BMW 5 Series (E39) Service Manual: 1997-2003 - Complete Index

INDEX 1

WARNING

Your common sense, goodjudgement, and general alertness arecrucial to safe and successful servicework. Before attempting any work onyour BMW, be sure to read 001General Warnings and Cautionsand the copyright page at the front ofthe manual. Review these warningsand cautions each time you prepareto work on your BMW. Please alsoread any warnings and cautions thataccompany the procedures in themanual.

3/2-way valve (running losses)see Fuel tank

A

Abbreviations, commonly used 600-14

ABS (antilock brake system)see Brakes

A/Cair distribution motors

see stepper motors (below)blower final stage (resistor pack), replacing 640-16

blower, removing/installing 640-15

compressor, replacing 640-24condenser, replacing 640-25control panel/module, removing/installing 640-11

evaporator, removing/installing 640-29

evaporator temperature sensor 640-12

expansion valve, removing/installing 640-27

IHKA / IHKR system description 640-5receiver/drier, replacing 640-26stepper motors 640-13ventilation microfilter, replacing 020-22, 640-17

see also Heating

Accelerator linkagesee Maintenance

Activated carbon canistersee Fuel tank

ADS (auxiliary throttle valve)130-57

Air compressor330-44

Air conditioningsee A/C

Air distribution (flap) motorssee A/C, stepper motors

Air filtersee Maintenance

Air spring300-8, 330-12

Airbag system (SRS)2-stage airbag 721-4control module, replacing 721-7driver airbag, removing/installing 721-8

head protection airbag 721-12components 721-11

indicator light 721-4passenger airbag, removing/installing 721-9

side-impact airbags crash sensor, replacing 721-7

Airflow sensorsee 130 under appropriate fuel injection system

Air pumpsee 130 under appropriate fuel injection system, secondary air injection system

Air suspensionsee Electronic height control (EHC)

Alarm see Anti-theft alarm

Alignmentsee Wheel alignment

Aluminum suspension components300-2

Antenna650-6

Alternatorsee Battery, starter, alternator

Amplifier650-4

Anti-theft alarm (DWA)515-24emergency disarming 515-31

Antifreeze (engine coolant)see Maintenancesee also Cooling system

Antilock brake system (ABS)see Brakes

ASCsee Brakes

ATF (automatic transmission fluid)see Automatic transmissionsee also Cooling system

Automatic headlight adjustment (LWR)

see Lights

Automatic seat belt tensioner720-4

Automatic shiftlocksee Gearshift

Automatic transmissionapplications 200-3, 240-4ATF 020-10, 200-4

capacity 240-8checking 240-6draining/filling 240-7heat exchanger 170-5

fluid pan and strainer 240-9gearshift

see GearshiftID tag 200-3range switch 610-6removal/installation 240-10steptronic

see Gearshift

Auxiliary cooling fansee Cooling system, electric fan

Auxiliary throttle valve (ADS)130-57

Axle jointsee Drive axle

B

Back-up light switchautomatic transmission

see Automatic transmission, range switch

manual transmission 230-8

Battery, starter, alternatoralternator (generator) 121-10

6-cylinder engine, removing/installing 121-15

M62 engine 121-16M62 TU engine (water cooled) 121-18

battery 121-5charging 121-9safety terminal 121-3testing 121-5

charging system, troubleshooting 121-12

starter 121-196-cylinder engine, removing/installing 121-20

V-8 engine, removing/installing 121-21

solenoid, removing/installing 121-23troubleshooting 121-19

see also Maintenance

Bearing, wheelsee Front suspension see also Rear suspension1007

2 INDEX

Beltssee Maintenance, drive belts

Blade, wipersee Wipers and Washers

Blower motorsee A/C

BMW emblemsee Exterior trim

BMW special tools010-18see also special tools section at beginning of each repair group

