese updates and retrofits will apply lo proceduresand specifications in this manual. We regret that we cannot supply updates to

purchasersof this manual.

We haveendeavoredto ensure the accuracyof the informationinthis manual. Pleasenote,however,that consideringthevast quantityand

the complexityof the service information involved, we cannot warrant the accuracy or completeness of the informationcontained inthis

manual.

FOR

THESE

REASONS,

NEITHER

THE

PUBLISHER

NOR

THE

AUTHOR

MAICES

ANY

WARRANTIES,

EXPRESSOR

IMPLIED,

THATTHE

INFORMATION

THIS BOOK

FREE OF

ERRORS

OMISSIONS. AND WE EXPRESSLY DISCLAIMTHE IMPLIED WARRANTIES

MERCHANTABILTTYAN0 OF FITNESS

FOR

PARTICULAR PURPOSE,EVENIFTHEPUBLISHER

AUTHOR HAVE BEENADVISED OFA PARTICULAR PURPOSE,AND EVEN

PARTICULAR

PURPOSE

INDICATED

THE MANUAL. THE PUBLISHER AND

AUTHOR

ALSO DISCLAIM ALL LlABlLrrY

FOR

DIRECT.

INDIRECT. INCIDENTAL

CONSEQUENTIALDAMAGESTHAT RESULT FROM ANY USE OFTHE EXAMPLES,INSTRUCTIONS

OTHER INFORMATIONINTHISBOOK. INNO EVENT

Your common sense and oood iudomentare crucial to safe and successful service work. Readorocedures throuoh before startinothem.

- -~

---~.

Think about whether the condition of your car, &r level ofmechanical skill, or your level of reading compreh&sion might resill in or

contributeinsomeway to an occurrencewhich mightcause you injuly, damage your car, or result inan unsafe repair.

you have doubts

for theseor other reasonsaboutyour ability to pelformsafe repairwork on your car,havethe work done at an authorizedBMW dealer or

other qualifiedshop.

Part numberslistedin this manual are for identificationpurposesonly, not forordering. Always check wilh your authorized BMW dealerto

verify part numbersandavailabilitybeforebeginningservicework lhatmayrequirenewpark.

Before anempting any work on your BMW, read the

001

General Warnings and Cautions, and any WARNING or CAUTION that

accompanies a procedureinthe service manual. Reviewthe WARNINGS and CAUTIONSeach time you preparetowork onyour BMW.

Spec a toos req.1 redto perlormcenan service

operations

arc oenlfed n the manLa an0 arc recomrnenoeolor

JSC

Jse ol loosolner

than those recommendedIn lhs serv ce manualmay beoelnmcnlallolrlc car's sale open1on as rvec as lnesalely

lnepersonservcng

the car.

Copies of this manual may be purchased from most automotive accessoriesand parts dealers specializing in BMW automobiles, from

selected booksellers, or directly from the publisher.

This manual was published by Robert Bentley, Inc., Publishers. BMW has not reviewed and does not vouch for the accuracy of the

technical specifications and proceduresdescribed in this manuai.

Libratv of Conaress

Cataloaino-in-Publication

Data

" "

BMW 5 Series (E39)

service manual

523. 528i,530i. 540i, sedan, sport wagon, 1997,

1998, 1999,2000,2001,2002

~Acludesindex.

ISBN0-8376-0317-X (obi<)

1. BMW 5 series automobiles--Maintenanceand repair--Handbooks manuals, etc.

Robert Bentley, Inc.

TL215.8258623 2003

629.28'722--dc23 2003052231

BentleyStock No.

8502

Editorialclosing 08/03

090807 10987654

The paper used in this publication is acid free and meets the requirements of the National Standard for Information Sciences-

Permanence of Paper for PrintedLibrary Materials.

closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced,stored in a

retrievalsystem, or transmittedin any form or by any means, electronic, mechanical,photocopying,recording,or ofhenvise, without the

prior written consent of the publisher.Thisincludestext,figures,andtables.All rightsreservedunderBerneandPan-AmericanCopyright

conventions.

