Honda Bmw 5 Service Manual

							
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General 
Many of the maintenance and repair  tasks in this manual  call 
forthe installation of new parts, orthe use  of new  gaskets  and 
other  materials  when reinstalling  parts. Most often,  the parts 
that will be needed should  be on hand before beginning the 
job.  Read  the introductorytext  and the complete procedure 
to 
determine  which parts will  be needed. 
NOTE- 
For  some  biggerjobs,  partial disassembly  and inspection  is 
required  to determine a complete  parts list. Read  the proce- 
dure carefully  and, if necessary,  male other arrangements  to 
get  the necessary  parts while your car is disassembled. 
Genuine BMW parts 
Genuine  BMW replacement parts  from an authorized  BMW 
dealer are designed  and manufactured to the same  high stan- 
dards as  the original parts.  They will be the correct  material. 
manufactured  to same specifications, and  guaranteed to fit 
and  work  as intended.  Most genuine BMW parts carry  a limit- 
ed  warranty. 
Many  independent repair shops  make a point  of using  genu- 
ine 
BMW parts, even though  they may at times  be more  ex- 
pensive than parts from other  sources. They know the value 
of  doing  the job  right with  ihe right parts.  Parts from other 
sources can be  as good  as BMW  parts, particularly  if manu- 
factured  by one  of 
BMWs or~ginal equipment  suppliers, but it 
is  often  difficult  to know. 
BMW  is constantly updating  and improving their  cars, often 
malting improvements during a given model  year. BMW may 
recommend a newer, improved part  as a replacement,  and 
your  authorized  dealers parts department  will know  about  it 
and  provide  it. The  BMW  parts organization  is best  equipped 
to  deal  with your  BMW parts needs. 
Non returnable  parts 
Some parts cannot be returned, even  for credit. The best ex- 
ample is electrical parts,  which are almost  universally consid- 
ered  non returnable.  Buy electrical  parts carefully, and be  as 
sure  as possible that a replacement is  needed, especially  for 
expensive parts such  as electronic control  units. It may  be 
wise  to let an authorized  BMW dealer  or other  qualified shop 
confirm  your diagnosis before replacing  an expensive  non re- 
turnable 
Dart.   
						

							
01 0-1 2 
1 General 
Information you need to know 
Model 
When ordering parts it  is important  that you know the correct 
model designation  for your  car. Models covered in this E39 
manual are the 
525i,5281,530i, 540i in Sedan and Station 
Wagon body  styles. 
Model  year 
This  is not necessarily the  same as date  of manufacture  or 
date  of sale. 
A 1999  model  may have been manufactured in 
late 1998, and perhaps  not sold until early  2000.  It is  still  a 
1999  model.  Model years covered  by this manual are  1997 to 
2002. 
Date  of manufacture 
This information is  necessary when ordering replacement 
parts  or determining  if any  of the  warranty recalls are applica- 
ble to your car. The label on the drivers door below  the door 
latch will specify  the month  and year  that the car was  built. 
Vehicle 
Identification Number  (VIN) 
This is  a combination  of letters and  numbers that identify the 
particular  car. The VIN  appears on the state registration doc- 
ument, and on the car  itself. One location is on the right front 
strut  tower  in the  engine compartment  (arrow), another in the 
lower  left corner  of the  windshield. 
Engine  code 
5  Series car covered in  this manual are powered  by 
6 and 8 - cylinderengines.  For information on engine codes  and en- -. - 
gine applications, see  100 Engine-General. - 
Transmission code 
The transmission type  with its identifying code  may be 
impor- : 
tant when  buying clutch  parts, seals, gaskets, and other .- transmission-related  parts. For information  on transmission 
codes  and applications,  see 200  Transmission-General.   
						

							
BMW dealers  are uniquely  qualified to provide service for 
BMW cars. Their authorized relationship with  the large BMW 
service  organization  means that they have access to special 
tools  and equipment, together with  the latest and most accu- 
rate repair information. 
The  BMW dealers service technicians  are highly trained  and 
very  capable. Authorized BMW dealers  are committed to  sup- 
porting the  BMW product.  On the other  hand, there  are many 
independent shops  that provide quality  repairwork. 
Checking 
with other  BMW owners for recommendations  on service fa- 
cilities is  good way to learn of reputable BMW shops  in your 
area. 
Most  maintenance  can be accomplished with a small selec- 
tion  of tools. Tools range  in quality  from inexpensive junk, 
which may break  at first use, to very expensive  and 
well- 
made tools for  the professional.  The best  tools for most  do-it- 
yourself BMW owners  lie somewhere  in between. 
Many  reputable tool manufacturers offer  good quality, moder- 
ately priced  tools with a lifetime guarantee. These  are your 
best buy.  They cost a little  more, but they are good  quality 
tools that  will do what 
Is expected  of them. Sears Craftsman@ 
line is one  such source  of good  quality  tools. 
Some  of the  repairs  covered in  this manual require the  use of 
special tools,  such as a custom puller or specialized electrical 
test equipment.  These special tools are  called out in the  text 
and can  be purchased through  an authorized BMW dealer. 
As  an alternative, some special tools mentioned may  be pur- 
chased from  the following tool manufacturers  and/or distribu- 
tors: 
Specialty  tool suppliers 
Assenmacher  Specialty Tools 
6440  Odeli  Place 
Boulder.  CO 80301 
Baum Tools  Unlimited, Inc. 
P.O.  Box 5867 
Sarasota. 
FL 34277-5867   
						

