BMW 540 1997 2002, 530 1997 2002, 528 1997 2002, 525 1997 2002, 528 User Manual

0 (0)

Service Manua

5251, 5281, 530i, 540i

Sedan, Sport Wagon

1997,1998,1999,2000,2001,2002

Benllcy Publishers, a divisionol Robcrt Bcnlley,In=.

1734 M~SB~CIIUP~IISAvenue

Cumbitdge. MA02138 USA	Informationlhat makes
800-423-4885/ 617.547.4170	the diiierence"
BentleyPublishe~

WARNING-important safety notice

Technical contact inlormation		I
Technical contact inlormation
We :.€	c3me ,o.lr leeooaca. Pieasc. ;Jam 1 cllriecl 00s an0
zoo ions lo our BhFLt/ recnns? o rcdss'unlo r ~ ma1
	http://~~~.BentleyPublishere.com
Errata information
We will	evaluate submissions and post appropriate editorial
changes online as text errata or tech discussion. Appropriate
errata will be incorporated with the boolc text in future printings.
Read errata information for this book before beginning work on

your vehicle. See the following web address tor additional information:

http://unw.BentleyPublishers.com/errata/

Do not use this manualunlessvou are familiar with basic automotive reoair oroceduresand safe workshoo oracfices.This manualillustrates the workshopproceduresrequked formoslservice work. It is not a subsiituti for full andup-to-dateinformationfromthevehiclemanufaciurer or for proper training as an automotive technician. Note that it is not possible for us to anticipate all of the ways or conditions under which vehicles may be servicedor to provide cautions as to all of the possible hazards that may result.

The vehicle manufacturerwill continueto issue service information updatesand parls retrofitsafterthe editorial closing of this manual.Some of lhese updates and retrofits will apply lo procedures and specifications in this manual. We regret that we cannot supply updates to purchasers of this manual.

We have endeavored to ensure the accuracy of the information in this manual. Pleasenote, however, that consideringthe vast quantity and the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information contained in this manual.

	FORTHESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAICES ANY WARRANTIES, EXPRESSOR IMPLIED, THATTHE INFORMATION IN
	THIS BOOK IS FREE OF ERRORS OR OMISSIONS. AND WE EXPRESSLY DISCLAIMTHE IMPLIEDWARRANTIES OF MERCHANTABILTTY AN0 OF FITNESS
1	FOR A PARTICULAR PURPOSE, EVEN IFTHEPUBLISHER OR AUTHOR HAVE BEEN ADVISED OFA PARTICULAR PURPOSE, AND EVEN IFA PARTICULAR				1
	PURPOSE IS INDICATED IN THE MANUAL. THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LlABlLrrY FOR DIRECT. INDIRECT. INCIDENTALOR
I	CONSEQUENTIALDAMAGES THAT RESULT FROM ANY USE OFTHE EXAMPLES,INSTRUCTIONS OR OTHER INFORMATION INTHISBOOK. INNO EVENT				1
I	Your.	common sense and oood iudomentare crucial to safe and successful service work. Read orocedures throuoh before startino them.			I
		- -	- -~	- - - ~ .-

Think about whether the condition of your car, &r level o f mechanical skill, or your level of reading compreh&sion might resill in or contribute in some way to an occurrence which might cause you injuly, damage your car, or result in an unsafe repair. If you have doubts for these or other reasons about your ability to pelform safe repair work on your car, have the work done at an authorized BMW dealer or other qualified shop.

Part numbers listed in this manual are for identificationpurposes only, not for ordering. Always check wilh your authorized BMW dealer to verify part numbers and availability beforebeginningservice work lhat may require new park.

Before anempting any work on your BMW, read the 001 General Warnings and Cautions, and any WARNING or CAUTION that accompanies a procedure in the service manual. Review the WARNINGS and CAUTIONS each time you prepare to work on your BMW.

Spec a too s req.1 red to perlorm cena n service operations arc oenl fed n the manLa an0 arc recomrnenoeolor JSC Jse ol loo s olner than those recommended In lh s serv ce manual may be oelnmcnlallo lrlc car'ssale open1on as rvec as lne salely 01 lne personservcng

the car.	I

Copies of this manual may be purchased from most automotive accessories and parts dealers specializing in BMW automobiles, from selected booksellers, or directly from the publisher.

This manual was published by Robert Bentley, Inc., Publishers. BMW has not reviewed and does not vouch for the accuracy of the technical specifications and procedures described in this manuai.

Libratv of Conaress Cataloaino-in-Publication Data

" "

BMW 5 Series (E39) :service manual :523. 528i, 530i. 540i, sedan, sport wagon, 1997, 1998, 1999,2000,2001,2002

~Acludesindex.
ISBN 0-8376-0317-X (obi<)
	,,	,
1. BMW 5 series automobiles--Maintenanceand repair--Handbooks manuals, etc. 1.
Robert Bentley, Inc.
	TL215.8258623 2003
	629.28'722--dc23	2003052231

Bentley Stock No. 8502
Editorial closing 08/03
0 9 0 8 0 7	1 0 9 8 7 6 5 4

The paper used in this publication is acid free and meets the requirements of the National Standard for Information SciencesPermanence of Paper for Printed Library Materials.@

All rights reserved. All information contained in this manual is based on the information available to the publisher at the time of editorial closing. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or ofhenvise, without the prior written consent of the publisher.This includes text, figures, and tables. All rights reserved under Berne and Pan-AmericanCopyright conventions.

Cover photos of car exteriors by Jonathan Richard for Bentley Publishers @ Robert Bentley, Inc. Cover design and use of blue band on spine and back cover are trademarks of Bentley Publishers. All rights reserved.

