Honda Bmw 5 Service Manual

							
Battery, Starter, ~iternatorl 
The battery  is mounted in  the right side of the  luggage  com- 
partment,  concealed behind  a trim panel.  Battery capacity is 
determined  by the  amount  of current  needed  to start the vehi- 
cle  and  by the amount of  current consumed by the electrical 
system.  This will vary  from model to model. 
BMW  batteries are rated  by 
amperelhours (Ah) and cold 
cranking amps (CCA) rating, which  are listed on the battery. 
The  Ah rating is  determined  by the  average amount  of cur- 
rent  the battery can  deliver over time without dropping below 
a specified voltage.  The CCA  is determined by the batterys 
ability to deliver  starting current at 
On F (-18 C) without drop- 
ping  below a specified voltage. Always  replace the battery 
with  one having  the same or higher ratings. 
Battery testing 
Battery testing determines the state  of battery charge. On 
conventional  or low-maintenance batteries.  the most com- 
mon  method  of testing the  battery is that 
ofchecking the spe- 
cific  gravity  of the electrolyte using a hydrometer. Before 
testing the  battery, check that the cables  are tight  and free  of 
- corrosion. 
Hydrometer testing 
Before  hydrometertesting, load the  battery with 15 amperes 
for one minute.  If the  battery is installed  in the vehicle, this  can 
be done  by turning on the  headlights without  the engine run- 
ning.  The state  of battery charge  based on specific gravity 
values  are given  in Table 
b. Specific  gravity of battery  elec- 
trolyte  at 
27 C (80°F). 
The hydrometer indicates  the specific gravity  of the  electro- 
lyte.  The more dense the  concentration of sulfuric acid  in the 
electrolyte,  the higher the  state of charge 
NOTE- 
Electrolyte temperature affects  hydrometer reading. Checlc 
the electrolyte temperature with a thermometer.  Add 0.004 to 
the  hydrometerreading 
forevery 6°C (10°F) that  the electro- 
lyte  is above  27°C 
(80°F). Subtract 0.004 from the reading 
forevery 6°C (10°F) that  the electrolyte  is below27C 
(80°F).   
						

							
. 
Battery, Starter, Alternator 
Table b. Specific gravity  of battery electrolyte  at 27°C (80°F) 
Specific gravity  State of charge 
1.265  Fully charged 
1.225  75% charged 
1.190  50% charged 
1.155  25% charged 
1.120 Fully discharged 
if  the  specific gravity is  at 
orabove 1.225, butthe battery lacks 
Dower  for 
startinq, determine  the battews service condition 
with a load volta& test. if the  average specific gravity  of the 
six  cells  is below  1.225,  remove  the battery  from the luggage 
compartment  and recharge. 
Battery  open-circuit voltage test 
Before testing, load battery  with 15 amperes for one  minute 
with  battery  load-tester or turn on  headlights for about one 
minute  without  engine running.  Connect digital voltmeter 
across battery  terminals.  Open-circuit voltage levels  are giv- 
en in Table 
c. Open-circuit voltage  and battery charge. 
If  open-circuit  voltage is 
OK but battery  still lacks power  for 
starting, perform a load  voltage test. 
If  open-circuit  voltage is 
below 12.4  volts, recharge battery 
and  retest. 
Table  c. Open-circuit  voltage and battery charge 
Open-circuit voltage  State of charge 
12.6  V or  more 
12.4  V 
12.2v 
12.0 v 
Fully charged 
75% charged 
50%  charged 
25%  charged 
11.7Vorless Fully  discharged 
Battery load  voltage test 
A battery load tester is required for  a load voltage test.  The 
test  is made  by applying  a high resistive  load to the  battery 
terminals  and then  measuring battery voltage.  The battery 
should  be 
fully charged forthe most accurate results.  The bat- 
tery  cables must be  disconnected before 
malting the test. Re- 
place the battery  if the voltage  is below  that listed  in Table  d. 
Battery  load test 
- minimum  voltage.   
						