Cover photos of car exteriors by Jonathan Richardfor Bentley Publishers

Robert Bentley, Inc. Cover design and use of blue band on

Manufactured inthe United States ofAmerica

YOU

are

now

Volume

Foreword

...................

..................................................................................

Index

........................

................................................................

rearofmanual

General,

001

General Warnings and Cautions

002

Vehicle Identificationand VIN Decoder

Maintenance

OiO

020

Maintenance

Engine

100

Engine-General

110

EngineRemovaland Installation

113

Cylinder HeadRemovaland

Installation

116

Cyiinder HeadandValvetrain

117

CamshaftTiming Chain

119

LubricationSystem

200

Transmission-General

Transmission

210

clutch

230

ManualTransmission

I20

IgnitionSystem

121

Battery,Starter,Alternator

130

Fuel Injection

160

FuelTank andFuel Pump

170

Radiatorand Cooling System

180

ExhaustSystem

240

AutomaticTransmission

250

GearshiftLinkage

260

Driveshaft

Suspension,

300

Suspension,Steering and

330

RearSuspension

Brakes-General

331

FinalDrive

Steering

and

Front Suspension

340

Brakes

320

Steering and Wheel Alignment

400

Body-General

410

Fenders, Engine Hood

411

Doors

412

Trunk Lid,Tailgate

510

ExteriorTrim, Bumpers

512

DoorWindows

Equipment

513

InteriorTrim

Equipmentand

720

seat Belts

Accessories

721

Airbag System (SRS)

OBD

On-BoardDiagnostics

............

515

Central Locitingand

Anti-Theft

520

Seats

540

Sunroof

....................................................................

Foreword

..............................

Index

...................

................................................................

rearof manual

Electrical

system

600

ElectricalSystem-General

620

Instruments

610

ElectricalComoonent Locations

630

Liohts

611

wipersandwashers

612

Switches

eati in^

andAir Conditioning

Radio

...........

........

.........................

ElectricalWiring Diagrams

SelectedBoolcs andRepairInformationfromBentleyPublishers

MINI

Cooper

MINI Cooper Service Manual: 2002-2004

Bc,illc!! Pirl~lisl!~~ISBN 0-8376-1068-0

AlexZanardi

MySwectest Victory

rllex Zmmrdiitjill! Ginrz11,cnGns~x~ri,,i

ISBN (1-8376-1249-7

BMW3 Series IE36)ScrvireManual:

1992-1998,318ilisliC. 323is/iC, 3?5i/is/iC,

328ilisliC, M3

Be~iili.!~Pirl?lisliersISBN 0-8376-0326-9

BMW

Series ScrviccManual: 1997-2002

525i, 528i. 530i. 540i, Sedan, SportWagon

Bcrrlluy P~rlilishensISBN 0-8376-0317-X

Porsclze

Tl~cUnfair Advantage

hlirrk Do,~ult,reISBN 0-8376-0073-Iilrcj; Porsche: Excellcncc Was Expected

I<iirlLcldui,~sse!tISBN 0-8371,-0235-1

0-8376-0069-3(~1bJ

GoingFaster! Mastering the Art of Race Porsche 911Carrcm Service Manual:

198G1989

B~.~iile!/Pllblislters ISBN 0-8376-0291-2

Porschc 911Enthusiast's CompanionT3'