Manufactured in the United States of America

Y O U are now in	V o l u m e				I
	Foreword ................... ....................................................................................					v
	Index........................ ..................................................................				rear of manual
General,	001 General Warnings and Cautions
General,	002	Vehicle Identification and VIN Decoder
Maintenance	O i O	Maintenance
	020	Maintenance
	100	Engine-General		I20	Ignition System
Engine	110	Engine Removal and Installation		121	Battery, Starter, Alternator
	113	Cylinder Head Removal and		130	Fuel Injection
		Installation		160	Fuel Tank and Fuel Pump
	116	Cyiinder Head and Valvetrain		170	Radiatorand Cooling System
	117	Camshaft Timing Chain		180	Exhaust System
	119	Lubrication System
Transmission	200	Transmission-General		240	Automatic Transmission
Transmission	210	clutch		250	Gearshift Linkage
	230	ManualTransmission		260	Driveshaft
Suspension,	300	Suspension, Steering and		330	Rear Suspension
Steering and		Brakes-General		331	Final Drive
Steering and	N o	Front Suspension		340	Brakes
	320 Steering and Wheel Alignment
	400	Body-General		411	Doors
	410	Fenders, Engine Hood		412	Trunk Lid,Tailgate
				.	.	..
	510	Exterior Trim, Bumpers		515	Central Lociting and
Equipment	512	Door Windows			Anti-Theft
	513	Interior Trim		520	Seats
				540	Sunroof
Equipmentand 720		seat Belts
Accessories	721	Airbag System (SRS)
Accessories
OBD	On-Board Diagnostics
	Foreword ..............................		...................................................................... v
	Index................... ..................................................................				rear of manual
Electrical	610	Electrical Comoonent Locations		630	Liohts
	600	Electrical System-General		620	Instruments
system	611	wipers and washers			eati in^ and Air Conditioning
	612	Switches			Radio
	. .	.			.

Electrical Wiring Diagrams

Selected Boolcs and Repair Information from Bentley Publishers

AlexZanardi - M y Swectest Victory rllex Zmmrdi itjill! Ginrz11,cnGns~x~ri,,i ISBN (1-8376-1249-7

T l ~ Unfairc Advantage

hlirrk Do,~ult,reISBN 0-8376-0073-Iilrcj; 0-8376-0069-3(~1bJ

Going Faster! Mastering the Art of Race

Driving

Tlw Skip Bizl.bul-Riicing Sclaiol

ISBN 0-8376-0227-0

A French I<iss With Dcalh: Steve McQuecn and the Making of LCM,!r~s

hliclael i(ei/scr ISBN 0-8376-0234-3

Soorts Car a n d Comoctition Drivins P;url ~ri'rpv i l hforc&rd I)!/ Phil Hill " ISBN 0-8376-0202-5

Boscll Fuel Injection and Enginc

Management

Clml-Its0.Pmbsi, S A E ISBN 0-8376-0300-5

Racc Car Aerodynamics losupli Kntz ISBN 0-8376-014>8

Road &Track Illustrated Automotive

Dictionary

Joltri Dilrkl ISBN 0-8376-11143-6

Scientific Design of Exl~austand Intake

Systems

I'lrililr H.S,sillr 0-8376-0309-9

Alfa Romco All-Alloy Twin Cam Companion 195G1994

1'nl Bncdulr ISBN 0-8376.0275-0

Alfa Romco Owner's B i b l ~ ' ~ ' 1'1~1Bmrlul! ISBN 0-8376-0707-8

Arldi

Audi A4 Repair Manual: 1996-2001.1.8L

lurbo, 2.8L. including Avant and quatlro

Buirile!/ Ptrhlislters ISBN 0-8376-0371-.I

Audi A6 Sedan 1998-2004, Avant 19992004, allroad quallro 2001-2005,

5 6 Avant 2002-2004, RS6 2003-2004 Official Factory Rcpair Manual on CD-ROM Ai!dioJ/in,er.ini ISBN 978-0-8376-1257-7

B M W

BMW 2 3 Sarvicc Manual: 1996-2002. including 2 3 Roadster, 2 3 Coupe, M Roadster, M Coupe Be~illqPi,blislicis ISBN 0-8376-1250-0

BMW 3 Scrics (Ed61Scrvicc Manual:

Urlilii-!~P ~ ~ B l i s iISBN~~rs11-8376-11772

BMW 3 Series IE36) Scrvire Manual: 1992-1998,318ilisliC. 323is/iC, 3?5i/is/iC, 328ilisliC, M3

Be~iili.!~Pirl?lisliersISBN 0-8376-0326-9

BMW 5 Series Scrvicc Manual: 1997-2002 525i, 528i. 530i. 540i, Sedan, Sport Wagon Bcrrlluy P~rlilishensISBN 0-8376-0317-X

BMW 6 Scries Enthusiasl's CompanionTh1

Jc~.li'iil!/liV0l10li ISBN 0-8376-0193-2

BMW 7 Series Servicc Manual:1988-1994, 735i,735iL, 74%. 740iL. 750iL

Beritlc!/ I'irblislrens ISBN 0-8376-0328-5

Bosclz

Boscl~Aulomativc Handbook 6th Edition Robul.1 Boscli, C I I I ~ISBNH 0-8376-1243-8

Bosch 1-landbookfor Automotive Elcctrics

and Elcchonics

Rillrcr I Bwcli, GrjilrH ISBN 0-8376-1050-8

Bosch Handbook for Diesel-Engine Managcmcnt

Ril1iei.t Bosdl, ClrrbH ISBN 0-8376-1051-6

Bosch Handbook for Gasolinc-Engine Management

Robcrf Bosclr, G~ribHISBN 0-8376-1052-4

Clzevrolet

Corvctlc Illustralcd Encyclopedia

Torn Beifurli ISBN 0-8376-0928-3

Corvette Fuel Injection &Electronic

Enginc Managcment 1982-2001:

