BMW 3 Series Service Manual (E39)

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Benllcy Publishers, a divisionol Robcrt Bcnlley,In=.

1734 M~SB~CIIUP~IISAvenue

WARNING-important safety notice

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

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

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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

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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

'7

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

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WARNINGS-

See also CAUTIONS

-Some repairs may be beyond your capability. If you lack the skills, tools and equipment, or a suitable workplace for any procedure described in this manual, we suggest you leave such repairs to an authorized BMW dealer service department or other qualified

.shop.

Do not reuse any fasteners that are worn or deformed. Many fasteners are designed to be used only once and become unreliable and mav fail when used a second time. This includes, but is not limited io, nuts, bolts, washers, self-locking nuts or bolts, clrclips

.and cotter pins. Always replace these fasteners with new parts. Never work under a lifted car unless it is solidly supported on stands desiqned for the purpose. Do not supeort a car on cinder blochs, hollow tiles orotherbrops that may drurnbie undercontinuous toad. Never work under a car that is supported solely by a iack. Never work under the car while the enqine- is runninq-.

If you aregoing to work underacaron the ground, makesure that the ground is level. Block the wheels to keep the car from rolling. Disconnect the battery negative (-) terminal to prevent others

-from starting the car while you are under it.

Never run the engine unless the work area is well ventilated. Carbon monoxide kills.

Rings, bracelets and other jewelry should be removed so that they cannot cause electrical shorts, get caught in running ma-

-chinery, or be crushed by heavy parts.

Tie long hair behind your head. Do not wear a necktie, a scarf. loose clothing, or a necklace when you work near machine tools or running engines. if your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.

DOnot attempt to work on your car if you do not feel well. You increase the danger of injuryto yourseliand others ifyou are tired, uDset or have taken medication or anv other substance that mav keep you from being fully alert.

Illuminate your work area adequately. but safely. Use a portable

.

safety lighiforworking lnsideor under the car. Make sure the bulb is enclosed bv a wire caoe. The hot filament of an accidentallv broken bulb can ignite spilled fuel, vapors or oil.

-Catch draining fuel, oil, or brake fluid in suitable containers. Do not use foodor beverage containers that might misleadsomeone into drinking from them. Store flammablefluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously.

Always observe good worRshop practices. Wear qoqqles when you operate machine tools or work with battery acid:kloves or other ~rotectiveclothino should be worn whenever the iob reyires'working with harmful substances.

Greases, lubricantsand other automotivechemicalscontain toxic substances, many of which are absorbed directly through the skin. Read the manufacturer'sinstructions and warninos carefuliy. Use hand and eye protection. Avoid direct skin conGct.

Disconnect the battery negative (-) terminal whenever you work on the fuel system orthe electrical system. Do not smokeorwork near heaters or other fire hazards. Keep an approved fire extinguisher handy.

.Friction materials (such as brake pads or shoes or clutch discs) contain asbestos fibers or other friction materials. Do not create dust by grinding, sanding, or by cleaning with compressed air.

Avoid breathing dust. Breathing any friclion material dust can lead to serious diseases and may result in death.

Batteries giveoff explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it will ignite gas trapped in the cells and cause the battery to explode.

Connect and disconnect battery cables, jumper cables or a battery charger only wilh the ignitionswitched off. Do not disconnect the battery while the engine is running.

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.

Do not allow battery charging vollage to exceed 16.5 volts. If the

,- ~roducina- -oas or boilino violentiv, reduce thebatten! beoins

charglng rate. ~oostlnga sutfaled battery at a i g h charging rate can cause an explosion.

IGeneral Warnings and Cautions

WARNINGS (continued)

.The air conditioning system is filled with chemical refrigerant, which is hazardous. The AIC system should be serviced only by trained technicians using approved refrigerant recoverylrecycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive

.chemical refrigerants.

Do not expose any part of the AIC system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst.

Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair.

Cars covered by this manual are equipped with a supplemental restraint system (SRS), that automatically deploys airbags and pyrotechnic seat belt tensioners In the event oi a frontal or side impact. These are explosive devices. Handled improperly or without adequate safeguards, they can be accidently activated and

- cause serious injury.

The ignition system produces high voltages that can be fatal. Avoid contact with exposedterminals and use extremecare when working on a car with the engine running or the ignition switched on.

.Placejack stands only at locationsspecified by the manufacturer. The vehicle illtino-.iack su~olied, . with the vehicle is intended fortire changes only. A heavy duty floor jack should be used lo lift vehicle

-before installing jacl( stands. See 010 General.

Battery acid (electrolyte) can cause severe burns. Flush contact area with water, seek medical attention.

Aerosol cleaners and solvents may contain hazardous or deadly vapors and are highly flammable. Use only in a well ventilated area. Do not use on hot surfaces (engines, brakes, etc.).

Do not remove coolant reservoir or radiator cap with the engine hot. Danger of burns and engine damage.

CAUTIONS-

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.

-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.