AiirinriSlr~,tzlli~~rISBN 0-8376-0293-9

BMW 6 Scries Enthusiasl's CompanionTh1

Jc~.li'iil!/liV0l10li ISBN 0-8376-0193-2

Driving

Tlw Skip Bizl.bul-Riicing Sclaiol

ISBN 0-8376-0227-0 BMW 7 Series Servicc Manual:1988-1994,

735i,735iL, 74%. 740iL. 750iL

Beritlc!/ I'irblislrens ISBN 0-8376-0328-5

A FrenchI<issWith Dcalh: SteveMcQuecn

and theMaking

M,!r~s

hliclael i(ei/scr ISBN 0-8376-0234-3 Porschc911SCCoupc,Targo,and Cabriolet

Scrvict. Manual: 1978-1983

Br>illu!yPtibiishersISBN 0-8376-0290-4

Bosclz

SoortsCarandComoctition Drivins

P;url

~ri'rp

~vilhforc&rd I)!/ Phil Hill

ISBN 0-8376-0202-5 Boscl~AulomativcHandbook 6th Edition

Robul.1 Boscli, CIII~HISBN 0-8376-1243-8

Bosch 1-landbookfor Automotive Elcctrics

and Elcchonics

Rillrcr I Bwcli, GrjilrHISBN 0-8376-1050-8

Bosch Handbook forDiesel-Engine

Managcmcnt

Ril1iei.t Bosdl, ClrrbH ISBN 0-8376-1051-6

Bosch Handbook for Gasolinc-Engine

Management

Robcrf Bosclr, G~ribHISBN 0-8376-1052-4

Battle forlheBcelle

I<iir.lLiid~,igsc>tISBN 0-8376-0071-5

Jells, Golf, GTI Scrvicc Manual: 1999-2005

1.8L lurbo, 1.9LTDIdiesel, PD dicscl,

2.0L ga5aline. 2.81VRG

B~.!iIlcyPt,blislicrs ISBN 0-8376-125-9

New Bcctle

ServiceManual:1998-20021.8L

turbo, 1.91TDIdiesel, 2.0L gasoline

Bailicy P~irirlishersISBN 0-8376-0376-5

New Bcctle 1998-2005,

New

Beetle

Convcrtible2003-2005 Official Factory

Rcpair Manual anCD-ROM

I~olkiatgurr~JAriicricnISBN 9784-8376-1265-2

Boscll Fuel Injection and Enginc

Management

Clml-Its

Pmbsi,

SAE

ISBN 0-8376-0300-5

Clzevrolet

CorvctlcIllustralcd Encyclopedia

Torn

Beifurli ISBN 0-8376-0928-3

Racc CarAerodynamics

losupli Kntz ISBN 0-8376-014>8

Road &Track

Illustrated

Automotive

Dictionary

JoltriDilrkl ISBN 0-8376-11143-6

Scientific Design

Exl~austand Intake

Systems

I'lrililr

S,sillr 0-8376-0309-9

CorvetteFuel Injection &Electronic

EngincManagcment 1982-2001:

Clmrlcs

I1rol,sl, SAE ISBN 0-8376-0861-9

I'acrat Ser\,irchl.>nu.~l:1998-2004.1.81.

lurbu, 2.RL

Vb,

.l.IIL

\\'8,

inrludinl:

tv.~gc>n

and 4blOTION

Giiitlc!/ P~iiblislicrsISBN 0-8376-0360-2

Zora

Arkus-Duntov:Thc Lcgcnd Behind

corvt.ttc

Je1.qBirl-1011ISBN 0-8376-0858-9

Ci~evmlclby the Numbers 1965-1969:

TheEssential Chcvrolct Paris Refcrcncc

illn,i Cnl2i11ISBN 0-8376-0956-9

Passat. Passat Waron 1998-2005 Official

Gnlf, GTI, Jctta1993-1999, Cabrio 199%

2002Official Factory Repair Manual on

CD-ROM

Volhsiraigu>toJA,rtrricn ISBN 978-0-8376-1263-8

Jetta, Golf,GTI: 1993-1999, Cabtio: 1995-

2002Scrvicc Manual

ll~iillcyI'trblisln.~~~ISBN 0-8376-0366-8

Alfa Romco All-Alloy Twin Cam

Companion

195G1994

1'nl Bncdulr ISBN 0-8376.0275-0

Alfa Romco Owner's Bibl~'~'