Clmrlcs 0.I1rol,sl, SAE ISBN 0-8376-0861-9

Zora Arkus-Duntov:Thc Lcgcnd Behind corvt.ttc

Je1.q Birl-1011ISBN 0-8376-0858-9

Ci~evmlclby the Numbers 1965-1969:

T h e Essential Chcvrolct Paris Refcrcncc illn,i Cnl2i11ISBN 0-8376-0956-9

Ford

Ford Fuel Injection and Electronic Engine

Control: 1988-1993

Clinrlcs 0.Pmirsl, SrlE ISBN 0-8376-03Lll-3

Tbc Official Ford Mustang 5.0 Technical Reference & I'crformancc Handbook: 1979-1993

A1 l<inci~u~ihrirri,iISBN 0-8376-0210-6

Jccp CJ Rubuildcr's Manual: 1972-1986

MOSI~SLltii~lISBN 0-8376-0151-7

Jccp Owner's Biblen', Third Edition

Moscs Lzrdel ISBN 0-8376-1117-2

Mcrcedes-Bcnz Technical C ~ m p a n i o n ' ~ ~ ' Bu,rllu!! P,rlilislio.i ISBN 11-8376-1033-8

Mcrccdcs-Bcnz E-Class (W124)O~vner's BibleT>':1986-1995 llu~tilc!~Pi~lriisiieisISBN 11-8376-0230-(1

MINI Cooper

MINI Cooper Service Manual: 2002-2004 Bc,illc!! P i r l ~ l i s lISBN!~~ 0-8376-1068-0

Porsclze

Porsche: Excellcncc Was Expected

I<iirlLcldui,~sse!tISBN 0-8371,-0235-1

Porsche 911 Carrcm Service Manual: 198G1989

B~.~iile!/Pllblislters ISBN 0-8376-0291-2

Porschc 911 Enthusiast's CompanionT3'

Aiirinri Slr~,tzlli~~rISBN 0-8376-0293-9

Porschc911 SC Coupc,Targo,and Cabriolet

Scrvict. Manual: 1978-1983

Br>illu!yPtibiishers ISBN 0-8376-0290-4

Battle for lhe Bcelle I<iir.lLiid~,igsc>tISBN 0-8376-0071-5

Jells, Golf, GTI Scrvicc Manual: 1999-2005

1.8L lurbo, 1.9LTDI diesel, PD dicscl,

2.0L ga5aline. 2.81 VRG

B~.!iIlcyPt,blislicrs ISBN 0-8376-125-9

New Bcctle ServiceManual:1998-20021.8L turbo, 1.91TDI diesel, 2.0L gasoline Bailicy P~irirlishersISBN 0-8376-0376-5

New Bcctle 1998-2005, New Beetle

Convcrtible2003-2005 Official Factory

Rcpair Manual a n CD-ROM

I~olkiatgurr~JAriicricnISBN 9784-8376-1265-2

I'acrat Ser\,irc hl.>nu.~l:1998-2004.1.81. lurbu, 2.RL Vb, .l.IIL \\'8,inrludinl: tv.~gc>n and 4blOTION

Giiitlc!/ P~iiblislicrsISBN 0-8376-0360-2

Passat. Passat Waron 1998-2005 Official

Gnlf, GTI, Jctta 1993-1999, Cabrio 199% 2002 Official Factory Repair Manual on CD-ROM

Volhsiraigu>toJA,rtrricn ISBN 978-0-8376-1263-8

Jetta, Golf, GTI: 1993-1999, Cabtio: 1995-

2002 Scrvicc Manual

ll~iillcyI'trblisln.~~~ISBN 0-8376-0366-8

EuroVan Official Factory Rcp.,ir Manual: 1992-1999

I/~llhio~sar,ifAii!wicn ISBN 0-8376-0335-8

Automotive Reference

Bcnlluy Publishers has published iewicc manualsand autornohilcboolissinrc 1950. Plcasc write to us at 1734 Mniincliusctts Ave..Cnmbridge, kIA02138,i~isitourivcb sitc, ol-c,lll 1-800-12345'15 ini a free copy ofnurcolaiog.

Foreword

For the BMW owner with basic mechanical skills and for independent auto service professionals. this manual includes many of the specifications and procedures that were available to an

authorized BMW dealer service deoartment as this manual went to Dress. The BMW owner with

no intention of working on his or her car will find that owning and referring to this manual makes it possible to be better informed and to more Itnowledgeably discuss repairs with a professional automotive technician.

If you are a BMW owner intending to do maintenance and repair work, make sure you have screwdrivers, a set of metric wrenches and sockets and metric Allen and Torx wrenches, since these basic hand tools are needed for most of the work described in this manual. Many procedures also require a torque wrench to ensure that fasteners are tightened properly and in accordance with specifications. Additional information on basic tools and other tips are in 010 General. In some cases, the text refers to special tools that are recommended or required to accomplish adjustments or repairs. These tools are usually identified by their BMW special tool number and illustrated.

Disclaimer

We have endeavored to ensure the accuracy of the information in this manual. When the vast array of data presented in the manual is talten into account, however, no claim to infallibility can be made. We therefore cannot be responsible for the result of any errors that may have crept into the text. Please also read the Important Safety Notice on the copyright page at the beginning of this book.

Prior to starting a repair procedure, read the procedure, 001 General Warnings and Cautions and the warnigns and cautions that accompany the procedure. Reading a procedure before beginning work will help you determine in advance the need for specific skills, identify hazards, prepare for appropriate capture and handling of hazardous materials, and the need for particular tools and replacement parts such as gasltets.