Bodydimensions 400-2interior features 400-9safety and security 400-7

Body side moldingsee Exterior trim

Bonnetsee Engine hood

Bootsee Trunk

Brake fluid020-24, 340-8

Brake fluid pressure sensor340-30

BrakesABS, ASC or DSC system 300-12

component replacement 340-26ASC/DSC switch

see Switchesbleeding brakes 340-8brake booster 340-19brake pads, calipers and rotors 340-11

description 300-10electronic brake & stability 300-11light switch

see Switchesmaster cylinder 340-16parking brake 340-22troubleshooting 340-5

Bulbssee Lights

Bumperfront 510-6

height, adjusting 510-12rear 510-9

Bus system600-4

C

Camber320-33

Camshaftremoving/installing

M52 engine 116-12M52 TU / M54 engine 116-19M62 engine 116-39

wear 116-6

Camshaft position sensorssee Ignition system

Camshaft timing chainadjusting


removing/installingM52 engine 117-26M52 TU / M54 engine 113-46, 116-28

M62 engine 117-66

Capacities, fluid020-10

Car memory/key memory600-10see also Central locking

Carbon canister, activatedsee Fuel tank

Caster320-33

Catalytic converterand oxygen sensor 020-19see also Exhaust system: exhaust manifolds

Cautions 001-3

CD changer650-4

Center bearing, driveshaftsee Driveshaft

Center brake lightsedan 630-13

Center console513-3

Central body electronics (ZKE III)600-8

Central locking car memory/key memory 515-12general module functions 515-2remote entry (FZV) 515-8remote key initialization 515-10single lock/double lock 515-6switch 515-4

Chainsee Camshaft timing chain

Characteristic map (electrically heated) thermostat

see Electrically heated thermostat

Charging systemsee Battery, starter, alternator

Clustersee Instruments

Clutchfluid

see Maintenancehydraulics 210-4mechanical 210-9switch

see Switches, pedal clustervariations 210-10

Codes, faultOBD-1

Coilsee Ignition system

Coil springsee Front suspensionsee also Rear suspension

Component locationssee Electrical system

Compression test113-5

Compressorsee A/C

Condensersee A/C

Constant velocity (CV) jointsee Maintenancesee also Driveshaftsee also Drive axles

Consumer cutoff600-10

Control armsee Front suspensionsee also Rear suspension, suspension arms

Coolant (antifreeze)see Maintenancesee also Cooling system

Coolant pumpsee Cooling system

1008

INDEX 3

WARNING


Cooling systemcoolant

bleeding 170-146-cylinder engine, draining/filling 170-10

V-8 engine, draining/filling 170-12coolant pump 170-3

6-cylinder engine, replacing 170-22V-8 engine, replacing 170-23

cooling fan 170-4viscous clutch fan, removing/installing 170-14

electric fan, removing/installing170-15

expansion tank, removing/installing 170-27

electrically heated (characteristic map) thermostat 170-4

radiator, removing/installing 170-25service

see Maintenancethermostat 170-16transmission fluid heat exchanger 170-5

troubleshooting 170-7combustion leak test 170-10pressure test 170-9

Crankshaft oil sealsfront 117-6rear 119-6

Crankshaft speed sensorsee Ignition system

Crash sensorsee Airbag system (SRS), side-impact airbag crash sensor

CV jointsee Maintenancesee also Driveshaftsee also Drive axles

CV joint bootsee Maintenancesee also Drive axles

Cylinder headremoving/installing


Cylinder head and valvetrainhydraulic lifters, checking and replacing 116-7

leak test 116-5valves 116-56see also Cylinder head

D

Dashboard513-7

Deck lidsee Trunk lid

Diagnostic monitorsOBD-4

Diagnostic trouble codes (DTCs)OBD-7

Digital multimeter010-17

Differentialsee Final drive

DLC (data link connector)020-4, OBD-4

DME (digital motor electronics)see 130 under appropriate fuel injection system

see also Ignition system

DM-TL (detection module-tank leak)see Fuel tank, leak detection unit

Drive beltssee Maintenance

Dome lightsee Lights, interior lights

Doordoor check, replacing 411-4hinge adjustment 411-5lock

see Door locksee also Central locking

removing/installing 411-2panel, removing/installing 411-7window

see Door window

Door checksee Door

Door handlesee Door lock

Door glasssee Door window

Door lockhandles and locks 515-16see also Central locking

Door molding510-13

Door panelsee Door

Door windowanti-trap 512-4convenience opening/closing 512-4regulator and motor 512-11service 512-5switches 512-3

