BMW E39 520i 523i 525i 528i 530i 535i 540i M5 520d 525d 525td 525tds 530d Workshop Repair Service Manual 1997-2003 PDF - MBMW5E39NPES.zip
A full factory-level service and repair guide covering the BMW 520i, 523i, 525i, 528i, 530i, 535i, 540i, M5, 520d, 525d, 525td, 525tds, and 530d, packed with the workshop knowledge needed to service, troubleshoot, fix, and rebuild these cars just like a trained technician.
This BMW (E39-generation) 520i, 523i, 525i, 528i, 530i, 535i, 540i, M5, 520d, 525d, 525td, 525tds, 530d workshop service repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
BMW (E39) 520i, 523i, 525i, 528i, 530i, 535i, 540i, M5, 520d, 525d, 525td, 525tds, 530d Repair Manual 1995-2004.pdf
BMW (E39-series) 525i, 528i, 530i, 540i Sedan, Sport Wagon Repair Manual 1997-2002.pdf
Total Pages: 5,404 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
00 - MAINTENANCE & GENERAL NOTES....3
0 operating fluid overview....8
00... BMW service-inspection (diesel vehicles)....22
00... Description of inspection work....25
0000... Battery check display (magic eye); if necessary, recharge battery....26
0000... Body and underbody checking for corrosion and damage - except cavities....27
0000... Brake and clutch hydraulic system checking fluid level, topping up if necessary....28
0000... Brake lines and connections visual inspection for leaks, damage and correct position....29
0000... Changing automatic transmission fluid....30
0000... Changing brake fluid....31
0000... Changing coolant....32
0000... Changing differential oil....33
0000... Changing engine oil and oil filter....34
0000... Check coolant level, if topping up checking concentration....35
0000... Check fuel cooler for external contamination, clean if necessary....36
0000... Checking clutch drive plate for wear....37
0000... Checking handbrake lever travel, adjusting according to setting specifications if necessary....38
0000... Checking horn, headlight flashers and hazard warning system....39
0000... Checking instrument and indication field lighting, heater blower....40
0000... Checking lighting system....41
0000... Checking roadworthiness....42
0000... Coolant hoses Perform visual inspection for tightness, check coolant level and concentration, top up if necessary....43
0000... Diagnostic brief test....44
0000... Exhaust system checking condition, mounting and inspecting for leaks....45
0000... Fault memory interrogation....47
0000... Front and rear brake linings checking lining thickness with measuring gauge. If linings are replaced cleaning brake shafts, checking brake disk thickness and surface, applying grease to wheel centering on alloy wheels...48
0000... Fuel cooler checking for external contamination, cleaning if necessary....50
0000... Fuel lines, fuel tank and fuel hoses visual inspection for routing, condition and leaks....51
0000... Heating _ air conditioning replacing microfilter _ carbon canister (shorten replacement interval accordingly in event of larger buildup of dust)....52
0000... Intake silencer Renew air filter element (shorten change interval if heavily clogged with dust)....53
0000... Locking systems checking status and function, oiling or greasing if necessary....54
0000... Oil change in manual transmission....55
0000... Oil change in rear differential....56
0000... Output shafts checking gaiters for leaks....57
0000... Parking brake checking function, adjusting _ repairing as prescribed....58
0000... Parking brake checking lining thickness....59
0000... Power steering _ ride-height control visual inspection for leaks, checking fluid level, topping up fluid if necessary....60
0000... Renew main fuel filter (if necessary, shorten filter-change intervals in case of poor diesel quality)....61
0000... Replacing main fuel filter (shortening change interval if necessary in event of poor diesel fuel quality)....62
0000... Resetting service interval indicator according to factory specifications....63
0000... Seat belts checking condition of belt strap, function of inertia reel mechanism, locking reel, belt buckle....65
0000... Steering components checking for zero clearance, leaks, damage and wear....67
0000... Steering fluid reservoir checking fluid level, topping up if necessary....69
0000... Tyres checking inflation pressure, correcting if necessary (incl. spare wheel), checking external condition, tread depth, pattern. In event of nonuniform wear, carry out measurement and correction of wheel alignment....70
0000... Underbody incl. all visible components checking for damage, leaks, corrosion....72
0000... Vehicle care measures for inventory vehicles (new and used vehicles) as well as vehicles to be taken off the road that are in the hands of customers....73