Bentley Publishers encourages comments from the readers of this manual with regard to errors, and/or suggestions for improvement of our product. These communications have been and will be carefully considered in the preparation of this and other manuals. If you identify inconsistencies in the manual, you may have found an error. Please contact the publisher and we will endeavor to post applicable corrections on our website. Posted corrections (errata) should be reviewed before beginning worlc. Please see the following web address:

BMW offers extensive warranties, especially on components of the fuel delivery and emission control systems. Therefore, before deciding to repair a BMW that may be covered wholly or in part by any warranties issued by BMW of North America, LLC, consult your authorized BMW dealer. You may find that the dealer can make the repair either free or at minimum cost. Regardlessof its age, or whether it is under warranty, your BMW Is both an easy car to service and an easy car to get serviced. So ifat any time a repair is needed that you feel is too difficult to do yourself, a trained BMW technician is ready to do the job for you.

Bentley Publishers

001 General Warnings and Cautions

PLEASE READ THESE WARNINGS AND CAUTIONS

BEFORE PROCEEDING WITH MAINTENANCE AND REPAIR WORK.

WARNINGS-

See also WARNINGS

-if you lack the slqills, tools and equipment, or a suitable worl(shop for any procedure described in this manual, leave such repairs to an authorized BMW dealer or other qualified shop.

BMW is constantly improving its cars and sometimes these changes, both in parts and specifications,are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always check with your authorized BMW dealer parts department for the latest information.

	Before starting a job, make certain that you have all the neces-
	sary tools and parts on hand. Read ail the instructions thorough-
	ly, and do not attempt shortcuts. Use tools appropriate to the
	work and use only replacement parts meeting BMW specifica-
	tions.
	Use pneumatic and electric tools only to loosen threaded parts
	and fasteners. Never use these tools to tighten fasteners, espe-
	cially on light alloy parts. Always use a torque wrench to tighten
	fasteners to the tightening torque specification listed.
	Be mindful of the environment and ecology. Beforeyou drain the
	crankcase, find out the proper way to dispose of the oil. Do not
	pour oil onto the ground, down a drain, or into a stream, pond or
	lake. Dispose of waste in accordance with Federal, State and
	Local laws.
	The control module for the anti-lock brake system (ABS) cannot
	withstand temperatures from a paint-drying booth or a heat lamp
-	in excess of 203" F (95°C) and should not be subjectedto tem-
	peratures in excess of 185°F (8S°C) for more than two hours.
	Before doing any electrical welding on cars equipped with ABS,
	disconnect the battery negative (-) terminal (ground strap) and

-the ABS control module connector.

Always make sure ignition is off before disconnecting battery.

Label battery cables before disconnecting. On some models, battery cables are not color coded.

Disconnectingthe battery may erase fault code@)stored in control module memory. Using special BMW diagnoslic equipment, check lor iauit codes prior to disconnectingthe battery cables. If the mal- I.mct on ndicator Ignt (MIL) s I. ..minaled. see OBD On-Board Diaanostics Tl11siant is iuenlfted as lne Check Ena~neoht (1997-2000modelsj o r ~ e r v l c EngineSoon light (2061 andlater models). If any other system iaults have been detected (indicated by an illuminated warning light), see an authorized BMW dealer.

If a normal or rapid charger is used to charge battery, the battery must be disconnected and removed from the vehicle in order to

-avoid damaging the vehicle.

Do not quick-charge the battery (for boost starting) for longer than one minute. Wait at least one minute before boosting the battery a second time.

* Connect and disconnect a battery charger only with the battery - charger switched off.

Sealed or "maintenance free" batteries should be slow-charged only, at an amperage rate that is approximately 10% of the battery's ampere-hour(Ah) rating.

.Do not allow battery charging voltage to exceed 16.5 volts. If the battery begins producing gas or boiling violently, reduce the charging rate. Boosting a sulfated battery at a high charging rate can cause an explosion.

002 Vehicie identification and VlN Decoder

Vehicle identification Number (VIN), decoding

Some of the information in this manual applies only to cars of a parlicuiar model year or range of vears. For examole. 1999 refers to the 1999 model vear but does not necessarilv malch the caiendsr year in which the car was manufactured or sold. To be sure of the modelyear of a particular car, checic the Vehicle ldentification Number (VIN) on the car.

The VIN is a unique sequence of 17 characters assigned by BMW lo identify each individual car. When decoded, the VIN tells the country and year of manufacture; make, model and serial number: assembly plant and some equipment specifications.

The BMW VIN is on a plate mounted on top of the dashboard, on the driver's side where the number can be seen through the windshield, The 10th character is the model year code. The letters I.0,Q and U are not used for model year designation. Examples: X for 1999, Y for 2000, 1for 2001,2 for 2002, etc. The table below explains some of the codes in the VIN for 1997 through 2002 BMW E39 5 Series BMWs covered by this manual.

Sample VIN: ~		~	I	z	~	o	~ 1w3 8 ~9 1 B	~	w	~
lposition		1 2 3	z i	5 6	7 8 9 10 11		12-17
VIN
position	Description				Decoding information
WBA1 - 3 Countrv of
IJ	1 znan~+qBT;
							BMW Molorsporl.Gmon, ;			c hGerrn;!n,	i
	Linc						525 (2UU1 - 2003) 528 (2000-2003. 530; 540				i
5	Series				D		5251(2001 - 2002), 528i (1997 - 2000)
					E		MS. 530i, 540i (1997		- 1998)
					J		5251Wagon

M528i (1999- 2000)

N5401Sedan (1999 - 2003) 540i wagon (2001)

-2000)

-20031PR 528i wagon (1999540i waaon 12002

Body type i	1	Aulomatic
Body type i	6,4	Aulomatic
engine lype	5,3	Manual
. ..
Vehicle type	3.4.7	Passenger vehicle
Restraintsystem	1 0	Manual belts
		Manual belts with dual airbags
	3	Manualbeltswith advanced airbaos
	3	Manual belts wilh driver & passengerairbags
	4	Manual belts with advanced passengerB driver airbags
Checlr digit		0 - 9 or X, calculated by NHTSA
Model year	V	1997
	W	1RRR