see also Switches

Double VANOSsee VANOS

Drive axleCV joint 331-15CV joint boot 331-15removing/installing 331-14

Drive beltsee Maintenance

Driveability troubleshooting100-4

Driveaway protectionsee EWS (electronic immobilization)

Driveshaftaligning 260-7center bearing, replacing 260-12CV joint, replacing 260-14flex-disc, replacing 260-11front centering guide, replacing 260-13

removing/installing 260-8troubleshooting 260-3U-joint 260-3

DSCsee Brakes

DTC (diagnostic trouble code)OBD-8

DWAsee Anti-theft alarm

E

E-box 610-37

ECM (engine control module)see 130 under appropriate fuel injection system

1009

4 INDEX

ECT (engine coolant temperature) sensor

see 130 under appropriate fuel injection system

EDKadaptation 130-69MS 43.0 130-35

EHCsee Electronic height control (EHC)

Electric cooling fan see Cooling system, cooling fansee also Cooling system, electric fan

Electrical switchessee Switches

Electrical systemabbreviations 600-14bus system 600-4component location table 610-3components

photos 610-36Sport Wagon 610-81

engine 121-2troubleshooting 600-15voltage and polarity 600-5wire color codes 600-12wiring diagrams 600-12

Electrical wiring diagramsELE-1

Electrically heated thermostat (characteristic map)

170-4

Electronic height control (EHC)300-8, 330-44

Electronic immobilizationsee EWS (electronic immobilization)

Electronics box (E-box) 610-37

Emergencies010-18

Emergency brakesee Brakes, parking brake

Enginesee also Cylinder head and valvetrainapplications 100-2compression, testing 113-5cooling

see Cooling systemcrankshaft front oil seal

see Crankshaft oil sealscylinder leak-down test 113-8diagnostic testing 113-1drive belts

see Maintenancedriveability troubleshooting 100-4engine management systems 100-2

see also Ignitionsee also Fuel injection

fuel supply 130-6ground connections 100-5

see also 610identifying features 100-3lubrication system

see Lubrication systemmount

6-cylinder 119-11V-8 119-16

on-board diagnostics OBD-1oxygen sensor

see Fuel injectionsee also Exhaust system

preventive maintenance see Maintenance

removal/installation6-cylinder 110-3V-8 110-16

Engine control module (ECM)see 130 under appropriate fuel injection system

Engine coolant temperature (ECT) sensor


Engine cooling fansee Cooling system, electric fan

Engine hood410-6raising to service position 410-6

Engine troubleshootingsee Engine, driveability troubleshooting

Evaporative control system160-3see also 130 under appropriate fuel injection system

Evaporatorsee A/C

Evaporator temperature sensorsee A/C

Exhaust manifoldsee Exhaust system

Exhaust systemdiagrams 180-11exhaust manifolds, removing/installing 180-4

muffler, replacing 180-8oxygen sensors 180-8

and catalytic converter 020-19see also Fuel injection

removing/installing 180-2see also Maintenance

Expansion tanksee Cooling system

Expansion valvesee A/C

Exterior lightingsee Lights

Exterior trimBMW emblem (Roundel), removing/installing 510-13

body side molding, replacing 510-13grill, removing/installing 510-14headlight housing trim, removing/installing 510-14

outside mirror 510-2

EWS (electronic immobilization)515-21ring antenna, removing/installing320-11

F

Fansee Cooling system

Fan clutchsee Cooling system, cooling fan

Fault codesOBD-2storage 100-4, 600-10

Fenderfront, removing/installing 410-2

Filterssee Maintenance

Final drivelubricant specifications 020-9mounts, replacing 331-12oil level 020-26, 331-6removing/installing 331-5seals 331-7