1'1~1Bmrlul! ISBN 0-8376-0707-8

Ford

Ford Fuel Injection

and

Electronic

Engine

Control: 1988-1993

Clinrlcs

Pmirsl, SrlE ISBN 0-8376-03Lll-3

Arldi

Audi A4 Repair Manual: 1996-2001.1.8L

lurbo, 2.8L. including Avant and quatlro

Buirile!/ Ptrhlislters ISBN 0-8376-0371-.I

EuroVan Official Factory Rcp.,ir Manual:

1992-1999

I/~llhio~sar,ifAii!wicn ISBN 0-8376-0335-8

TbcOfficial Ford Mustang 5.0 Technical

Reference

I'crformancc Handbook:

1979-1993

A1 l<inci~u~ihrirri,iISBN 0-8376-0210-6

Audi A6 Sedan

1998-2004, Avant 1999-

2004, allroad quallro 2001-2005,

56Avant 2002-2004, RS6 2003-2004 Official

Factory Rcpair Manual on CD-ROM

Ai!dioJ/in,er.ini ISBN 978-0-8376-1257-7

Jccp CJ Rubuildcr's Manual: 1972-1986

MOSI~S

Lltii~lISBN 0-8376-0151-7

Jccp Owner's Biblen', Third Edition

Moscs Lzrdel ISBN 0-8376-1117-2

Automotive

Reference

Bcnlluy

Publishers

has

published

iewicc

manualsand autornohilcboolissinrc1950.

Plcascwrite to

at 1734 Mniincliusctts

Ave..Cnmbridge,kIA02138,i~isitourivcb

sitc, ol-c,lll1-800-12345'15 ini

free

copy

ofnurcolaiog.

BMW

BMW 23SarviccManual: 1996-2002.

including 23Roadster, 23Coupe, M

Roadster, M Coupe

Be~illqPi,blislicis ISBN 0-8376-1250-0

BMW 3 Scrics (Ed61Scrvicc Manual:

Mcrcedes-Bcnz Technical C~mpanion'~~'

Bu,rllu!! P,rlilislio.i ISBN 11-8376-1033-8

Mcrccdcs-Bcnz E-Class (W124)O~vner's

BibleT>'

1986-1995

llu~tilc!~Pi~lriisiieisISBN 11-8376-0230-(1

Urlilii-!~P~~Blisi~~rsISBN 11-8376-11772

Foreword

For the BMW owner with basic mechanical skills and for independent auto serviceprofessionals.

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 hisor hercar will find that owning and referring to this manual makes it

possible to bebetterinformedand to moreItnowledgeably discuss repairs with a professional

automotive technician.

Ifyou 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 handtoolsare neededfor mostof the work describedin

this manual.Manyprocedures

also require a torque wrench to ensure that fasteners are tightened properly and in accordance

with specifications. Additional informationon 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 inthis manual.When the vast

array of data presented in the manual is talten into account, however, noclaim to infallibilitycan

be made. We therefore cannot beresponsiblefor the resultofany errors that may have crept into

the text. Please also readthe Important Safety Noticeonthe copyright page at the beginningof

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 inadvance the needfor specific skills, identify hazards,

preparefor 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 regardto errors,

and/or suggestionsforimprovement ofour product.These communications have beenandwill be

carefully considered in the preparation of this and other manuals. If you identify inconsistenciesin

the manual, you may have found an error. Pleasecontact the publisher and we will endeavor to

post applicable corrections onour website. Postedcorrections (errata) should be reviewedbefore

beginning worlc. Please see the following web address:

BMW offers extensive warranties, especially on components of the fuel delivery and emission

control systems.Therefore, beforedeciding to repaira BMW that maybecovered wholly or in part

by any warranties issued by BMW of North America,

LLC,

consult your authorized BMW dealer.

You mayfindthat the dealer can make the repair either free or at minimum cost. Regardlessof its

age, orwhether it is under warranty, your BMW Is both an easy car to service and an easy car to

getserviced. So

atany timea repair isneededthat you feel istoodifficultto doyourself, atrained

BMW technician is ready to do the job for you.