Assembly plant	A, F, K	Munich, Germany
	B, C, D, G Dingolfing. Germany
	E, J. P	Reqensburq. Germany
		.
Serial number		Sequentialproduclion number lor specificvehicle

010-1

010 General

General . . . . . . . . . . . . . . . . . . . . . . . . . ...010.2

How to Use this Manual . . . . . . . . . . . ..010.2

Warnings. cautions and notes . . . . . . . . . . .. 0l 0.3

Getting Started . . . . . . . . . . . . . . . . . . . .. 0 i0.5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O10.5

Lifting the car . . . . . . . . . . . . . . . . . . . . . . . .O10.5

Raising car . . . . . . . . . . . . . . . . . . . . . . . . .O10.5 Working under car . . . . . . . . . . . . . . . . . . ..O1. 0.6

Advice for the Beginner . . . . . . . . . . . ..O10.7

Planning ahead . . . . . . . . . . . . . . . . . . . . . ..O10.7

Workshop practices. . . . . . . . . . . . . . . . . . ..O10.7

Non-reusable fasteners . . . . . . . . . . . . . . . ..O10.7

Tightening fasteners . . . . . . . . . . . . . . . . . ..O10.8

Gaskets and seals . . . . . . . . . . . . . . . . . . . .O10.9

Electrical testing . . . . . . . . . . . . . . . . . . ..O1. 0.10 Wire repairs . . . . . . . . . . . . . . . . . . . . . . ..O1. 0.10

Buying Parts . . . . . . . . . . . . . . . . . . . . ..010.11 Genuine BMW parts . . . . . . . . . . . . . . . . . .O10.11

Non-returnable parts . . . . . . . . . . . . . . . . .O10.11 Information you need to know . . . . . . . . . .. 0l 0.12

Service . . . . . . . . . . . . . . . . . . . . . . . . . . .	010-13
TOOIS. . . . . . . . . . . . . . . . . . . . . . . . . . . .	010. -13
Basic tool requirements . . . . . . . . . . . . . . .	010-14
Jack stands.........................	010-16
Oil change equipment. . . . . . . . . . . . . . . . .	010-16
Torque wrench . . . . . . . . . . . . . . . . . . . . . .	010-17
Digital multimeter . . . . . . . . . . . . . . . . . . . .	010-17
BMW special tools . . . . . . . . . . . . . . . . . . .	010-18

Emergencies. . . . . . . . . . . . . . . . . . . . . .010-18

Changing a tire . . . . . . . . . . . . . . . . . . . . . .010-18 Jump starting . . . . . . . . . . . . . . . . . . . . . . .010-19

Indicator and warning lights . . . . . . . . . . . .010-19

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-20

Spare parts kit . . . . . . . . . . . . . . . . . . . . . .010-21

010-2

General

This section is intended to help the do-it-yourselfer get started. Tips on workshop practices, basic tools, and a quick reference guide to emergencies can be found here.

WARNING-

Do not use this manual unless you are familiar with basic automotive repair procedures and safe workshop practices.

0 This manual illustrates the worl<shopprocedures required for most service work; it is not a substitute for full and up-to-date information from the vehicle manufacturer or for proper training as an automotive technician.

Note that it is not possible to anticipate all of the ways or conditions under which vehicles may be serviced or to provide cautions as to all of the possible hazards that may result.

MOW TO USE THIS MANUAL

WARNING-

Your common sense and goodjudgement are crucial to safe and successful service work. Read procedures through before starting them. Think about whether the condition of your cac your level of mechanical skill, or pour level of reading comprehension might result in or contribute in some way to an occurrence that might cause you injury, damageyour car; or result in an unsafe repair. If you have doubts for these or other reasons about your ability to perform safe repair work on your car; have the work done at an authorized BMW dealer or other qualified shop.

The manual is divided into ten sections:

0 GENERAL, MAINTENANCE

0I ENGINE

2 TRANSMISSION

3 SUSPENSION, STEERING AND BRAKES

4 BODY

5 BODY EQUIPMENT

6 ELECTRICAL SYSTEM

-7 EQUIPMENT AND ACCESSORIES ELE ELECTRICAL WIRING DIAGRAMS

OBD ON-BOARD DIAGNOSTICS

General

0 GENERAL, MAINTENANCEcovers general vehicle information (010 General) as well as the recommendedmaintenance schedules and service proceduresto performBMW scheduled maintenancework (020 Maintenance).

The next seven sections (1 through 7) are repair based and organized by three digit repair groups. Most major sections begin with a GENERAL repair group, e.g. 100 Engine-Gen- eral. These " 0 0 (double zero) groups contain descriptivetheory of operation and systemtroubleshootinginformation.The remainder of the repair groups within a section contain the service and repair information.The last two sections contain detailedelectricalwiring schematicsand OBD IIscan tool and diagnostic information.

Warnings, cautions and notes

Throughout this manual are many passageswith the headings WARNING, CAUTION, or NOTE. These very important headings have different meanings.

WARNING-

The text under this heading warns of unsafepractices that are very likely to causeinjury, eitherbydirectthreat to theperson(~)performingthe work orby increasedrisl( of accident or mechanicalfailure while drivinq.

CAUTION-

A CAUTIONcalls attention to importantprecautionsto be obsenfedduring the repair work that willhelpprevent accidentally damagingthe car or itsparts.

NOTE-

A NOTEcontains helpful information, tips that will help in doing a betterjob and completing it more easily.

Please read every WARNING, CAUTION,AND NOTEin 001 General Warnings and Cautions and as they appear in repair procedures.They are very important. Read them before you begin any maintenanceor repairjob.

General

WARNING-

Never run the engine in tile work area unless it is well-ven- tilated. The exhaust should be vented to the outside. Carbon monoxide (CO) in exhaust kills.