Firing ordersee Ignition system

FISsee Interior protection

Flex discsee Driveshaft

1010

INDEX 5

WARNING


Fluids and lubricantssee Maintenance

Flywheelremoving/installing 210-13

Foglightsee Lights

Front centering guidesee Driveshaft

Front oil sealsee Crankshaft oil seals

Front suspensioncontrol arm 310-12description 300-2ride height 300-14stabilizer bar, removing/installing 310-21

struts/springs 310-4tension strut 310-16thrust arm 310-12variations 310-4wheel bearing 310-18see also Maintenance

Fuel filtersee Maintenance

Fuel injectionapplications 130-2Bosch M5.2, M5.2.1 130-46Bosch ME 7.2 130-66fuel delivery


see also Fuel pumpsee also Fuel tank

oxygen sensors 130-72, 180-8Siemens MS 41.1 130-7Siemens MS 42.0, MS 43.0 130-23

Fuel injectorsee 130 under appropriate fuel injection system

Fuel level sender160-15see also Fuel pump

Fuel pressure160-10see also Fuel pump

Fuel pump 160-3electrical circuit, testing 160-7removing/installing (includes right side fuel level sender) 160-15

siphon pump, removing/installing 160-19

troubleshooting 160-6see also Fuel tank

Fuel railsee 130 under appropriate fuel injection system

Fuel supply130-6see also Fuel pumpsee also Fuel tank

Fuel tank3/2-way valve (running losses, removing/installing 160-24

carbon canister 160-24draining 160-20evaporative control system 160-3expansion tank, removing/installing 160-23

leak detection unit (LDP or DM-TL), removing/installing 160-24

level sender 160-15removing/installing 160-21

Fuse locations 610-29

FZV (remote entry)see Central locking

G

Gasketsand seals 010-9

Gearshiftautomatic transmission

adjusting 250-7shift interlock, checking function 250-9

shiftlock, checking function 250-8manual transmission

gearshift lever, removing/installing 250-5

steptronic 250-7

General module (GM III)600-8see also Central locking

Generatorsee Battery, starter, alternator

Glasssee Door window

Glove compartment513-16see also

Global positioning system (GPS)620-9

Grillsee Exterior trim

Grounds100-5

Guide linksee Rear suspension, suspension arms

H

Halogen headlight630-5

Hand brakesee Brakes, parking brake

Handle, doorsee Door locks

Hatchsee Tailgate

Hazard warning switchsee Switches

Headlighthousing trim

see Exterior trimwasher 611-17see also Lights

Headlight spray nozzle611-17

Headlight switchsee Switches

Heater coresee Heating

Heater valvesee Heating

Heating heater core, replacing 640-18heater core temperature sensor, removing/installing 640-12

heater valve, replacing 640-17IHKA housing, removing/installing 640-21

see also A/C

Hood410-6

Hood latch and release410-10

Hydraulic valve lifterssee Cylinder head and valvetrain

1011

6 INDEX

I

IAT (intake air temperature) sensorsee 130 under appropriate fuel injection system

Idle speed control valvesee 130 under appropriate fuel injection system

Idle stabilizersee 130 under appropriate fuel injection system, idle speed control valve

Idler arm320-30

Ignition coilsee Ignition system

Ignition interlock320-13

Ignition lock cylinderremoving/installing 320-11, 612-4

Ignition switchsee Switches

Ignition systemdiagnosis

checking for spark 120-10disabling ignition system 120-10misfire detection 120-6oscilloscope diagrams 120-6troubleshooting 120-6

camshaft position sensors 120-14coils 120-10crankshaft speed sensor 120-12firing order 120-9knock sensors 120-16