							
01 0-1 4 
General 
Specialty tool suppliers 
Peake Research, Automotive Products  Division 
P.O.  Box 28776 
San  Jose,  CA 95159 
408-369-0406 
[email protected] 
http://www.peakeresearch.com 
Basic tool requirements 
The  basic  hand tools described below  can be used to accom- 
plish most  of the simple maintenance and  repair tasks. 
Screwdrivers 
4 The  common  flat-blade  type,  Phillips type,  and TorxO type 
screwdrivers  will  handle almost all screws used  on 
BMWs. 
Two or three different  sizes of each type  will be required, 
since a  screwdriver  of the  wrong size  will damage the  screw 
head. 
Wrenches 
4 Wrenches  come in different  styles,  including open-end.  12 
point  box-end, 
6 point box-end and  flare nut. The basic  open- 
end wrench is the  most widely  used, but grips  on only two 
sides.  The box-end wrench  has better grip on all six  sides  of 
a nut  or bolt. 
A 12 point box-end  can loosen a nut or bolt  where  there is less 
room  for movement,  while 
a 6 point box-end provides  better 
grip. For hex  fasteners on fluid  lines, like  brake lines and  fuel 
lines,  a flare-nut wrench  offers the advantages  of a box-end 
wrench with  a slot that  allows it to  fit over the  line. 
The combination wrench is  the most  universal.  It has one 
open-end  and one box-end.  10 mm  and  13 mm  wrenches  are 
the most  common  sizes needed. 
A more complete  set of 
wrenches  would include 
6 mm through  19 mm  sizes.   
						

							
Sockets Socltets are used  with a ratchet handle for speed  and conve- 
nience  and can be combined  with extensions  and universal 
joints  (swivels) to reach fasteners more easily.  The most 
common  socket drive sizes are 
114 inch, 318 inch and 112 inch. 
Sockets  come in 
6 point and 12 point styles.  The 6 point offers 
a  better  grip on tight nuts  and bolts. 
6 mm to 19 mm socltets 
are  the most  needed  sizes. Below is a list  of typical  bolt 
diarn- 
eters and the corresponding wrench sizes. 
Common  bolt diameters and wrench sizes 
M5 8 rnrn 
M6 
10 rnm 
M8 12rnrnor13rnrn 
MI 0 17 rnrn 
MI2 19 rnrn 
M14 22 mm 
Spark  plug socket 
4 A 518 deep-well socket for sparlt plugs  includes a rubber  in- 
sert  to both  protect  the spark  plug from damage and grip  it for 
easier  removal. 
Pliers 
There are  many types  of pliers including snap-ring, 
needle- 
nose, adjustable-joint, slip-joint (Channel-lock@),  and locking 
(Vice-Grip@) most  of which are  used for holding irregular  ob- 
jects,  bending, or crimping.  Some have special applications. 
Needlenose  pliers are used  for gripping small and poorly ac- 
cessible  objects, and are useful  forwiring and  other electrical 
work.  Locking pliers  such as the Vise-Grip@ are useful  be- 
cause  of their tight grip. 
Snap-ring  and circlip  pliers with special tipped jaws are  used 
to  remove  and install snap-rings or circlips. Channel-lock@ or 
water  pump pliers have adjustable jaws that can  be quicltly 
changed  to match  the size  of the  object  being held  to give 
greater  leverage,   
						