Bentley Publishers

001

General

Warnings

and

Cautions

PLEASE READ THESE WARNINGS AND CAUTIONS

BEFORE PROCEEDING WITH MAINTENANCE AND REPAIR WORK.

WARNINGS-

See

also CAUTIONS

Some repairs maybebeyondyour capability.

youlacktheskills,

Catch draining fuel, oil, or brakefluid in suitable containers. Do

tools andequipment, or a suitable workplace for any procedure notusefoodor beveragecontainersthat mightmisleadsomeone

described in this manual, we suggestyou leave such repairsto into drinking from them. Store flammablefluids away from fire

anauthorized BMW dealerservice department or other qualified hazards. Wipe up spills at once, but do not store the oily rags,

shop. which can ignite and burnspontaneously.

Do not reuse any fasteners that are worn or deformed. Manyfas- Always observe goodworRshop practices.Wear qoqqles when

teners are designed to be usedonly onceandbecome unreliable you operate machinetools or work with batteryacid:kloves or

and mav fail when used a second time. This includes,but is not other ~rotectiveclothino should be worn whenever the iob re-

limited io, nuts, bolts, washers,self-lockingnuts or bolts,clrclips yires'working with harmfulsubstances.

andcotter pins. Always replacethese fastenerswith new parts. Greases, lubricantsandotherautomotivechemicalscontaintoxic

Neverwork under a liftedcar unless it is solidly supported on substances, many of which are absorbeddirectly through the

stands desiqned for the purpose. Do not supeort a car on cinder skin. Readthe manufacturer's instructionsandwarninos careful-

blochs, hollowtiles orotherbrops that maydrurnbie undercontin-

uous toad. Neverwork under a car that issupported solely by a

iack. Neverwork under the car while the enqine is runninq.

youaregoingtowork underacaronthe ground, makesurethat

the ground is level. Blockthe wheels to keep the car from rolling.

Disconnect the battery negative

(-)

terminalto prevent others

from starting the car while you are under it.

Neverrunthe engine unlessthe work areais well ventilated.Car-

bonmonoxide kills.

Rings, bracelets and otherjewelry should be removedso that

they cannot cause electrical shorts, get caught inrunning ma-

chinery, or be crushed by heavy parts.

Tie long hair behind your head. Do not wear a necktie, a scarf.

loose clothing, or a necklacewhen you work nearmachinetools

or running engines. if your hair,clothing,or jewelry were to get

caught inthe machinery, severe injurycould result.

DOnot attempt to work on your car if you do not feel well. You in-

crease the danger of injuryto yourseliand others

you aretired,

uDsetor have taken medicationor anv other substance that mav

keep you from being fully alert.

Illuminate your work area adequatelybut safely. Use a portable

iy. Use hand and eye protection.Avoid direct skin conGct.

Disconnectthe battery negative

(-)

terminalwhenever you work

onthe fuelsystemortheelectricalsystem. Do notsmokeorwork

near heatersor other fire hazards. Keep an approvedfire extin-

guisherhandy.

Frictionmaterials (such as brakepads or shoes or clutch discs)

containasbestosfibers or other friction materials. Do notcreate

dust by grinding, sanding, or by cleaningwith compressedair.

Avoid breathingdust. Breathingany friclion materialdust can

lead to serious diseases and may result in death.

Batteriesgiveoff explosivehydrogengas during charging. Keep

sparks, lightedmatchesandopenflameaway from the top of the

battery. If hydrogengas escapingfromthe cap vents is ignited,it

will ignitegas trapped in the cells and cause the batteryto ex-

plode.

Connectand disconnect battery cables,jumper cables or a bat-

terychargeronlywilh the ignitionswitchedoff. Donot disconnect

the battery while the engine is running.