Remove all neckties, scarfs, loose clothing, or jewelry when working near a running engine or power tools. Tuck in shirts. Tie long hair and secure it under a cap. Severe injury can result from these things being caugiit in rotating parts.

Remove rings, watches, and bracelets. Aside from the dangers of moving parts, metallic jewelry conducts electricity and may cause shorts, sparks, burns, or damage to the electricalsystem when accidentally contacting the battery or other electrical terminals.

Disconnect the battery negative (-)cable whenever working on or near the fuel system or anything that is electrically powered. Accidental electrical contact may damage the electrical system or cause a fire.

Fuelis highly flammable. When working around fuel, do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

The fuel system is designed to retain pressure even when the ignition is off When worlcing with the fuelsystem, loosen the fuel lines slowly to allow the residual pressure to dissipate gradually. Takeprecautions to avoid spraying fuel.

.Illuminate the worlc area adequately and safely Use a portable safety light for worlcinginside or under the car. A fluorescent type light is best because it gives off less heat. If using a light with a normal incandescent bulb, use rough service bulbs to avoid breakage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Keep sparks, lighted matches, and any open flame away from the top of the battery. Hydrogen gas emitted by the battery is highly flammable. Any nearby source of ignition may cause the battery to explode.

Never lay tools or parts in the engine compartment or on top of the battery. Theymay fallinto confinedspaces and be difficult to retrieve, become caught in belts or other rotating parts when the engine is started, or cause electrical shorts and damage to the electrical system.

General

Much of the necessary maintenanceand minor repairthat an automobile will need can be done with ordinary tools. Below you'llfind important informationon how to work safely, a discussion of what tools will be needed and how to use them.

Safety

Although an automobile presents many hazards, common sense and good equipment can help ensure safety. Many accidents happen because of carelessness. Pay attention and stick to the safety rules in this manual.

Lifting the car

4 The proper jacking points should be used to raise the car safely and avoid damage. The jack supplied with the car can only be used at the four side points (arrows) just behind the front wheels or just in front of the rear wheels.

.WARNING-

Never work undera lifted car unless it is solidlysupported onjack stands that are intendedfor that purpose.

When raising the car using a floorjack or hydrauliclift, carefully position thejack padto prevent damaging the car body.

* Watch thejack closely. Male sure it stays stable and does not shift or tilt. As the car is raised, it may roll sliahtlv and the jack mav shift.

Raising car

-Park car on flat, level surface.

-If changing a tire, loosen lug bolts before raising car. See

Changing a tire.

Place jack into position. Malte sure jack is resting on flat, solid surface. Use a board or other support to provide a firm surface for jack, it necessary.

-Raise car slowly while constantly checking position of jack and car.

-Once car is raised, bloclc wheel that is opposite and farthest from jack to prevent car from unexpectedly rolling.

(General

WARNING-

Do not rely on the transmission or the parking brake to keep the car from rolling. Theyare not a substituteforpositively bloclcing the opposite wheel.

Never work undera car that is supported only by ajaclc.

Usejack stands designed to support the car. See

Tools.

Working under car

-Disconnect negative (-) cable from battery so that car cannot be started. Let others know what you will be doing.

CAUTION--

Prior to disconnecting the battery, read the battery disconnection cautions given in 001 General Cautions and Warnings.

Raise car slowly as described above.

Use at least two jack stands to support car. Use jack stands designed for the purpose of supporting a car. See Tools.

WARNING-

*A jaclc is a temporary lifting device and should not be used alone to support the car whileyou are under it.

Do not use wood, concrete blocks, or bricks to support a ca,: Wood may split Blocks and bricks, while strong, are not designed for that kind of load, and may break or

Place jaclc stands on firm, solid surface. If necessary, use a flat board or similar solid object to provide a firm footing.

Lower car slowly until its weight is fully supported by jack stands. Watch to make sure that the jack stands do not tip or lean as the car settles on them.

Observe all jacking precautions again when raising car to remove jack stands.

General

ADVICEFOR THE BEGINNER

The tips that follow are general advice to help the do-it-your- self BMW owner periorm repairs and maintenance taslts more easily and more professionally.

Planning ahead

Know what the whole job requires before starting. Readthe procedurethoroughly,from beginningto end, inorderto know just what to expect and what parts will have to be replaced.

Workshop practices

Keepingthings organized, neat, and clean is essentialto doing a good job. When working under the hood, iender covers will protectthe finish from scratchesand otherdamage. Make sure the car finish is clean so that dirt underthe cover does not scratch the iinish.

Any repairjob will be less troublesome if the parts are clean For cleaning old parts, there are many solvents and parts cleaners commercially available.

For cleaning parts prior to assembly, commerciallyavailable aerosol cans of parts cleaner or brake cleaner are handy to use, and the cleaner will evaporatecompletely.

WARNING-

Most solvents usedfor cleaningparts are highly flammable as wellas toxic, especiallyin aerosolform. Use with extreme care. Do not smoke. Do not use theseproducts indoorsor near any source of heat, sparks or flame.

Non reusable fasteners

Many fasteners used on the cars covered by this manual must be replaced with new ones once they are removed. These include but are not limitedto: bolts, nuts (self-locking, nylock, etc.), roll pins, clips and washers. Genuine BMW parts should be the only replacementparts used for this purpose.

Some bolts are designedto stretch during assembly and are permanently altered, renderingthem unreliableonce removed. These are known as torque-to-yieldfasteners. Always replacefasteners where instructedto do so. Failure to replace these fasteners could cause personal injury orvehicle damage. See an authorized BMW dealer for applications and ordering information.

General

Tightening fasteners

When tightening the bolts ornuts on acomponent, it is always good practice to tighten the bolts gradually and evenly to avoid misalignment or over-stressing any one portion of the component. For components sealed with gaskets, this method helps to ensure that the gasket will seal properly.