							
Battery, Starter, ~lternatorl 
WARNING- 
Always wear protective goggles  and clothing  when perform- 
ing  a load  test. 
Table 
d. Battery load test - minimum  voltage 
Ambient  temperature  Voltage* 
27 
 C (80  F)  9.6 V 
-I 8 C (0 
F)  8.5 V 
* Measure 
after applying  a 200  amp  load for 15 seconds. 
Closed-circuit current measurement 
If the  vehicle battery  is discharged for  an unknown reason, 
perform a closed-circuit current measurement as the first test. 
For  diagnostic purposes,  it is important to  not disconnect  the 
battery. Disconnecting  the battery may reset a faulty control 
unit,  preventing  proper diagnosis. 
The  following test is generally completed overnight using a 
multimeterwith  a closed circuitcurrent  measurement adaptor 
with a recording function 
- Check that  battery voltage  is 12 volts or higher.  If lower, 
recharge battery. 
- Switch  off electrical  consumers (interior lights, telephone, 
aftermarket  equipment, or others). 
- Open  luggage compartment  and remove  battery trim panel. 
Use  screwdriver  to lock latch  on trunk lid or hatch, simulating 
closed  luggage compartment.  Close other  doors. 
- Open drivers door, then close  it, simulating driver entering 
vehicle. 
- Switch ignition  to RUN position for at least five seconds,  then 
turn ignition  to OFF  position.  This simulates driving  vehicle. 
- Open and close  drivers  door, simulating driver leaving 
vehicle. 
- Lock car and  arm alarm. 
- Wait at least 16 minutes  for consumer cut-off.   
						

							
121-8 
/Battery, Starter, Alternator 
NOTE- 
Automatic transmission cars: ambershifier LED willgo out at 
consumer  cut-off. 
4 Attach closed-circuit current  measurement adaptor 
(BMW  special  tool 
61 2 300): 
Connect  red clamp  (marked A -BATT (+)) to positive  bat- 
tery  terminal. 
Connect 
black clamp (marked B -CHASSIS)  to chassis 
ground point. 
NOTE- 
Green LED will light  up to indicate correct installation  of 
closed-circuit current measurement 
adaotor. 
< Connect blaclc clamp (marked B - BATT (-)) to  negative bat- 
tery  terminal.  Green 
LED light will go out. 
NOTE- 
Any  electrical overloading  will be indicated  at this  point  by 
lighting  the red 
LED. If the  red LED lights  up, check the  adap- 
tor  connections. 
< Set  multimeter (A) to 10 amp  measuring range  and connect 
it  to  adaptor. 
NOTE - 
Set  multimeter  to record  average readings. 
Ifpossible,  turn offpowersaving  features of multimeter 
which  prevent  a long  term  (overnight)  test by automatically 
powering  down 
meter. 
- Disconnect  battery ground strap (B) at chassis mounting 
point. 
- Measure  closed-circuit  current using multimeter. 
- Typical  average  closed-circuit  current for E39 vehicles is 
40 mA. Readings  over 50 mA must be further  investigated.   
						

							
121-9 
Battery, Starter, ~lternatorl 
Battery charging 
Discharged batteries  can be recharged using a batterycharg- 
er.  Remove  the battery from  the trunk during charging. 
Prolonged charging  causes  electrolyte evaporation  to a level 
that  can damage  the battery.  It is  best  to use a low-current 
charger 
(6 amperes  or less)  to prevent battery damage 
caused  by overheating. 
WARNING - 
Hydrogen  gas given  off by the battery during charging  is ex- 
plosive.  Do not smoke. 
Keep open flames  away from the top 
ofthe batte~ and  prevent  electrical sparks by turning  off the 
battery charger before connecting or disconnecting  it. 
Battery  electrolyte (sulfuric acid)  can  damage  the  car. If 
electrolyte  is spilled, clean  the area  with  a solution 
ofbak- 
ing soda  and water. 
Always  allow a frozen  battery to  thaw before attempting 
to recharge  it. 
Always  disconnect  both battery cables  and remove  bat- 
tery  from  vehicle during battery  charging. Do not  ex- 
ceed 
16.5 charging  voltage at the battery 
Battery safety terminal,  replacing 
If the  battery safety terminal  has been  triggered,  investigate 
and  correct  the cause  prior to replacement. 
- Working  in right  side of luggage  compartment,  remove  bat- 
tery trim  panel. 
- Disconnect  negative (-) battery terminal  and cover  with 
insulator. 
- Disconnect  positive (+) cable from  battery. 
- Release positive (+) cable from  cable brackets on luggage 
compartment  wall. Lay  new  repair cable parallel  to positive 
cable. 
- Mark  off length  of new  cable  on old  cable.  Allow 10 cm 
(2.5 in) of slack. 
- Saw  through  old cable. 
Do not use bolt cutters or similar  tools to cut  through cable. 
A  cable  end that has been squashed 
flat will not fit into  the   
						

