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2001 530i Sedan
BMW 2001 530i Sedan Manuals
Manuals and User Guides for BMW 2001 530i Sedan. We have
1
BMW 2001 530i Sedan manual available for free PDF download: Service Manual
BMW 2001 530i Sedan Service Manual (1002 pages)
Sedan/Sport Wagon 1997-2002 5 Series E39
Brand:
BMW
| Category:
Automobile
| Size: 47.11 MB
Table of Contents
Table of Contents
11
General
12
Warnings. Cautions and Notes
13
Safety
15
Lifting the Car
15
Raising Car
15
Working under Car
16
Advice for the Beginner
17
Planning Ahead
17
Workshop Practices
17
Non-Reusable Fasteners
17
Tightening Fasteners
18
Gaskets and Seals
19
Electrical Testing
20
Wire Repairs
20
Genuine BMW Parts
21
Non-Returnable Parts
21
Information You Need to Know
22
Basic Tool Requirements
24
Jack Stands
26
Oil Change Equipment
26
Torque Wrench
27
Digital Multimeter
27
Changing a Tire
28
Jump Starting
29
Indicator and Warning Lights
29
Towing
30
Spare Parts Kit
31
Maintenance
34
Special Tools
34
Service Interval Indicator (Sll)
35
Service Interval Indicator (Sll), Resetting
35
Maintenance Tables
38
Fluid and Lubricant Specifications
41
Fluids and Lubricants
42
Engine Oil. Checking Level
44
Engine Oil and Filter. Changing
45
Accelerator and Linkage
46
Air Filter. Replacing
46
Idlespeed
51
Catalytic Converter and Oxygen Sensors
51
Power Steering Fluid, Checking Level
52
Spark Plugs
52
Spark Plugs, Replacing
53
Interior Ventilation Microfilter, Replacing
54
Brake Fluid. Replacing
56
Brake Pad 1 Rotor Wear. Checking
56
Brake System, Inspecting
57
Parking Brake. Checking
57
Clutch Fluid. Checking
58
Differential Oil Level. Checking
58
Drive Axle Joint (CV Joint) Boots. Inspecting
59
Exhaust System. Inspecting
59
Fuel Filter. Replacing
59
Fuel Tank and Fuel Lines. Inspecting
60
Suspension. Front. Inspecting
61
Suspension. Rear. Inspecting
61
Tires. Checking Inflation Pressure
61
Tires. Rotating
61
Transmission Service. Automatic
61
Transmission Service. Manual
62
Transmission Fluid. Checking and Filling (Manual Transmission)
62
Wheels. Aligning
62
Body and Interior Maintenance
63
Body and Hinges. Lubricating
63
Exterior Washing
63
Interior Care
63
Leather Upholstery and Trim
63
Polishing
64
Seat Belts
64
Special Cleaning
64
Washing Chassis
64
Waxing
64
Windshield Wiper Blade Maintenance
65
Cylinder Head Removal and Installation (M52 Engine)
97
Cylinder Compression, Checking
99
Wet Compression Test
101
Cylinder Leak-Down Test
102
Cylinder Head, Removing, M52 Engine
102
Cylinder Head, Installing, M52 Engine
111
Cylinder Head Removal and Installation (M52 TU and M54 Engines)
112
Cylinder Head, Removing, M52 TU and M54 Engines
116
Cylinder Head, Installing, M52 TU and M54 Engine
133
Double VANOS Timing
140
Chain Components
140
Double VANOS Timing Chain Components, Installing, M52 TU and M54 Engines
140
Cylinder Head Removal and Installation (M62 Engine)
140
Intake Manifold, Removal and Installation, M62 Engine
150
Left Cylinder Head, Removing, M62 Engine
155
Left Cylinder Head, Installing, M62 Engine
160
Right Cylinder Head, Removing, M62 Engine
166
Right Cylinder Head, Installing, M62 Engine
171
Special Tools
178
Cylinder Head
181
Valves. Leak Test
182
Hydraulic Lifters, Checking and Replacing
183
Camshaft Andlifter Removal and Installation
188
Camshaft and Lifter. Removal and Installation (M52 TU and M54 Engine)
195
Double VANOS Timing Chain Components
204
Camshaft Removal and Installation (M62 Engine)