4 Where there are several fasteners, tighten them in a sequence alternating between opposite sides of the component. Repeat the sequence until all the bolts are evenly tightened to the proper specification.

For some repairs a specific tightening sequence is necessary, or particular order of assembly is required. Such special conditions are noted in the text, and the necessary sequence is described or illustrated. Where no specific torque is listed,

BOO~FNG Table a: General bolt tightening torques i n Nm (max. permissible) can be used as a general guide for tighteningfasteners.

WARNING-

Table a: General bolt tightening torques in Nm (max. permissible) isa generalreferenceonly The valueslistedin the table are not intendedto be usedas a substitutefor torques specificallycalled out in the text or in manufacturer'sinformation.

NOTE-

*Metric bolt classes or grades are rnarlcedon the bolt head.

*Do notconfuse wrench size with bolt diameter. Fora listing of the common wrenches usedon various bolt diameters, see Basic tool requirements.

General

Table a. General bolt tightening torques in Nm (max. permissible)

Bolt Class (according to DIN 267)

Gaskets and seals

Gasket aredesigned to crush and become thinner as the mating parts are bolted together. Once agasket has been used, it is no longer capablef; malting as good a seal as when new, and is much more likely to leak. Forthis reason, gaskets should not be reused.

Some gaskets and seals are d~rectionalMake. sure thatthese are ~nstalledcorrectly. In places where a shaft must pass through a housing, flex~blelip seals are used to keep the lubricating 011or grease from leaking out past the rotatlng shaft. Seals should never be reused once they have been removed. When rernovlng a seal, be careful not to damage the metal surfaces.

The ltey to seal installation is to get the seal in straight without damaging it. Use a seal driver that is the same diameter as the seal housing to gently and evenly install into place. If a proper size seal driver is not available, a socket of the right size will do.

Some seals are directional and special installation instructions apply. Make sure a seal is installed with the lip facing the correct way. Note the installation direction of the old seal before removing it.

010-10

General

Battery

	(LW, 1
	Light bulb	' -
	(consumer)	' -
	(consumer)
	Car body
	(ground)	i

BOZLiEL

Electrical testing

Many electrical problems can be understood and solved with only a little fundamental knowledge of how electrical circuits function.

Electrical current only flows in a complete circuit. To operate. every electrical device in the car requires a complete circuit including a voltage source and a path to ground. The positive

(+) side of the battery is the original voltage source, and ground is any return path to the negative (-) side of the battery, whether through the wiring harness or the car body. Except for portions of the charging system, all electrical current in the car is direct current (DC) and flows from positive (+) to negative (-).

4 Switches are used to turn components on or off by completing or interrupting the circuit. A switch is "open" when the circuit is interrupted, and "closed" when the circuit is completed. See 600 Electrical System-General for electrical trouble-

shooting

Wire repairs

Repairs to a wiring harness require special care to make the repair permanent. The wire ends must be clean. if frayed or otherwise damaged, cut off the end and remove enough insulation to complete the repair. if the wire is too short, splice in a new piece of wire of the same size and make two connections.

Use connectors that are designed for the purpose. Crimped on orsoldered-on connectors are best. Crimp connectors and special crimping pliers are widely available. If soldering, use needle nose pliers to hold the wire near the solder joint and create a "heat dam". This keeps the heat and the solder from traveling up the wire. Always use a solder made specifically for electrical work (rosin core).

NOJE-

Twisting wires together to make a repair is not recommended. Corrosion and vibration will eventually spoil the connection and may lead to irreparable damage to sensitive electronic components.

Insulatethe finished connection. Electronics stores can supply heat-shrinkable insulating tubing that can be placed on to the wire before connecting, slid over the finished joint, and shrunic to a tight fit with a heat gun or hair dryer. The next best alternative is electrical tape. Make sure the wire is clean and free of solder flux or other contamination. Wrap the joint tightly to seal out moisture. See 600 Electrical System-General for more information.

- - ..

General

Many of the maintenanceand repair tasks in this manual call forthe installationof new parts, orthe use of new gaskets and other materialswhen reinstalling parts. Most often, the parts that will be needed should be on hand before beginningthe job. Readthe introductorytextandthe complete procedure to determine which parts will be needed.

NOTE-

For some biggerjobs, partial disassemblyand inspection is required to determine a complete parts list. Read the procedure carefully and, if necessary, male other arrangementsto get the necessary parts while your car is disassembled.

Genuine BMW parts

Genuine BMW replacement parts from an authorized BMW dealer are designed and manufacturedto the same high standards as the original parts. They will be the correct material. manufacturedto same specifications, and guaranteedto fit and work as intended. Most genuine BMW parts carry a limited warranty.

Many independent repair shops make a point of using genuine BMW parts, even though they may at times be more expensivethan 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 manufactured by one of BMW'sor~ginalequipment suppliers, but it is often difficult to know.

BMW is constantly updating and improvingtheir cars, often malting improvementsduring a given model year. BMW may recommenda newer, improved part as a replacement, and your authorized dealer'sparts department will know about it and provide it. The BMW parts organizationis best equipped to deal with your BMW parts needs.

Non returnable parts

Some parts cannot be returned, even for credit. The best example is electrical parts, which are almost universallyconsidered non returnable. Buy electrical parts carefully, and be as sure as possiblethat a replacement is needed, especiallyfor 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 replacingan expensive non returnable Dart.

010-12

1General

Information you need to know

Model

When ordering parts it is importantthat 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 manufactureor 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 1997to 2002.

Date of manufacture

This information is necessary when ordering replacement parts or determining if any of the warranty recalls are applicable to your car. The label on the driver's door belowthe 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 registrationdocument, and on the car itself. One location is on the right front strut tower inthe 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 informationon engine codes and engine applications, see 100 Engine-General.