							
.- 
General 
4 An adjustable wrench  can be a  useful addition to  a small tool 
kit.  It can  substitute  in a pinch  if two  wrenches  of the  same 
size  are needed  to remove  a nut and bolt.  Use extra  care with 
adjustable wrenches, as they tend to  loosen, slip, and dam- 
age fasteners. 
Jack  stands 
v 
BOOBFNG 
4 Strong  jack stands  are extremely important  for any work that 
is  done  under  the car.  Use  only jack stands that are designed 
for  the  purpose. 
Blocks of wood, concrete, bricks, etc.  are not 
safe  or suitable substitutes. 
A 
jaclc should  be used  only to raise  the vehicle,  not to support 
the  car  for a long  period.  Always  use 
jack stands to support  a 
Jackstands  are available in  several styles. The best ones  are 
: 
made of heavy material for strength, have  a wide base for sta- 
bility, and  are equipped  to positively  lock in their raised  posi- 
tion.  Get the best ones available. 
Compared to 
a wrench  of the correct size,  an adjustable 
Oil  change  equipment 
wrench is always  second  best. They  should only  be used 
when  the correct size wrench is not available. Choose one  of 
average size range, about 
6 to 8 inches in  length. 
4 Changing  engine oil  requires  a 17 mm socket or wrench  to 
loosen  and tighten  the drain  plug and a drain  pan (at least 
8 
quart  capacity).  A wide,  low drain  pan will fit more easily un- 
der the  car. Use a funnel  to pour the new oil into the engine. 
BMW engines  use an oil filter canister with  a disposable  filter 
cartridge insert.  A 
36 mm socket or wrench is required  to re- 
move  the oil filtercanistercover.  See 
020 Maintenance foroil 
change instructions.   
						

							
. 
General 
Torque wrench 
A torque wrench  is used  to precisely tighten threaded fasten- 
ers to  a predetermined  value. Many of the  repair procedures 
in  this  manual include  BMW-specified torque values 
in New- 
ton-meters (Nm)  and the equivalent values  in foot-pounds 
(ft- 
Ib). 
4 Several  types of torque  wrenches are  available. An inexpen- 
sive beam-type (top) is adequate but must  be read visually. A 
ratchet-type  (bottom) can be preset to indicate (click)  when 
the  torque value  has been reached. They  all do the same job, 
but  offer different convenience features  at different prices. 
The  most  convenient ones  have a built-in ratchet, and  can be 
preset  to indicate when  a specific torque value  has been 
reached. Follow  the wrench manufacturers directions 
for use 
to  achieve the greatest  accuracy. 
A torque wrench with a range  up to about 150 Nm (1 10  ft-lb) BOIBFNG has adequate  capacity for most  of the  repairs covered  in this 
manual. For recommended  torque values of 
10 Nm orbelow, 
the English system equivalent is given  in inch-pounds (in-lb). 
These  small values may  be most easily  reached using a 
torque wrench calibrated  in inch-pounds.  To convert 
inch- 
pounds  to foot-pounds,  divide by 12. 
Digital multimeter 
4 Many of the  electrical tests  in this manual  call for the mea- 
surement  of resistance (ohms) or voltage values.  For safe 
and  accurate tests  of sensitive electronic component  and 
systems,  a multimeter or digital 
volt/ohm meter  (DVOM)  with 
high  input impedance  (at least 
10,000Sr) should  be used. 
Some meters have automotive functions  such  as dwell and 
pulse width  that are useful  for troubleshooting  ignition  and 
fuel  injection  problems. 
CAUTIOI\C 
Vehicle electronic systems may  be damaged  by the high cur- 
rent  draw  of a test light  with a normal  incandescent  bulb. As 
a  general  rule, use a high  impedance  digital multimeter  or an 
LED test light  for all electrical  testing.   
						

							
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General 
BMW special tools 
Many repairs covered  in this manual call for the use  of BMW 
special  tools. Many of the  BMW  special tools mentioned  in 
this manual are simply the best thing to  use to do the  job cor- 
rectly.  In these cases, the tool is identified with a 
BMW parl 
number. See  your authorized  BMW dealer parts department 
for  information  on how  to order  special tools. 
There are  some jobs for which  expensive special tools are  es- 
sential, and  not a cost-effective purchase  for a one  time  repair 
by  the do-it-yourself owner. This manual includes such  re- 
pairs for the benefit  of those with the necessary experience 
and access to  tools. For the do-it-yourselfer, the need for  spe- 
cial tools  is noted in the  text, and whether or not  BMW  dealer 
service is recommended. 
Changing a tire 
- Stop  car on  as flat a surface  as possible, in a place where  you 
can  be easily  seen by other drivers. Avoid  stopping just over 
the crest  of a hill. 
WARNING - 
If a tire  goes flat  while driving,  pull well off the road.  Changing 
a  tire  on a busy  slreet  or liigliway  is very  dangerous.  If 
nec- 
essag drive a short  distance  on the  flat tire to  get to a safe 
place.  It is  much better  to ruin a  tire or rim  than to 
risk being 
hit. 
- 
- Turn  on emergency  flashers, and set out flares  or emergency 
markers  well behind  car. 
Choclc wheel (wheel chock located 
in  trunk) diagonally opposite to the one being  changed.  Pas- 
sengers should  get out of car and  stand well  away from road. 
- Take jaclc and tools from tool area beneath trunk mat. Re- 
move  spare tire from tire  storage tray. 
- Loosen wheel bolts  while car is on  ground, but leave  them a 
little  snug. 
< Place jack in lifting point nearest wheel being changed.  Use 
a board  to provide a firm  footing for jack  if ground is  soft. 
Raise car only  far enough  so that  the wheel  is fully  off ground 
and  then remove wheel  nuts and wheel. 
- Install spare wheel. Install wheel nuts  and tighten  them hand 
tight using lug nut  wrench.   
						