215
Valves
216
Valves. Leak Test
232
Valves. Removing and Installing
232
Valve Guides
233
Valve Stem Oil Seals
234
Special Tools
238
Crankshaft Oil Seal, Front
242
Crankshaft Oil Seal, Front, Replacing (M52 Engine
242
Crankshaft Oil Seal, Replacing (M52 TU and M54 Engines
245
Crankshaft Oil Seal, Replacing (M62 and M62 TU Engines)
247
VANOS Control Unit, Removing (M52 Engine)
250
VANOS Control Unit, Installing (M52Engine)
255
VANOS Timing, Checking and Adjusting (M52 Engine
258
Timing Chains, Removing (M52 Engine)
262
Timing Chain, Installing (M52 Engine)
266
(M52 TU and M54 Engines)
270
Double VANOS Control Unit
272
VANOS Control Unit, Removing (M52 TU and M54 Engines)
273
VANOS Control Unit, Installing (M52 TU and M54 Engines)
277
VANOS Timing, Checking and Adjusting (M52 TU and M54 Engines)
279
Timing Chains Assembly (M52 TU and M54 Engines)
286
Timing Chains, Removing (M52 TU and M54 Engines)
287
Timing Chains, Installing (M52 TU and M54 Engines)
293
Timing Chain (M62 Engine to 9/98)
302
Timing Chains, Removing (M62 Engine to 9/98)
302
Timing Chains, Installing (M62 Engine to 9/98)
310
Camshaft Timing, Checking and Adjusting (M62Engine)
315
Special Tools
322
Engine Lubrication
323
Oil Pressure. Checking
324
Oil Pressure Warning System. Testing
325
Crankshaft Rear Main Seal. Replacing (V-8)
328
Oil Pan. Removing and Installing (6-Cylinder
330
Lower Oil Pan. Removing and Installing (V-8)
333
Upper Oil Pan. Removing and Installing (V-8)
335
Oil Pressure Warning Switch. Replacing
340
(6-Cylinder and V-8)
341
Oil Level Warning Switch. Replacing
341
Oil Pump. Removing and Installing (6-Cylinder)
342
Oil Pump. Removing and Installing (V-8)
344
Oil Pressure Relief Valve (6-Cylinder)
346
Oil Pressure Relief Valve (V-8)
347
Warnings and Cautions
351
Engine Management
351
Lgnition System
354
Oscilloscope Diagnostic Diagrams
354
Misfire Detection
354
Ignition Firing Order
357
Disabling Ignition System
358
Checking for Spark
358
Crankshaftspeedsensor
360
Camshaft Position Sensors 120-1
362
Knocksensors
364
Battery. Starter. Alternator
368
Special Tools
368
Engine Electrical System
368
Battery Safety Terminal
369
Warnings and Cautions
370
Battery Testing
371
Hydrometer Testing
371
Battery Open-Circuit Voltage Test
372
Battery Load Voltage Test
372
Closed-Circuit Current Measurement
373
Battery Charging
375
Battery Safety Terminal, Replacing
375
Alternator (Generator
377
Alternator. Basic
377
Alternator with Multi-Function Control (MFR
377
Water-Cooled Alternator
378
Charging System Quick-Check
379
Charging System. Checking
379
Alternator. Removing and Installing (6-Cylinder Engine)
381
Alternator. Removing and Installing (M62 Engine. Air Cooled)
382
Alternator. Removing and Installing (M62 TU Engine. Water Cooled)
384
Starter
385
Starter Troubleshooting
385
Starter. Removing and Installing (6-Cylinder Engine)
386
Starter. Removing and Installing (V-8 Engine)
387
Solenoid Switch. Removing and Installing
389
Tools and Test Equipment
393
Warnings and Cautions
395
Fuel Supply
396
Relieving System Fuel Pressure
396
ECM Relay. Testing
397
Mass Air Flow (MAF) Sensor
399
Checking and Replacing
399
Engine Coolant Temperature (ECT) Sensor
400
Testing and Replacing
400
Testing and Replacing
401
Throttle Position Sensor (TPS)
402
Testing and Replacing
402
Ldle Speed Control Valve
403
Checking and Replacing
403
Fuel Injectors. Checking and Replacing
405
Evaporative Emissions. Overview