Transmission code

The transmission type with its identifyingcode may be important when buying clutch parts, seals, gaskets, and other transmission-related parts. For informationon 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 accurate repair information.

The BMW dealer's service techniciansare highly trained and very capable. Authorized BMW dealers are committed to supporting 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 facilities is good way to learn of reputable BMW shops in your area.

Most maintenance can be accomplished with a small selection of tools. Tools range in quality from inexpensive junk, which may break at first use, to very expensive and wellmade 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, moderately 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 purchased from the following tool manufacturersand/or distributors:

Specialty tool suppliers

Assenmacher Specialty Tools

6440 Odeli Place

Boulder. CO 80301

Baum Tools Unlimited, Inc.

P.O. Box 5867

Sarasota. FL 34277-5867

010-14

General

Specialty tool suppliers

Peake Research, Automotive Products Division P.O. Box 28776

San Jose, CA 95159 408-369-0406 support@peakeresearch.com http://www.peakeresearch.com

Basic tool requirements

The basic hand tools described below can be used to accomplish 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 openend 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 convenience and can be combined with extensions and universal joints (swivels) to reach fasteners more easily. The most common socket drive sizes are 114inch, 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 diarneters and the corresponding wrench sizes.

Common bolt diameters and wrench sizes

M5	8 rnrn
M6	10 rnm
M8	12rnrnor13rnrn
M I0	17 rnrn
M I 2	19 rnrn
M14	22 mm

Spark plug socket

4 A 518" deep-well socket for sparlt plugs includes a rubber insert to both protect the spark plug from damage and grip it for easier removal.

Pliers

There are many types of pliers including snap-ring, needlenose, adjustable-joint, slip-joint (Channel-lock@),and locking (Vice-Grip@)most of which are used for holding irregular objects, bending, or crimping. Some have special applications.

Needlenose pliers are used for gripping small and poorly accessible objects, and are useful forwiring and other electrical work. Locking pliers such as the Vise-Grip@are useful because 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 neededto remove a nut and bolt. Use extra care with adjustable wrenches, as they tend to loosen, slip, and damage fasteners.

BOOBFNG

Compared to a wrench of the correct size, an adjustable 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.

Jack stands

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.
Ajaclc should be usedonly to raise the vehicle, notto support
the car for a longperiod. Always usejack stands to support a
Jackstands are available in several styles. The best ones are	:
	:
made of heavy materialfor strength, have a wide base for sta-
bility, and are equipped to positively lock in their raised posi-
tion. Get the best ones available.

Oil change equipment

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 under 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 removethe oil filtercanistercover. See 020 Maintenanceforoil change instructions.

General

Torque wrench

A torque wrench is used to precisely tighten threaded fasteners to a predeterminedvalue. 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 (ftIb).

4 Several types of torque wrenches are available. An inexpensive 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 samejob, 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. Followthe wrench manufacturer's directionsfor use to achieve the greatest accuracy.

A torque wrench with a range up to about 150 Nm (110 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 inchpounds to foot-pounds, divide by 12.

Digital multimeter

4 Many of the electrical tests in this manual call for the measurement 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 electronicsystems may be damagedby the high current draw of a test light with a normalincandescentbulb. As a general rule, use a highimpedance digitalmultimeteror an LED test light for all electricaltesting.

General

B M W 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 correctly. 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 essential, and not a cost-effectivepurchasefor a one time repair by the do-it-yourself owner. This manual includes such repairs for the benefit of those with the necessary experience and access to tools. For the do-it-yourselfer,the needfor special tools is noted in the text, and whether or not BMW dealer service is recommended.

Changing a tire

-Stop car on as flat a surfaceas possible, in a place where you can be easily seen by other drivers. Avoid stopping just over the crest of a hill.

WARNING -

Ifa tiregoes flat while driving, pull well off the road. Changing a tire on a busy slreet or liigliway is very dangerous. Ifnecessag 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 emergencyflashers, and set out flares or emergency markers well behind car. Choclc wheel (wheel chock located in trunk) diagonally opposite to the one being changed. Passengers should get out of car and stand well away from road.

Take jaclc and tools from tool area beneath trunk mat. Remove 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.

120 Nm (89 ft-ib)

General

B4 Lower car. With all wheels on ground, fully tighten nuts in a crisscross pattern. Torque wheel nuts when installing wheel. Check inflation pressure of spare tire.

Tightening torque

Wheel to wheel hub

Jump starting

BOOIFNG.

Cars with discharged or dead batteries can bejump-started usingthe good battery from another car. See owner'smanual for proper instruction on jump starting. When jump-starling the engine, always note the following warnings.

WARNING-

*Batteryacid (electrolyte) can cause severe burns, and will damage the cal; clothing, andyou. If electrolyte is spilled, wash thesurface withlargequantitiesof water. M itgetsinto eyes, flush them with water for severalminutes and call a doctor.

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 battery is frozen. Trappedgas may explode. Allow the battery 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.

Indicator and warning lights

Many vehicle systems are self-monitoredfor faults while driving. Generally, a redwarning lamp that comes on during driving should be considered serious. If you cannot immediately determinethe seriousness of the warning light, stop the vehicle in a safe place and turn the engine off as soon as possible. Consultthe owner's manualfor additional informationon the warning lamp and the recommendedaction.

If the Malfunction Indicator Lamp (MIL) (Check Engine or Service Engine Soon warning light) comes on orflashes, it indicates that an emissions-relatedfault has occurred. Faults such as a bad oxygen sensor or a dead fuel injector can cause the exhaust or evaporative emissionsto 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, althoughthe emission systems should be checked as soon as possible. See OBD On-Board Diagnostics for

010-20

General

more information on the Check Engine Light and the onboard 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.

CAUJION-

Do not tow with sling-type equipment The front spoilers and b ~ m ~coversr 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.

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.

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