IHKA see A/C

IHKR see A/C

Injectorsee 130 under appropriate fuel injection system, fuel injector

Input shaft oil sealsee Manual transmission, oil seals

Inspection see Maintenance

InstrumentsGPS

see Global positioning system (GPS)

layout 620-2removing/installing 620-8self-testing 620-6

Intake air temperature sensor (IAT)see 130 under appropriate fuel injection system

Intake manifoldremoving/installing

6-cylinder engine 113-22V-8 engine (M62) 113-56

Integral linksee Rear suspension, suspension arms

Interior lightssee Lights

Interior protection (FIS/UIS)515-25

Interior trim513-13

Interior ventilation microfiltersee A/C, ventilation microfilter

J

Jack stands010-16

Jump starting010-19

K

Keys515-11

Knock sensorsee Ignition system

L

Leak detection, fuel tanksee Fuel tank, leak detection unit

Leather upholsterysee Maintenance, leather upholstery and trim

LDP (leak detection pump)see Fuel tank, leak detection unit

Level sendersee Fuel tanksee also Fuel pump

License plate light630-11

Lifterssee Cylinder head and valvetrain

Lifting the car010-5

Lightsbulb applications 630-2control module (LCM) 630-3foglights 630-8headlights 630-4

automatic headlight adjustment (LWR) 630-7

vertical aim system 630-8interior lights 630-12

bulb applications 630-13side turn signal 630-9taillight 630-10trunk light bulb 630-14turn signals, taillights 630-12

Lockssee Central lockingsee also Door locks

Lubrication systemoil level warning switch, replacing 119-20

oil pan, removing/installing6-cylinder 119-10V-8 lower 119-13V-8 upper 119-15

oil pressurechecking 119-4warning system, testing 119-5warning switch, replacing 119-20

oil pressure relief valve6-cylinder 119-26V-8 119-27

oil pump, removing/installing6-cylinder 119-22V-8 119-4

troubleshooting 119-3

Luggage compartmentsee Trunk

M

MAF (mass air flow) sensorsee 130 under appropriate fuel injection system

1012

INDEX 7

WARNING


Maintenanceaccelerator linkage 020-14air filter 020-14automatic transmission 020-29battery 020-22body lubrication 020-31body and interior 020-31brake fluid 020-24brake pad/rotor wear 020-24brake system 020-25clutch fluid 020-26cooling system 020-15CV joint boots 020-27differential oil level 020-26drive belts 020-16engine compartment 020-14engine cooling system 020-16engine oil 020-11exhaust system 020-27exterior washing 020-31fluid and lubricant specifications 020-9fuel filter 020-27fuel tank and fuel lines 20-28idle speed 020-19inspection 020-5interior care 020-31leather upholstery and trim 020-31maintenance tables 020-6manual transmission oil 020-30microfilter 020-22oxygen sensors 130-72, 180-8parking brake 020-25power steering fluid level 020-20seat belts 020-32service indicator 020-3spark plugs 020-20special cleaning 020-32suspension, front 020-29suspension, rear 020-29tires 020-29washing 020-32waxing 020-32windshield wiper blade 020-33wheels, aligning 020-30

Malfunction indicator light (MIL)OBD-2

Manifold, exhaustsee Exhaust system

Manifold, intakesee Intake manifold

Manual transmissionapplications 200-2, 230-5back-up light switch, replacing 230-8gear ratios 230-6gearshift

see GearshiftID tag 200-2fluid 020-10, 200-4fluid service 230-6oil seals

input shaft seal, replacing 230-17output shaft seal, replacing 230-11selector shaft seal, replacing 230-8

pilot bearing 210-16removal/installation 230-19see also Maintenance

Map lightsee Lights, interior

Mass air flow (MAF) sensorsee 130 under appropriate fuel injection system

Master cylindersee Brakessee also Clutch, hydraulics

MDK130-42

Microfiltersee A/C, ventilation microfiltersee also Maintenance

Mirrorsee Exterior trim

Misfiresee Ignition system, diagnosis

Motor mountsee Engine, mount

MRS (multiple restraint system)see Airbag system (SRS)