							
121-10 
I Battery, Starter, Alternator 
- Strip approximately 15 rnm (0.6 in) of insulation  from cable 
end. 
terminal harness 
Shrink insulation 
Terminal  connector 
4 Push terminal connector  of new  cable  over stripped end  of 
old  cable.  Tighten  clamp. 
- Slip shrink-fit insulation  over positive cable. Attach  new safe- 
ty  harness  to end  of positive  cable. Shrink insulation with  hot 
air  blower. 
- Reinstall cable  in cable  bracket  and attach  to battery. 
- Reattach  negative battery cable. Reinstall luggage cornpart- 
rnent trim pieces. 
- Use BMW scan tool DlSplus or equivalent to  read out airbag 
control module  fault memory. Correct faults, then  clear mem- 
ory. 
1 1 4 Various versions  of alternators  have been  used in E39 
vehicles.  See Table e. 
Table e. Alternator  application chart 
Model  Alternator type 
Air cooled,  90 amp  or 120  amp 
Air  cooled,  with multi-function control 
(MFR),  120 amp  or  140  amp 
Air  cooled with  multi-function control 
(MFR),  120 amp  or  140  amp 
540i  1997  Air 
cooled.  120 
amp or 140amp sazrz~orsl 1998 ~~~ ~ .~ . ...~ ~ ~-~~~~ Air cooled; with integrated mu~ii- 
function control  (MFR). 120 amp  140 
amp 1999-2002  Water 
cooled,  with integrated multi- 
function control  (MFR), 90-150  amp 
(variable output)   
						

							
121-11 
Battery, Starter, ~lternatorl 
Alternator 1997 - 98 5281 1997 540i 
/-- -----, 
I 
----------- 
F15 / 7.5A/ : 
&.. .... , 30 1 Xi0015 
Battery 
Hol in run 61 E (D+) Alternator 
and stsrt 
lBL 
(Generator) 
1 .--------,charge , . I , indicator I xGoli i 
I 
						

							
Battery, Starter, Alternator 
Water-cooled alternator 
The water-cooled alternator, used on 1999 and later M62 TU 
engines,  is a sealed  unit housed inside the  engine block wa- 
ter  jacket.  It  is cooled via the engine cooling  system. It is a 
brushless sealed  unit that cannot  be serviced.  Maintaining 
consistent alternator temperatures increases the life  span of 
the  alternator,  and elimination  of the  alternator  cooling fan re- 
duces alternator noise 
significantly. 
The M62 TU water-cooled alternator incorporates  load start 
reduction.  This function is intended to shorten the  duration of 
engine starting, particularly at low ambienttemperatures. The 
current load is limited to 
20 amps  during starting in  order to re- 
duce alternator braking torque on  the engine. Following  the 
current limiting phase, full power  output is then progressively 
reached. 
Charging system diagnostics  requires special test equip- 
ment.  If the  test  equipment is not  available, charging system 
fault  diagnosis can be performed  by an authorized 
BMW 
dealer  or other  qualified repair  shop. See Table  a. Battery, 
alternator and starter  troubleshooting for general  electri- 
cal  component troubleshooting. 
Before checking the alternator, make  sure the battery is fully 
charged and capable  of holding a charge.  Check that the bat- 
tery terminals  are clean  and tight and the alternator drive belt 
is properly tensioned  and not severely  worn. 
NOTE- 
Some model  require  up to 15 second  to reacli  full alternator 
output. 
CA UTIOG 
If the  charge  indicator  light in the  instrument cluster remains 
on,  the charge warning  circuit in the  instrument cluster may 
be  faulty.  Check that  the ground  lead is securely 
affached to 
the  grounding  stud on the cylinder  head 
(A). Replacing the 
instrument cluster before  repairing the ground  lead will both 
damage  the instrument  cluster and cause  the failure  to 
reoccur.   
						