406
Secondary Air Injection. Overview
407
Engine Control Module (ECM)
408
Removing and Installing
408
Siemens MS 41.1 ECM Pin Assignments
409
ECM Relay. Testing
417
Engine Coolant Temperature (ECT) Sensor
420
Testing and Replacing
420
Intake Air Temperature (IAT) Sensor
421
Testing and Replacing
421
MS 42.0 Throttle Valve Assembly. Replacing
422
MS 43.0 Throttle Valve Assembly. Replacing
425
Throttle Cable. Adjusting (MS 42.0
428
Ldle Speed Control Valve. Checking and Replacing
428
Evaporative Emissions Control Diagrams
429
Evaporative Emissions Control
429
Engine Control Module (ECM)
430
Removing and Installing
430
Siemens MS 42.0 and MS 43.0
431
ECM Pin Assignments
431
M5.2 System Features
437
M5.2.1 System Features
437
ECM Relay. Testing
439
Oxygen Sensors. Checking
441
Fuel Injectors. Checking and Replacing
442
Mass Air Flow (MAF) Sensor. Replacing
443
Ldle Speed Control Valve. Testing and Replacing
444
Throttle Position Sensor (TPS)
445
Testing and Replacing
445
Engine Coolant Temperature (ECT) Sensor
445
Testing and Replacing
447
Auxiliary Throttle Valve (ADS) (M62 and M62 TU Engine). Replacing
447
Bosch 5.2 ECM Pin Assignments up to 911 997)
449
ME 7.2 System Overview
457
EDK Adaptation
459
Engine Coolant Temperature (ECT) Sensor. Testing
461
Engine Coolant Temperature (ECT) Sensor. Replacing
461
Oxygen Sensors. Replacing
462
Fuel Injectors. Removing and Installing
462
Mass Air Flow (MAF) Sensor
463
Removing and Installing
463
Evaporative System Pressure Leak Diagnosis. Overview
464
Secondary Air Injection. Overview
465
Bosch ME 7.2 ECM Pin Assignments
466
Fuel Tank and Fuel Pump
473
Fuel Tank Evaporative Control System
473
Evaporative System Troubleshooting
474
Warnings and Cautions
475
Fuel Pump Fuse and Relay
476
Operating Fuel Pump for Tests
476
Fuel Pump Electrical Circuit, Testing
477
Fuel Pump Power Consumption, Testing
479
Fuel Pressure Gauge, Installing (6-Cylinder Models
480
Fuel Pressure Gauge, Installing
480
(V-8 Models
481
Fuel Delivery, Testing
482
Fuelpump and Fuellevelsender
485
Fuel Level Sender (Right Side) and Fuel Pump. Removing and Installing
485
Fuel Level Sender (Left Side). Removing and Installing
487
Siphon Pump. Removing and Installing
489
Fuel Tank. Draining
490
Fuel Tank. Removing and Installing
491
Fuel Expansion Tank. Removing and Installing
493
Activated Carbon Canister I Fuel Tank Leak Detection Unit (LDP or DMTL). Removing and Installing
494
Running Losses (312-Way) Valve
494
Removing and Installing
494
Special Tools
498
Cooling System Overview (M52 TU Shown. Others Similar
499
Coolant Pump
499
Thermostat
499
Mechanical Thermostat (M52 Engine
500
Electrically Heated Thermostat
500
Radiator and Expansion Tank
500
Mechanical Cooling Fan with Viscous Clutch
500
Electric (Auxiliary) Cooling Fan
500
Transmission Fluid Heat Exchanger
501
Warnings and Cautions
503
Cooling System Inspection
504
Cooling System Pressure Test
505
Combustion Chamber Leak Test
506
Thermostat
506
Coolant. Draining and Filling (6-Cylinder Models)
506
Coolant. Draining and Filling (V-8 Models)
508
Cooling System. Bleeding
510
Mechanical (Viscous Clutch) Cooling Fan
510
Removing and Installing
510
Thermostat. Removing and Installing (M52Engine)
512
Thermostat. Removing and Installing (M52 TU or M54 Engine)
513
Thermostat. Removing and Installing (V-8 Models)
514
Coolant Pump. Replacing (6-Cylinder Models)
515
Coolant Pump. Replacing (V-8 Models)
516