Do not quick-chargethe battery (forbooststarting) for longer

than one minute.Wait at least one minutebefore boostingthe

battery a second time.

safety lighiforworking lnsideor underthe car. Makesurethe bulb

Donot allow battery charging vollage to exceed

16.5

volts. Ifthe

is enclosed bv a wire caoe. The hot filament of an accidentallv batten! beoins ~roducinaoas or boilinoviolentiv, reducethe

brokenbulb can ignitespilled fuel, vapors or oil.

- -

charglngrate.~oostlngasutfaledbattery at a ighchargingrate

can cause an

explosion.

Continuedon nextpage

General Warnings and Cautions

WARNINGS

(continued)

The air conditioning system is filled with chemical refrigerant,

which ishazardous.The AIC system should beserviced only by

trained technicians usingapprovedrefrigerantrecoverylrecycling

equipment, trainedinrelatedsafetyprecautions,andfamiliarwith

regulationsgoverningthedischarginganddisposalof automotive

chemical refrigerants.

Do not expose any part of the AIC system to high temperatures

such as open flame. Excessiveheat will increase system pres-

sure and may cause the system to burst.

Some aerosol tire inflators are highly flammable. Be extremely

cautious when repairinga tire that may have been inflated using

anaerosol tire inflator.Keep sparks, openflameor othersources

of ignition away from the tire repairarea. Inflate and deflate the

tire at least four times before breaking the bead from the rim.

Completely removethe tirefrom the rimbeforeattemptingany re-

pair.

Cars covered by this manualare equipped with a supplemental

restraint system (SRS),that automaticallydeploys airbags and

pyrotechnic seat belt tensioners Inthe event oia frontal or side

impact.These are explosive devices. Handledimproperlyor with-

out adequate safeguards,they can be accidently activated and

cause serious injury.

The ignition system produces highvoltages that can be fatal.

Avoidcontact with exposedterminalsanduseextremecarewhen

working ona car with the engine runningor the ignition switched

on.

Placejack standsonly at locationsspecifiedbythe manufacturer.

Thevehicle illtino iacksu~oliedwiththevehicleisintendedfortire

changesonly.A heavydutyfloorjack shouldbeusedloliftvehicle

before installing jacl( stands. See

010

General.

Battery acid (electrolyte)can cause severe burns. Flushcontact

area with water, seek medicalattention.

Aerosol cleaners and solventsmay containhazardousor deadly

vapors andare highlyflammable.Useonly inawell ventilatedar-

ea. Do not use on hot surfaces (engines,brakes, etc.).

Do not remove coolant reservoiror radiator cap with the engine

hot. Danger of burns andengine damage.

CAUTIONS-

See

also

WARNINGS

if you lack the slqills, toolsandequipment,or asuitableworl(shop

forany procedure describedin this manual,leavesuch repairsto

an authorized BMW dealer or other qualifiedshop.

BMW is constantly improvingitscars andsometimes these

changes, both inpartsandspecifications,aremadeapplicableto

earlier models.Therefore,part numberslisted in this manualare

for reference only. Always check with your authorized BMW deal-

er parts department for the latestinformation.

Beforestarting ajob, make certain that you have allthe neces-

sary tools and parts onhand. Readailthe instructionsthorough-

ly, and do not attempt shortcuts. Use tools appropriate to the

work and use only replacementparts meetingBMWspecifica-

tions.

Usepneumaticand electric tools only to loosenthreaded parts

and fasteners.Never use these tools to tighten fasteners,espe-

cially on light alloy parts. Always use a torque wrench to tighten

fastenersto the tighteningtorque specificationlisted.

Be mindfulof the environmentand ecology.Beforeyou drain the

crankcase,find out the proper way to disposeof the oil. Do not

pouroil onto the ground, down a drain, or into a stream, pondor

lake. Disposeof waste inaccordancewith Federal, State and

Locallaws.

The control modulefor the anti-lock brakesystem (ABS) cannot

withstandtemperaturesfroma paint-dryingboothoraheatlamp

inexcess of 203" F (95°C) and should not be subjected to tem-

peraturesinexcess of 185°F (8S°C)for more than two hours.