							
Battery, Starter, ~lternatorl 
Charging system quick-check 
Use a digital multimeter to measure voltage across  the bat- 
tery terminals with key  off and  then again with engine running. 
Battery voltage  should be about 12.6 volts with key  off and be- 
tween  13.5 and 14.5 volts with engine running. 
NOTE- 
The regulated  voltage (engine running) should be between 
13.2 and 14.5, depending on  temperature andoperating  con- 
ditions. 
If the  voltage  is higher  than 14.8, the voltage regula- 
tor  or 
mulitfunction controller  is most likely faulty 
Check for clean  and tight battery cables. Check ground cable 
running  from negative 
(-) battery  terminal  to chassis  and 
ground cable  running from engine  to chassis. Check alterna- 
tor  drive  belt condition and tension. 
Charging system, checking 
CAUTIOI\C 
* Do not  disconnect  the battery  while the  engine is running. 
Damage  to the  alternator  and/or engine electronic  systems 
may  result. 
Only use  a digital multimeter  when testing  charging 
system  components. 
--7 
4 Turn ignition  key on. Check that  battery  warning light comes 
on. 
NOTE- 
If  the warning  light does  not come  on, repair  bulb or wiring 
faults  before  continuing to  checlc the charging  system. 
/ Charge indicator 
502820805 
4 6-cylinder  engines  only, remove complete air filter housing: 
Loosen 
intake duct  hose clamp (A) at  throttle  assembly. 
Loosen clamp  and remove idle control  hose from intake 
duct 
(B) and  disconnect idle speed control  valve electrical 
harness connector. 
Disconnect electrical harness connector 
(C) from mass  air 
flow  sensor. 
Remove  air filter housing  mounting screw 
(D). 
Disconnect  vent tube (E). 
Loosen air intake duct clamp (F). 
Carefully  lift air filter  housing out  of engine  bay.   
						

							
- - 
/Battery, Starter,  Alternator -- - -. - --I 
< Check for battery  voltage  at alternator  terminal 30 (B+) (ar- 
row): 
Pull back rubber insulating cover  at terminal 30 at rear of 
alternator. 
Connect  voltmeter  between  terminal 30 and ground  and 
check  for battery voltage. 
If voltage  is not present, check 
wiring  for faults. 
NOTE- 
On V-8 engines,  access to the  rear  of the alternator  is limited. 
Check for  battery voltage  between  the jump start  post on the 
left cylinder  head and ground. 
r Disconnect harness connector from alternator.  Turn ianition 
on  and check  for battery voltage between terminal 
lgand 
ground.  If voltage  is not  present, check wiring  and fuses  for 
faults. 
Reconnect connector  to alternator. 
Locate the  blue wire coming  from terminal 
61E of the alter- 
nator connector. Carefully connect  the positive 
(+) test  lead 
to  the wire using  a piercing  test lead  end. 
Turn  ignition  key on and  check for voltage.  Voltage should be 
less than  1.5 VDC  and charge  indicator lamp should light. 
- Making  sure all test equipment  and tools  are clear,  start en- 
gine.  Voltage  should increase to 
8.0 VDC or higher.  The 
charge  indicator light  should go out. 
If  voltage does  not increase  and system  is  not charging, 
the  fault  is  in alternator. 
- If voltage does  not increase, but system  is charging, inter- - roaate svstem  for faults  usina  an appropriate  BMW  scan - .. . tool andreset  fault  memory. 
- If a load  tester  is not available, a quick alternator output test 
can  be done by running engine  at about  2000 rpm and turn- 
- - 
ing on electrical  loads  (fans, lights, rear window defroster, - 
- and wipers). With  all accessories  on, battery voltage should 
be  above  12.6 
V.