Radiator. Removing and Installing
518
Expansion Tank. Removing and Installing
520
Exhaust System
524
Muffler, Replacing
526
Exhaust Manifolds, Removing and Installing (M52 Engine)
527
Exhaust Manifolds, Removing and Installing (M52 TU and M54 Engines)
528
Exhaust Manifolds, Removing and Installing (M62 Engine)
528
Oxygen Sensors
531
Oxygen Sensors (Precatalyst), Replacing (M52 TU and M54)
531
Oxygen Sensors (Post-Catalyst), Replacing (M52 TU and M54)
531
Oxygen Sensor, Replacing (M52 and M62 Engine)
532
M52 Engine (528I 1997-1 998)
533
M52 TU and M54 Engines
534
M62 Engine (540I 1997-1 998)
536
M62 TU Engine
537
Clutch
544
Special Tools
544
Clutch Hydraulic System
546
Bleeding and Flushing
546
Clutch Master Cylinder. Replacing
548
Clutch Slave Cylinder. Replacing
550
Clutch Variations
551
Clutch. Removing
553
Clutch Components. Inspecting
553
Flywheel. Removing and Installing (6 Cylinder Engine)
554
Flywheel. Removing and Installing (V-8 Engine)
555
Clutch. Installing (New SAC Components)
559
Special Tools
566
Transmission Fluid Level. Checking
570
Transmission Fluid, Replacing .23
570
Back-Up Light Switch, Replacing
571
(Transmission Installed)
572
Put Shaft Seal. Replacing
574
Transmission Removal
585
Transmission, Removing and Installing
585
Special Tools
586
Automatic Transmission Applications
588
ATF Level, Checking
590
ATF, Draining and Filling
591
Automatic Transmission Fluid Pan and Strainer
593
Transmission Removal and Installation
594
Transmission, Removing and Installing
594
Special Tools
600
Manual Transmission Gearshift
600
Gearshift Lever, Removing (Manual Transmission)
601
Gearshift Lever, Installing (Manual Transmission)
602
Automatic Transmission Gearshift
604
(Automatic Transmission)
604
Automatic Shiftlock, Checking Function (Automatic Transmission)
605
Shift Interlock, Checking Function (Automatic Transmission)
606
Special Tools
608
Driveshaft Description
609
Troubleshooting
609
Driveshaft. Aligning
613
Driveshaft. Removing
614
Driveshaft. Installing
616
Flex.disc. Replacing
617
Center Bearing Assembly. Replacing
618
Front Centering Guide. Replacing
619
Constant Velocity (CV) Joint. Replacing
620
General
622
Aluminum Suspension Components
622
Front Suspension 6-Cylinder Models
623
Front Suspension V-8 Models (540I)
624
Rear Suspension Sedan Models
626
Sport Wagon Models
626
Rear Suspension Sport Wagon (with Coil Springs)
627
Rear Suspension Sport Wagon (EHC with Air Springs)
628
EHC Operational Diagram
629
Rack-And-Pinion Steering
630
Recirculating Ball and Nut Steering
630
Rim and Tire Sizes Table
631
Control Systems
631
E39 Electronic Brake and Stability Control Systems Application Table
632
ABS System
632
Automatic Stability Control (ASC)
632
Dynamic Stability Control (DSC)
634
Front Ride Height Specifications
635
Rear Ride Height Specifications
636
Front Suspension
638
Special Tools
638
Front Suspension Variations
640
Front Strut Assembly, Removing and Installing
641
Front Strut Assembly Components (6-Cylinder Models)
645
And Assembling
645
Front Suspension Arms
648
Control Arm, Removing and Installing (6-Cylinder Models)
648
Control Arm, Removing and Installing ("-8 Models)
648
Tension Strut, Removing and Installing
652
Tension Strut Bushing, Replacing
654
Stabilizer Bar, Removing and Installing
658
Steering and Wheel Alignment
660
Special Tools
660
Steering System
662
Steering System Variations
663
Steering System Warnings and Cautions
664
Steering Wheel