Mufflersee Exhaust system

N

Neutral safety switchsee Automatic transmission, range switch

O

OBD II (on-board diagnostics)OBD-1

Oil change equipment010-16

Oil level sensorsee Lubrication system

Oil pansee Lubrication system

Oil pressuresee Lubrication system

Oil pumpsee Lubrication system

Oil service020-11

On-Board Monitor640-12

On-board diagnosticsOBD-1

Outside air temperature sensor610-14

Outside door handlesee Door lock

Outside mirror switchsee Switches

Output shaft oil sealsee Manual transmission, oil seals

Overheatingsee Cooling system, troubleshooting

Overload protection600-11

Oxygen sensors130-72, 180-8

P

P codesOBD-10

Panic mode operation515-11

Parking brakesee Brakessee also Maintenance

Parts, buying010-11

Pedal cluster switchessee Switches

Pedal position sensor (PWG)6-cylinder engine

MS 42.0 130-32MS 43.0 130-35

V-8 engine (M62 TU) 130-68

1013

8 INDEX

Pitman armsee Steering

Power steeringsee Steering

Power steering fluidsee Maintenance

Power window switch512-3

see also Switches

PWGsee Pedal position sensor (PWG)

R

Rack and pinion steeringsee Steering

Radiatorsee Cooling system

Radiator cooling fansee Cooling system, cooling fansee also Cooling system, electric fan

Radiator grillsee Exterior trim

Radio650-2see also Antennasee also Speakers

Rain sensor611-6

Raising car safely010-5

Readiness codesOBD-6

Rear door windowsee Door window

Rear main sealsee Crankshaft oil seals

Rear parcel shelf513-16

Rear suspensionball joints 330-19bushings 330-13control arms

see suspension arms, belowdescription 300-5electronic height control (EHC) 330-44

ride height 300-14ride height sensor 330-46shock absorbers and springs 330-9stabilizer bar 330-42struts and springs 330-5subframe 330-13suspension arms 330-13variations 330-4wheel bearing, replacing 330-32see also Maintenancesee also Drive axlessee also Final drive

Rear window (Sport Wagon)see Tailgate

Rear window defroster610-17

Receiver/driersee A/C

Relay positionssee Electrical component locations table 610-3

Remote entry (FZV)see Central locking

Reversing light switchsee Back-up light switch

Ride height300-14

Ride height sensorsee Rear suspension

Ring antennasee EWS (electronic immobilization)

Rotorsee Brakes

Roundelsee Exterior trim

Running losses (3/2-way) valvesee Fuel tank

S

SCA (soft close)see Tailgate, soft closesee also Trunk lid, soft close

Scan toolsOBD-3

Sealsgaskets and 010-9see also Crankshaft seals

Seatfront, removing/installing 520-5memory system 520-4rear 520-7see also Seat belt

Seat beltfront 720-4rear 720-8troubleshooting 720-2see also Maintenance

Secondary air injectionsee 130 under appropriate fuel injection system

Selector shaft sealsee Manual transmission, oil seals

Self-adjusting clutch (SAC)see Clutch, variations

Service indicatorsee Maintenance

Shift interlocksee Gearshift

Shift leversee Gearshift

Shift linkagesee Gearshift

Shiftlocksee Gearshift

Shock absorbersee Rear suspension

Side turn signal assemblysee Lights

Sill trim panel411-10

Slave cylindersee Clutch, hydraulic

Sleep mode600-11

Soft close (SCA)see Tailgatesee also Trunk lid

Solenoid121-23

Sound system650-2

Spare parts kit010-21

Spark plugssee Maintenance 1014

INDEX 9

WARNING


Speakers650-4

Specifications, fluid020-9

Sport wagon400-4

Springssee Front suspensionsee also Rear suspension

SRS (supplemental restraint system)see Airbag system (SRS)