0000... When driving on a race track....77
0000... Windscreen wash _ wipe system checking washer fluid reservoir and spray nozzle adjustment....83
0000... Windscreen washer system and intensive cleaning system checking fluid level, topping up if necessary....84
0000... Work instruction for removing the protective film....85
0001... Symbols used and information in repair instructions....87
0002001 Raising the vehicle using a vehicle lift....92
5.1.1 Axles....94
7.1.1 Installation safety of the seat belts _ seat belt buckles....97
7.1.2 Status of the seat belts _ seat belt buckles....101
7.1.3 Belt force limiter....104
7.1.4 Seat belt tensioner....105
7.1.5 Airbag....106
7.1.6 Supplementary restraint systems (SRS)....109
7.11 Odometer (if present)....110
7.12 Driving dynamics control (Electronic Stability Program, ESP) (if installed _ required)....111
Abbreviations....112
Addition to special tools cabinet All model series....116
Arguments pertaining to engine oil consumption....118
Brake fluid - Operating Fluids Specification....121
Brake fluid service - extension of the first brake fluid interval to 36 months....122
Brake fluid service ? Bonnet gas strut check with active pedestrian impact mitigation?(SA8TF)....124
CBS general - Reset is lost....126
Changed emissions test indicator BMW Condition Based Service....127
Emergency Services (BMW _ MINI) from issue September 2009....128
Engine oil - varying colours _ smell after initial filling in the works....129
Engine oil service - countries with higher levels of dust Check the air filter element for contamination....130
Extract from BMW Group Standard?GS?90003-2....131
FEB-FEB-NED-TESTMODULE-AKTUELL....133
General and legal information on performing the periodic exhaust-gas (emissions) test in EU countries....134
Handling the acoustic camera....140
IMIB_Next....142
Ignition key data tapping on CBS vehicles....145
Introduction of new service interval for ECE countries (RDE diesel fuel)....151
List of contents....154
M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2....156
M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2....157
M14 and M14x1.5 - maximum tightening torques acc. to BMW GS 90003-2....158
M16 and M16x1.5 - maximum tightening torques acc. to BMW GS 90003-2....159
M18 and M18x1.5 - maximum tightening torques acc. to BMW GS 90003-2....160
M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2....161
M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2....162
M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2....163
Main group 00....164
Master document for vehicle-specific Service Information bulletins All model series up to Model Year 2004....165
Master document for workshop literature _ workshop equipment....168
New Maintenance Records service booklet and maintenance documentation All models....170
Revised scope of maintenance work, MY 2002....172
Revised scope of maintenance work....175
Service Sheets - Condition-based Service _ Pre-delivery Check (ISTA, ISPA, Commercial Service Data)....176
Service intervals for countries with low fuel grade (SA988 _ SA8KE, SA8KM, SA984, SA8KK, SA8KL, SA8KH, SA8KP)....178
Standard work scope - expansion of work scope (with slide _ tilt sunroof and panorama glass roof)....184
Supplement for target exhaust emissions inspection data of BMW and MINI vehicles from 04 _ 2009. Modified test specifications for petrol lean-mixture engines N43 and N53. Test procedure for hybrid vehicles....186
Supplement of nominal values for emissions test on new BMW models since 09 _ 2001....190
Test instructions for the exhaust gas test (AU) on BMW vehicles with diesel engines from European emission classification EURO 6....193
Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines from European emission classification EURO 6....206
Test instructions for the exhaust-gas (emissions) test on BMW vehicles with diesel engines....219
Workshop Equipment - Planning Documentation....227
Workshop equipment sales....228
11 - ENGINE ....229
0000250 BMW engine oil service incl. supplementary service (M57 _ M47TU)....234
11 operating fluid overview....237
11. . . . . Equipment recoding special tool number of the transverse member for fixing the engine in the installation location....239
1100 Overview of tightening torques....241
1100... Engine oil consumption measurement....245
1100... Overview of consumables (Electronic Parts Catalogue)....246
1100039 Checking compression in all cylinders (M47 _ M57 _ M47TU)....252
1100050 Removing and installing engine (M57)....254
1100300 Engine oil consumption measurement....266
1112 Overview of Technical Data....270