665
Steering Wheel. Removal and Installation
665
Steering Column
668
Steering Column Components
668
Steering Column Trim, Removing and Replacing
668
Removing and Installing
669
Steering Column Lock. Removing and Installing
670
(Models with Automatic Transmission)
672
Interlock Cable. Adjusting (Models with Automatic Transmission)
672
Steering Column Adjustment Motors
674
Removing and Installing
674
Power Steering Pump. Removing and Installing
675
(6-Cylinder Models)
677
Steering Rack. Removing and Installing
677
Steering Rack Boot. Replacing
680
Tie Rod (Outer). Replacing
680
Tie Rod (Inner). Replacing
681
Steering Gearbox (V-8 Models)
682
Steering Gearbox System Components
682
Steering Gearbox, Removing and Installing
683
Pitman Arm. Removing and Installing
686
Pitman Arm. Adjusting
687
Steering Idler Arm. Removing and Installing
688
Center Tie Rod. Replacing
690
Camber
691
Caster
691
Front Toe and Toe Difference Angle
692
Reartoe
692
Preparing for Alignment
693
Alignment Specifications Tables
693
Special Tools
698
Rear Suspension Variations
700
Rear Struts and Springs (Sedan Models)
701
Rear Strut Assembly, Removing and Installing
701
Rear Strut Assembly, Disassembling and Assembling
703
Springs (Sport Wagon Models)
705
Rear Shock Absorber, Removing and Installing
705
Coil Spring, Removing and Installing
707
Air Spring, Removing and Installing
708
Rear Suspension Arms, Subframe and Bushings
709
Rear Suspension Arm Components
709
Swing Arm, Removing and Installing (Sedan Models)
710
Swing Arm, Removing and Installing (Sport Wagon Models)
712
Swing Arm Ball Joint, Replacing
715
Upper Rear Control Arm, Removing and Installing (Sedan Models)
718
Upper Rear Control Arm, Removing and Installing (Sport Wagon Models)
719
Upper Front Control Arm (Traction Strut), Removing and Installing
721
Rear Axle Assembly, Removing and Installing (Sedan Models)
722
Rear Axle Assembly, Removing and Installing (Sport Wagon Models)
724
Rear Subframe Mounting Bushings, Removing and Installing
727
Special Tools
746
Final Drive
746
Final Drive, Removing and Installing
749
Differential Oil Level, Checking
750
Final Drive I N ~ U T Shaft Seal, Replacing
751
Final Drive Cover, Removing and Installing ,331-12
756
Final Drive Mounts, Replacing
756
Drive Axle Assembly
758
Drive Axle, Removing and Installing (Sedan)
758
Special Tools
764
E39 Brake System
766
Electronic Braking and Stability Control
766
Troubleshooting
767
Warnings and Cautions
769
Brakes, Bleeding
771
Brake Pads, Calipers and Rotors
773
Braking System Components
773
Brake Pads, Checking and Replacing
774
Brake Rotors, Removing and Installing
777
Master Cylinder, Removing and Installing
779
Brake Booster Check Valve
781
Brake Booster, Removing and Installing
782
Parking Brake
784
Parking Brake Components
784
Parking Brake, Adjusting
784
Parking Brake Cable, Replacing
786
ABS Component Replacement
788
Wheel Speed Sensor. Replacing
788
ABS Impulse Wheel
789
DSC Lateral Acceleration or Rotational Rate (Yaw) Sensor. Replacing
789
DSC Pressure Sensor
792
(1 999 - 2002 Models)
793
ABS DSC Control Module
793
Models)
793
Body Dimensions (in Inches)
796
Bodyshell
797
Sport Wagon
797
Tailgate
799
Tailgate Lock System
799
Rear Wiper System
800
Safety and Security Features
801
Safety Cage
801
Door Locks and Door Handles
801
Seat Belts
801
Airbags
802
Battery Safety Terminal (BST)
803
Security
803
Seats
804
Instruments and Controls
804
Central Body Electronics
