BMW 3 Series Service Manual (E39)

WARNING

Your common sense, good judgemenl, and general alertness are crucial to sale and successiul service worlr. Belore attempting any work on your BMM be sure lo read 001 General Warnings and Cautions and the copyriglll page at the front 01 the manual. Review these warnings and caulions each lime you prepare lo work on your BMW. Please also read any warnings and cautions that accompany tile procedures in the manual.

312-way valve (running losses) see Fuel tank

Abbreviations, commonly used 600-14

ABS (antilock brake system) see Bral(es

A/C

air distribution motors

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

blower, removinglinslalling 640-15

compressor, replacing 640-24 condenser, replacing 64045 control panellmodule, removing1 installing 640-11

evaporakr, removinglinstalling 640-29

evaporator temperature sensor 640-12

expansion valve, removinglinstailing 640-27

IHKA/ IHKR system description640-5 receiveridrier, replacing 640-26 stepper motors 640-13

ventilation microiilter, replacing 020-22. 640-17

see also Heating

Accelerator iinlcage see Maintenance

Activated carbon canister see Fuel tank

ADS (auxiliary throttle valve) 130-57

-. ~ .

-

-

I

2 INDEX

Battery, starter, alternator alternator (generator) 121-10

6-cylinder engine, removingi installing 121-15

M62 engine 121-16

M62 TU engine (water cooled)

121-18 battery 121-5

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

charging system, troubleshooting 121-12

starter 121-19

6-cylinder engine, removingi

instaliinq 121-20

.

V-8 engine, rernovinglinsialiing 121-21

solenoid, removinglinstalling121-23 troubleshooting 121-19

see also Maintenance

Bearing, wheel

see Front suspension see also Rear suspension

Belts

see Maintenance, drive belts

Blade, wiper

see Wipers and Washers

Blower motor see A/C

BMW emblem see Exterior trim

BMW special tools 010-18

see also special tools section at beginning of each repair group

Body

dimensions 400-2 interior features 400-9 salety and security 400-7

Body side molding see Exterior trim

Bonnet

see Engine hood

Boot

see Trunk

Brake fluid 020-24, 340-8

Brake fluid pressure sensor 340-30

Brakes

ABS, ASC or DSC system 300-12 component replacement 340-26

ASCIDSC switch see Switches

bleeding bralces 340-8 brake booster 340-19

descriotion 300-10 e~ectrdnicbrake & stability 300-11 light switch

see Switches master cylinder 340-16 pariking brake 340-22 troubleshooting 340-5

Bulbs

see Lights

Bumper lront 510-6

height, adjusting 510-12 rear 510-9

Bus system 600-4

Camber

320-33

Camshaft removingiinslaiiing

M52 engine 116-12

M52 TU / M54 engine 116-19

M62 engine 116-39 wear 116-6

Camshaft position sensors see ignition system

Camshaft timing chain adjusting

M52 engine 117-22

M52 TU IM54 engine 117-43

M62 engine 117-79 removinglinstalling

M52 engine 117-26

M52TU 1 M54 engine 113-46.116- 28

M62 engine 117-66

Capacities, fluid 020.10

Car rnemorvlicev. . memorv 600-10

see also Centrai lociking

Carbon canister, activated see Fuel tank

Caster

320-33

Catalytic converter

and oxygen sensor 020-19

see also Exhaust system: exhaust manilolds

Cautions

001-3

CD changer 650-4

Center bearing, driveshaft see Driveshait

Center brake light sedan 630-13

Center console 513-3

Centrai body electronics (ZKE 111) 600-6

Central locking

car memoryiey memory 515.12 general module iunctions 515-2 remote entry (FZV) 515-8 remote lkey initialization515-10 single lociddouble ioclk 515-6 switch 515-4

Chain

see Camshaft liming chain

Characteristic map (electrically heated) thermostat

see Electrically heated thermostat

Charging system

see Battery, starter, alternator

Cluster

see instruments

Clutch fluid

see Maintenance hydraulics 210-4 mechanical210-9 switch

see Switches, pedal ciuster variations 210.10

Codes, fault

OED-1

Coil

see Ignitionsystem

Coil spring

see Front suspension see also Rear suspension

WARNING

Your common sense, good judgement, and general alertness are crucial lo sale and successlul service work. Belore attempling any work on your BMW, be sure to read 001 General Warnings and Cautions and lhe copyright page a1 llle Iron101 the manual. Review lliese warnings and cautions each time you prepare lo work on your BMW Please also read any warnings and caulions lhal accompany the procedures In !he manual.