Beforedoing any electricalwelding on cars equippedwith ABS,

disconnect the battery negative

(-)

terminal (groundstrap) and

the ABS control module connector.

Always makesure ignition is off beforedisconnectingbattery.

Labelbatterycablesbeforedisconnecting.Onsome models, bat-

tery cablesare not color coded.

Disconnectingthe battery may erase fault code@)storedincontrol

modulememory. Usingspecial BMW diagnoslicequipment, check

loriauitcodes priorto disconnectingthe batterycables. Ifthe mal-

I.mct on ndicatorIgnt (MIL) s

..minaled. see OBDOn-Board

Diaanostics Tl11siant is iuenlftedas lneCheck Ena~neoht

(1997-2000modelsjor~ervlceEngineSoonlight(2061andlater

models). If any other systemiaults havebeendetected(indicated

by an illuminatedwarning light),see an authorizedBMW dealer.

Ifa normalor rapidcharger is usedto chargebattery,the battery

must be disconnected and removed from the vehicle inorder to

avoid damagingthe vehicle.

Do not quick-chargethe battery (for boost starting) forlonger

than one minute. Wait at least one minute before boostingthe

battery a second time.

Connectand disconnecta battery charger onlywith the battery

chargerswitched off.

Sealedor "maintenancefree" batteries should be slow-charged

only, at anamperage rate that is approximately10%of the bat-

tery's ampere-hour (Ah)rating.

Do notallow battery chargingvoltageto exceed 16.5volts. Ifthe

battery begins producinggas or boilingviolently, reducethe

charging rate. Boostingasulfatedbattery at a highcharging rate

can cause an explosion.

002

Vehicie

identification

and

VlN

Decoder

Vehicle identification Number (VIN), decoding

Some of the information inthis manual applies only to cars of a parlicuiar modelyear or range

of vears. For examole. 1999refers to the 1999 modelvear but does not necessarilv malchthe

caiendsr year in which the car was manufacturedor sold. To besure of the modelyearof a

particular car, checic the Vehicle ldentification Number (VIN)on the car.

The VIN is a unique sequence of 17characters assigned by BMW loidentify each individual

car. Whendecoded, the VIN tellsthe country andyear of manufacture; make, modeland serial

number: assembly plant and some equipment specifications.

The BMW VIN is on a plate mountedontop ofthe dashboard, on the driver's side where the

number can be seen through the windshield, The 10thcharacter is the modelyear code. The

letters

and

arenot usedfor modelyear designation. Examples:

for 1999,

for 2000,

for 2001,2 for 2002, etc. Thetable below explains some of the codes inthe VIN for 1997

through 2002 BMW

E39

Series BMWscovered by this manual.

Sample

VIN:

~~Iz~o~w~B~w~

lposition

10 11 12-17

VIN

position Description Decodinginformation

1-3 Countrv of WBA

znan~+q

;BT BMW Molorsporl.Gmon,~;nchGerrn;!n,

Linc 525

(2UU1

2003) 528 (2000-2003. 530; 540

Manual beltswith dual airbags

Manualbeltswith advancedairbaos

Series

Body type

engine lype

5251(2001

2002),528i (1997

2000)

MS. 530i,540i (1997

1998)

5251Wagon

M 528i (1999

2000)

N 5401Sedan (1999

2003)540i wagon (2001)

P 528i wagon (1999

2000)

540i waaon 12002

20031

6,4

Aulomatic

5,3 Manual

Vehicle type 3.4.7 Passenger vehicle

Checlr digit

Model year

Restraintsystem

0 Manualbelts

3 Manual belts wilh driver

passengerairbags

4 Manualbeltswith advanced passenger

driver airbags

9or

calculatedby NHTSA

1997

1RRR

Assembly plant A,

Munich,Germany

B,C,

G Dingolfing.Germany

Reqensburq. Germany

Serialnumber Sequentialproduclion number lorspecificvehicle

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