Stabilizer barsee Front suspensionsee also Rear suspension

Startersee Battery, starter, alternator

Steering description 300-10fluid

see Maintenancegearbox 320-25idler arm 320-30lock 320-12pitman arm 320-28power steering pump 320-17rack & pinion 320-19steering column 320-10

motors 320-16removing/installing 320-14trim 320-10

steering wheel 320-7tie rods

6-cylinder, replacing 320-22V-8 center tie rod, replacing 320-32

variations 310-5

Steering boxsee Steering, gearbox

Steering column switchessee Switches

Steering columnsee Steering

Steering locksee Steering

Steering wheel switchessee Switches

Stepper motorsee A/C

Steptronic transmissionsee Gearshift

Strutsee Front suspensionsee also Rear suspension

Subframesee Rear suspension

Sunroofinitializing 540-2adjusting 540-5components, removing/installing 540-9

emergency closing 540-4

Suspension, frontsee Front suspensionsee also Aluminum suspension components

Suspension, rearsee Rear suspensionsee also Aluminum suspension components

Swing armsee Rear suspension, suspension arms

SwitchesASC/DSC 612-12back-up

manual transmission 230-8automatic transmission, see Automatic transmission, range switch

center console switches 612-11central locking 612-11hazard 612-11headlight 612-9ignition cylinder 320-11, 612-6outside mirror 612-11pedal cluster switches 612-8seat heater 612-12steering column positioning 612-7steering column switches 612-6steering wheel switches 612-2turn signal/headlight dimmer 612-6window 612-11wipers 612-6

T

Tailgate412-6emergency release 400-4, 412-6, 515-21

tailgate/rear window locking 515-14see also Trunk/tailgate locksee also Central locking

Taillightssee Lights

Tape player650-3

TCM (transmission control module)see Automatic transmission

Tension strutsee Front suspension

Thermostatsee Cooling systemsee also Electrically heated thermostat

Throttle bodysee 130 under appropriate fuel injection system

Throttle cable130-38

Throttle position sensorsee 130 under appropriate fuel injection system

Throw-out bearingsee Clutch, mechanical

Thrust armsee Front suspension

Tie rodsee Steering

Tightening fasteners010-8

Tilt sensor515-24

Timing chainsee Camshaft timing chain

Tire, changing010-18

Tires300-11see also Maintenance

Toe320-34

Tools010-13

1015

10 INDEX

Towing010-20

Traction controlsee Brakes, ABS, ASC or DSC system

Traction strutsee Rear suspension, suspension arms

Transmission fluid 200-4see Maintenancesee also Automatic transmissionsee also Manual transmission

Transmission fluid heat exchangersee Cooling system

Transmission input shaft oil sealsee Manual transmission

Transmission lubricant200-4see also Automatic transmissionsee also Manual transmission

Transmission output shaft oil sealsee Manual transmission

Transmission pilot bearingreplacing 210-16

Transmission servicesee Manual transmission, oil seals

Trim, interiorsee Interior trimsee also Steering, steering column trim

Trunk lid412-2soft close (SCA) 515-13see also Trunk/tailgate locksee also Central locking