							
General 
Cars with discharged or dead batteries can be jump-started 
using the good battery from another  car. See owners  manual 
for proper instruction on jump  starting. When jump-starling 
the engine, always note  the following  warnings. 
4 Lower car. With all wheels on  ground, fully tighten nuts in a 
WARNING- 
* Battery  acid (electrolyte)  can cause severe burns, and will 
damage  the 
cal; clothing, and you.  If electrolyte  is spilled, 
wash  the surface  with large  quantities  of water. 
M itgets into 
eyes,  flush them  with  water  for several minutes and call a 
doctor. 
B4 
5 
43 
2 BOOIFNG. 
Batteries  produce explosive  and noxious  gasses. 
Keeps sparks  and flames  away. Do not  smoke near 
batteries. 
Do  notjump-start  the engine 
ifyou suspect that the bat- 
tery  is frozen.  Trappedgas  may explode.  Allow the  bat- 
tery  to thaw  first. 
Do  not  quick-charge the  battery (for boost  starting)  for 
longer  than one minute,  and do not  exceed 
16.5 volts 
at  the  battery  with the boosting  cables attached.  Wait at 
least  one minute before boosting  the battery  a second 
time. 
crisscross pattern. 
Torque wheel nuts when  installing  wheel. 
Check  inflation pressure  of spare  tire. 
Tightening torque 
Wheel to wheel hub 120 Nm (89 ft-ib) 
Jump starting 
Indicator  and warning  lights 
Many vehicle systems are self-monitored  for faults while driv- 
ing. Generally, 
a red  warning lamp that comes  on during  driv- 
ing should  be considered serious.  If you  cannot immediately 
determine the seriousness  of the warning light, stop the  vehi- 
cle in  a safe place and turn the  engine off as soon as possible. 
Consult  the owners manual  for additional information  on the 
warning lamp and  the recommended action. 
If the Malfunction Indicator Lamp (MIL) 
(Check Engine  or Ser- 
vice Engine Soon warning light)  comes on orflashes,  it indi- 
cates  that an emissions-related  fault has occurred. Faults 
such  as a bad oxygen  sensor or a dead fuel injector  can 
cause the exhaust  or evaporative emissions to exceed  a 
specified  limit. When these  limits are exceeded, the MIL  will 
be turned  on. The engine can be  safety driven  with the light 
on, although  the emission systems  should be 
checked as 
soon  as possible. See  OBD On-Board  Diagnostics for   
						

							
01 0-20 
General 
more information  on the Check Engine Light  and the on- 
board  diagnostic system. 
Towing 
The cars  covered  by this  manual  should be towed  with a tow 
truck using wheel  lift or flat  bed  equipment.  Do not tow  the car 
on  all four  wheels  except 
forvery short distances  to move  it to 
a safe  place. 
CA U JION- 
Do not tow with sling-type equipment  The front spoilers  and 
b~m~er covers may sustain damage. 
4 To access threaded  towing  eye socltet, pry open  trim on front 
or  rear  bumper. 
NOJE- 
A towing eye  is provided in the luggage compartment tool  lcit. 
The  towing eye  can be screwed into  the front or rear bumper. 
4 Install  towing  eye into threaded  hole. 
- Standard  transmission:  Do  not tow with  rear wheels  on 
ground  unless absolutely  necessary. 
- Automatic  transmission:  Have rear wheels placed on dollies, 
or  use  flat bed  truck.  Use towing eye for  winching vehicle  on 
flat  bed. 
CAUTION- 
Automatic  transmission  fluid (ATF) does  not circulate when 
I the car is towed.  Severe transmission  damage may result. 
NOTE- 
Be sure  transrnission  fluid has  been topped off before 
starting  tow. 
Always  tow car with  transrnission lever  in 
N (neutral). 
. ATF draining  and filling  is covered in 240 Automatic 
Transmission. 
Be sure  to read the  filling and draining  pro. 
cedure,  as special  service equipment is  required to 
checlc 
the fluid  level.