1112 Overview of tightening torques....273
1112036 Replacing oil separator....287
1112100 Removing and installing cylinder head (M57)....289
1112101 Replacing cylinder head gasket (M57 _ M47TU)....315
1112500 Removing and installing cylinder head (M57)....316
1112501 Replacing cylinder head gasket (M57)....318
1112504 Dismantling and assembling cylinder head (M57)....319
1112595 Checking a valve guide for wear (M57)....323
1112729 Checking cylinder head for water leaks (M57)....324
1112800 Cleaning cylinder heat intake channels and intake plenum (M47, M57)....326
1113000 Removing and installing, sealing or replacing oil sump (M57)....336
1113500 Removing and installing, sealing _ replacing oil sump (M57)....346
1114110 Removing and installing, sealing _ replacing timing case cover (M57)....349
1114141 Replacing radial seal in lower timing case cover (M57)....354
1114151 Replacing crankshaft radial seal (M47 _ M57)....357
1121500 Replacing crankshaft (M57)....361
1121531 Replacing all main crankshaft bearing shells (M57)....366
1121571 Replacing deep-groove ball bearing in crankshaft (M47 _ M47TU _ M57)....373
1122500 Removing and installing or replacing flywheel (M57)....375
1123010 Removing and installing or replacing vibration damper (M57)....378
1124571 Replacing all conrod bearings (M57)....380
1125530 Removing and installing _ replacing all pistons (M57)....384
1125671 Replacing piston rings on all pistons (M57)....392
1128010 Removing and installing _ replacing alternator drive belt (M57 _ M47TU)....394
1128020 Removing and installing alternator drive belt (M57 _ M47TU)....397
1128050 Replacing A _ C compressor drive belt (M57 _ M47TU)....400
1128060 Removing and installing A _ C compressor belt tensioner (M57 _ M47TU)....401
1130 Overview of tightening torques....403
1131 Overview of tightening torques....404
1131001 Replacing camshafts (M57)....416
1131005 Checking camshaft timing (M57)....433
1131052 Replacing both timing chains (M57)....435
1131091 Removing and installing _ replacing hydraulic chain tensioner (M57)....436
1131505 Adjusting camshaft timing (M57)....437
1134560 Replacing all valve stem seals (M57)....443
1134715 Replacing all valve springs (M57)....445
1140000 Checking engine oil pressure (M57)....447
1141000 Installing and removing or replacing oil pump (M57)....451
1142020 Removing and installing _ sealing or replacing complete oil-filter housing (M57)....453
1144000 Removing and installing, sealing or replacing oil-water heat exchanger (M57)....457
1151000 Removing and installing or replacing water pump (M57)....460
1152020 Removing and installing _ replacing fan clutch (M47 _ M47TU _ M57 _ M57TU)....462
1153000 Removing and installing or replacing coolant thermostat (M57)....464
1161050 Removing and installing intake air manifold (M57)....468
1162000 Removing and installing, sealing or replacing exhaust manifold (M57)....476
1165... Test steps in the event of turbocharger damage....481
1165020 Damage on the exhaust turbocharger due to obstructed oil supply lines....482
1165020 Removing and installing or replacing exhaust turbocharger (M57)....488
1166000 Removing and installing or replacing vacuum pump (M57)....497
1171100 Removing and installing _ replacing exhaust gas recirculation cooler (M57 _ M47TU)....500
1174... Layout of vacuum hoses (M57)....503
1174... Layout of vacuum hoses for exhaust turbocharger (M57)....504
1174505 Replacing pressure converter for EGR valve (M57)....505
1174508 Replacing pressure converter for exhaust turbocharger (M57)....507
6.1.9 Engine performance....509
9.0 BMW Longlife-17 FE+....510
Adjust the installation position of the exhaust-gas recirculation valve....512
BMW Quality Longlife-04 All....513
Camshaft, M57....514
Camshaft....515
Case Covers....517
Cleaning the cylinder head intake ports and the combustion chamber with the walnut blaster....518
Connecting Rods and Bearings, M57, D25....519
Connecting Rods and Bearings, M57, D30....520
Connecting Rods and Bearings....521
Crankshaft and Bearings, M57....522
Crankshaft and Bearings....524
Cylinder Head with Cover....526
Cylinder Head with Valve Seat Cover, M57....527
Cylinder head....528
Emissions-control, Lambda oxygen sensor....529
Engine block, BMW, M57, D30....530
Engine block....531
Engine identification....536
Engine in general, E39, M57, D25....546
Engine in general, E39, M57, D30....547
Exhaust gas recirculation (EGR)....548
Exhaust manifold....549
Fan....550
Flywheel, M57....551
Flywheel....552
Intake manifold....553
Leak-testing the air-intake system....554
Main group 11....557
Oil Filter and Lines....558
Oil Filter and Pipes....559
Oil Pan....561