Trunk/tailgate locktailgate lock emergency release 400-5, 515-21

tailgate/rear window locking 515-14trunk lock 515-19

key positions 515-7

Turn signal assemblysee Switchessee also Lights

U

UISsee Interior protection

U-jointsee Driveshaft

Upholsterysee Maintenance, leather upholstery and trim

V

Vacuum boostersee Brakes

Valve guidessee Cylinder head and valvetrain

Valve sealssee Cylinder head and valvetrain

Valve seatssee Cylinder head and valvetrain

Valvessee Cylinder head and valvetrain

Valvetrainsee Cylinder head and valvetrain

VANOScontrol unit, removing/installing

M52 engine 117-14M52 TU / M54 engine 117-36

double VANOSfunction 117-34timing chain service 113-46, 116-28

timing, adjustingM52 engine 117-22M52 TU / M54 engine 117-43

Vehicle identification number (VIN)010-12

Ventilation microfiltersee A/Csee also Maintenance

Viscous clutchsee Cooling system, cooling fan

Voltage and polarity600-5

Voltage testssee Electrical system, troubleshooting

W

Warnings 001-1

Warnings, cautions and notes010-3

Washer fluid pumpsee Wipers and washers

Washerssee Wipers and washers

Washingsee Maintenance

Water pumpsee Cooling system, coolant pump

Waxingsee Maintenance

Wheel, steeringsee Steering

Wheel alignment320-33ride height 300-14see also Maintenance

Wheel bearingsee Front suspensionsee also Rear suspension

Wheels300-11

Window motorsee Door window

Window regulatorsee Door window

Window switch512-3see Switches

Windows, doorsee Door window

Windshield wipers and washerssee Wipers and washerssee also Maintenance

Wiper motorsee Wipers and washers

Wipers and washersrain sensor 611-6rear window (Sport Wagon)

wiper motor, removing/installing 611-15

wiper shaft, removing.installing 611-15

wiper/washer system 611-8washer system 611-16wiper assembly 611-12wiper blades and arms 611-9

Wiring codes and abbreviations600-12

Wiring diagramsELE-1see also Electrical system

Working under car safely010-6

X

Xenon headlght630-6

Z

ZKE (central body electronics)600-8

1016

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BMW 5 Series (E39)Service Manual: 1997–2003525i, 528i, 530i, 540i, Sedan, Sport Wagon Price: $169.95Bentley Stock Number: B503Publication Date: 2011.feb.18ISBN: 978-0-8376-1672-82 volume hardcover set, 8 3/8 in. x 11 in.Case quantity: 12072 pages, 2667 photos, illustrations and diagrams Includes color 14 page BMW 5 Series Product Familiarization section

The BMW 5 Series (E39) Service Manual: 1997-2003 contains in-depth maintenance, service and repair information for the BMW 5 Series from 1997 through 2003. The aim throughout has been simplicity and clarity, with practical explanations, step-by-step procedures and accurate specifications. Whether you’re a professional or a do-it-yourself BMW owner, this manual helps you understand, care for and repair your BMW.

Technical features:

• Procedures from the basic oil change service to interpreting the Malfunction Indicator Light (MIL). This manual tells you what to do and how and when to do it.

• Engine and cylinder head service, including camshaft timing chain setup and adjustment.

• Information for specific driveability problems, including explanation of engine management systems and BMW OBD II Diagnostic Trouble Codes (DTCs).

• Theory of operation and repair information for the Siemens and Bosch engine management systems.

• Drivetrain maintenance, troubleshooting, adjustment and repair of self-adjusting clutch (SAC), gearshift linkage, driveshaft, and drive axles.

• Manual and automatic transmission removal, installation, seal replacement and external service.

• System description and repair information for Antilock Brakes (ABS), Automatic Stability Control (ASC) and Dynamic Stability Control (DSC).

• Heating and air conditioning repair (IHKA and IHKR), including component replacement.

• Body adjustments and repairs, including sunroof and tailgate.

• Wiring schematics and extensive electrical component section specifying relay, control module and ground locations with detailed illustrations and photos.

Engines covered6-cylinder engines: M52, M52 TU, M54V-8 engines: M62, M62 TU

Manual transmissions coveredGetrag S5D 250G, S6S 420GZF S5D 320Z

Automatic transmissions coveredA4S 270R, A4S 310RA5S 360R, A5S 390RA5S 325ZA5S 560Z, A5S 440Z

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Detailed instructions on replacing front struts310 Front Suspension

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Engine and cylinder head service, including Double VANOS timing chain setup and adjustment.117 Camshaft Timing Chain

Access Diagnostic Trouble Codes (DTCs) to diagnose engine management problems. 130 Fuel Injection

Two Volume SetVol. 1 - MechanicalVol. 2 - Electrical

BMW 5 Series (E39) Service Manual: 1997-2003 - Complete Index

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Transcript of BMW 5 Series (E39) Service Manual: 1997-2003 - Complete Index