805
Doors
820
Front or Rear Door. Removing and Installing
820
Door Check. Replacing
822
Door Hinge Adjustment
823
Door Hinge Assembly
824
Door Trim Panel. Removing and Installing
825
Sill Trim Panels
828
Outside Mirror Glass. Replacing
852
Outside Mirror Housing
853
Bumpers
855
Front Bumper Assembly
856
Front Bumper, Removing and Installing
857
Front Bumper Impact Absorber. Replacing
858
Rear Bumper Assembly
859
Rear Bumper. Removing and Installing
860
Rear Bumper Impact Absorber. Replacing
861
Front Bumper Height. Adjusting
862
Exterior Trim
862
BMW Emblem. Removing and Installing
863
Body Side Molding. Replacing
863
Radiator Grill. Removing and Installing
864
Headlight Housing Trim Panel
864
Special Tools
866
Power Windows
866
Window Switches
867
Rear Window Child Lockout Switch
867
Power Window Motors
868
Window Anti-Trap Protection
868
Window Motor Limit Stop Function
869
Window Anti-Trap Strip, Testing
870
Front Window Anti-Trap Strip, Removing
870
Rear Window Anti-Trap Strip, Removing
871
Door Window. Adjusting
872
Door Window. Removing and Installing
873
Front Window Regulator Removing and Installing
875
Rear Window Regulator. Removing and Installing
877
Lnterior Trim
880
Lower Dash Panel Assembly, Removing and Installing
885
Upper Dash Assembly, Removing and Installing
889
Window and Door Post Trim Panels, Removing and Installing
890
Dash Panel Support, Removing and Installing
893
Glove Compartment, Removing and Installing
894
Central Locking
896
General Module
896
Central Locking Inputs and Outputs
897
Remote Entry (FZV)
901
Remote Entry (FZV) Inputs and Outputs
902
Trunk Lid Soft Close (SCA)
907
SCA Subsystem
908
Tailgate and Rear Window Locks
908
Sport Wagon Tailgate and Rear Window Lock Schematic
909
Door Handles and Locks
910
Door Handle (Outer), Removing and Installing
910
Door Latch, Removing and Installing
911
Outer Door Lock Cylinder, Removing and Installing
912
Trunk Lock. Removing and Installing
913
Trunk Lock Striker Plate. Removing and Installing
914
Tailgate Lock. Emergency Release
915
EWS Variations
916
EWS Control Module. Replacing
917
Transmitter Receiver Module
917
Ring Antenna
917
Anti-Theft System (DWA)
918
DWA LED Status
918
Tilt Sensor
918
Interior Protection
919
Glass Breakage Sensors
920
Emergency Disarming
920
Seatimirrorlsteering Column Memory
922
Seat Memory Position. Setting
922
Seat Switch and Memory Module
924
Rear Seat Cushion and Backrest, Removing and Installing (Sedan Only)
927
Headrest. Removing and Installing
928
Sunroof
930
Sunroof Electronic Controls, Initializing
930
Sunroof, Normalization
931
Sunroof Panel, Emergency Closing
932
Sunroof with Glass Roof Panel, Adjusting
935
Sunroof Panel, Removing and Installing (Steel or Glass)
936
Sunroof Panel Gasket, Replacing (Steel or Glass)
937
Sunroof Motor, Replacing
938
Troubleshooting
940
Front Seat Belt Tensioner
942
Rear Seat Belt Assembly
946
Rear Seat Belt Assembly (Sedan)
946
Rear Seat Belts (Sedan)
947
Rear Seat Belt Assembly (Sport Wagon)
947
Rear Seat Belts (Sport Wagon)
948
Two-Stage Airbag (MRS 111)
952
Airbag Indicator Light
952
MRS Airbag System Diagram
954
MRS Control Module. Replacing
955
Side-Impact Crash Sensor
955
Driver Airbag. Removing and Installing
956
Passenger Airbag. Removing and Installing
957
Door Mounted Side-Impact Airbag
958
Head Protection Airbag Components
959
Head Protection Airbag (Hps)
959
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