Oil Pump with Strainer and Drive, M57....562
Oil Supply, E38, E39, M57....563
Oil pump with strainer and motor....564
Pistons with Rings and Pins, BMW, M57, D25....565
Pistons with Rings and Pins, M57, D25....566
Pistons with Rings and Pins, M57, D30....567
Retrofit edge guard on acoustic cover, front E38 _ E39 with M57....568
Thermostat and Connections, M57....570
Turbocharger and Control....571
Vacuum pump....572
Vacuum supply All models....573
Valves with Springs, M57....577
Vibration Damper....578
Water Pump and Drive....579
12 - ENGINE ELECTRICAL SYSTEM....580
1200... Instructions for removal and replacement of control units....582
1214... Relay assignment, engine wiring harness in electronics box (M47 _ M57)....584
1214700 Encoding the control unit (DME _ DDE)....587
1214705 Programming the control unit (DME _ DDE)....588
1221500 Removing and installing _ replacing glow plug relay (M47 and M57)....589
1223 Overview of tightening torques....593
1223505 Replacing all glow plugs (M57 _ M57TU _ M47TU _ M47T2 _ M57T2)....594
1231009 Checking alternator and regulator switch....597
1231020 Removing and installing _ replacing the alternator (M57)....602
1231230 Removing and installing _ replacing alternator mounting block (M57 _ M47TU)....605
1232501 Replacing controller switch for alternator (M57)....607
1241020 Removing and installing _ replacing starter (M57)....611
1241041 Replacing the engagement solenoid switch....614
1242500 Replacing battery positive lead (between battery positive connection point, starter and alternator)....616
1242540 Replacing safety battery terminal (SBK)....621
1242550 Replacing battery positive lead (between battery positive connection point and starter)....628
1251001 Replacing wiring harness section for engine (M57)....632
1251200 Replacing wiring harness section for injectors (M57)....640
1261280 Removing and installing _ replacing oil pressure switch (M57)....646
1261285 Removing and installing _ replacing oil level sensor....648
Alternator with Drive and Mounting Parts, E39....649
Alternator with Drive and Mounting Parts....650
Control Unit Housing....652
Electronic Shift Units or Control Units....653
Engine wiring harness....654
Glow Plugs, M57....655
Glow elements....656
Heating Time Control Unit, M57....657
Ignition Coil E39....658
Installation instructions for the adapter line kit, E39 M57....659
M57TU2 and M67TU diesel engines E65, E66....662
Oil pressure, oil temperature, oil level display, E39....676
Oil pressure, oil temperature, oil level display....677
Preheating Relay....678
Regulator, E39....679
Starter and Mounting Parts, E39....680
Starter and Mounting Parts....681
Vehicle electrical system influences on alternator regulator E38 E39 with M62LEV, M73LEV....682
Vibrations _ misfiring without DDE fault entry E46 _ M57 E38 _ M57 E39 M57....686
Wires to starter....689
13 - FUEL PREPARATION & CONTROL....690
13 operating fluid overview....692
1331025 Checking fuel return pressure (M57)....693
1331028 Checking fuel delivery pressure (M57, M67)....695
1332040 Removing and installing _ replacing fuel cooler (M57)....697
1332051 Replacing fuel filter (M57)....699
1332061 Replacing fuel filter unit (M57)....701
1332070 Replacing preheating valve (M57)....703
1351004 Removing and installing _ replacing high pressure pump (M57)....704
1351542 Checking high-pressure pump and pressure regulator (M57)....710
1351544 Checking injectors (M57)....713
1353... Arrangement of Common Rail System (M57)....716
1353... Cleaning injector sockets (M67 _ M57 _ M57TU _ M57T2 _ M47TU _ M47T2)....717
1353155 Removing and installing _ replacing pressure accumulator of injection system (M57)....720
1353170 Replacing all pressure lines (M57 _ M57TU)....722
1353180 Replacing pressure line (between high-pressure pump and pressure accumulator) (M57 _ M47TU _ M57TU _ M47T2)....724
1353315 Removing and installing _ replacing all injectors in injection system (M57 _ M57TU)....726
1353330 Replacing all leakage oil lines (M57)....730
1353560 Removing and installing _ replacing pressure sensor on pressure accumulator of injection system (M57)....734
1353570 Replacing pressure regulator on high-pressure pump (M57)....738
1361501 Replacing control unit (DDE) for M47 and M57....740
1362520 Removing and installing _ replacing pedal travel sensor (M47, M57 and M67)....742
1362531 Replacing coolant dual temperature switch (M57)....746
1362535 Replacing charge-air pressure sensor (M57 _ M47TU)....749
1362560 Removing and installing _ replacing air-mass flow sensor (M57)....751
1362610 Replacing crankshaft pulse generator (speed sensor) (M57)....753
1362650 Replacing camshaft pulse generator (M57)....755