Component locations see Electrical system

Compression test 113-5

Compressor

see AlC

Condenser

see AlC

Constant velocity (CV) joint see Maintenance

see also Driveshall see also Drive axles

Consumer cutoff 600-10

Control arm

see Front suspension see also Rear suspension, suspension arms

Coolant (antifreeze) see Maintenance

see also Cooling system

Coolant pump

see Cooling system

Cooling system coolant

bleeding 170-14

6-cylinder engine, draininglfilling

170-10

V-8 engine, draininglfilling 170-12 coolant pump 170-3

6-cyiinder engine, replacing 170-19 V-8 engine, replacing 170-20

cooling fan 170-4

viscous ciutch fan, removingi installing 170-14

electric fan, removlngiinstailing 170-15

expansion tank, removinglinstalling 170-22

electrically heated (ciiaracterislic map) therrnostat 170-4

radiator, removinglinstaliing170-22 service

see Maintenance therrnostat 170-16

transmission fluid heat exchanger 170-5

troubleshooting 170-7 combuslion leal( test 170-10 pressure test 170-9

Crankshaft oil seals iront 117-6

rear 119-6

Crankshaft speed sensor see Ignitionsyslem

Crash sensor

see Airbag system (SRS), side-impact airbag crasii sensor

Cruise control clutch switch 612-9

CV joint

see Maintenance see also Driveshalt see also Drive axles

CV joint boot

see Maintenance see also Drive axles

Cylinder head removinglinslaliing

M52 engine 113-8

M52 TU / M54 engine 113-22

M62 engine 113-56

Cylinder head and valvetrain hydraulic lifters, checking and replacing 116-7

leak test 116-5 valves 116-56

see alsocylinder head

Dashboard

513-7

Deck lid seeTrunk lid

Diagnostic monitors

OED-4

Diagnostic trouble codes (DTCs) 080 - 7

Digital multimetel 010-17

Differential

see Final drive

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

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

see also ignition system

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

Drive belts

see Maintenance

Dome light

seeLighls, interior lights

Door

door check, replacing 411-4 hinge adjustment 411-5 loci(

see Door lock

see also Central locking removinglinslaliing411-2 panel, removinglinstaliing411-7 window

see Door window

Door check see Door

Door handle see Door lock

Door glass

see Door window

Door lock

handles and loci(s 515-16 see also Central locking

Door molding 510-13

Door panel see Door

4 INDEX

Door window anti-trap 512-4

convenience openinglclosing 512.4 regulator and motor 512-11 service 512-5

switches 512-3 see also Switches

Double VANOS

see VANOS

Drive axle

CV joint 331-15

CV joint boot 331-15 rernovinglinstalling331-14

Drive belt

see Maintenance

Driveabiiity troubleshooting 100-4

Driveaway protection

see EWS (eiectronic immobilization)

Driveshaft aligning 260-7

center bearing, replacing 260-12 CV joint, replacing 260-14 itex-disc, replacing260-11

iront centering guide, replacing 260-13

rernovinglinstailing260-6 lroubleshooting 260-3 U-joint 260-3

DSC

see Braires

DTC (diagnostic trouble code) OBD-8

DWA

see Anti-theft alarm

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

ECT (engine coolant temperature) sensor

see 130 under appropriate iuei injection system

EDK

adaptation 130-69 MS 43.0 130-35

EHC

see Electronic iieigiit control (EHC)

Electric cooling fan

see Cooling system, cooling fan

see also Cooiing system, eiectric fan

Electrical switches see Switches

Electrical system abbreviations 600-14 bus System 600-4

component location table 610-3 components

photos 610-36 Sport Wagon 610-81

engine 121-2 troubleshooting600-15 voltage and polarily 600-5 wire color codes 600-12 wiring diagrams 600-12

Electrical wiring diagrams

ELE-1

Eiectricaliy heated thermostat (characteristic map)

170-4

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

Eiectronic immobilization

see EWS (electronic immobilization)

Eiectronics box (E-box) 610-37

Emergencies

010-18

Emergency brake

see BraBes, parking brake

Engine

see also Cylinder head and valvetrain applications 100-2

compression, testing 113-5 cooling

see Cooiing system crankshaft front oil seai

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

see Maintenance

driveability troubleshooting 100-4 engine management systems 100-2

see also Ignition

see also Fuel injection fuel supply 130-6

ground connections 100-5 see also 610

identilying ieatures 100-3 lubrication svstem

see ~ubricetionsystem mount

on-board diagnosticsOBD-I oxygensensor

see Fuel injection

see also Exhaust system Dreventive maintenance

see Maintenance removal/installation

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

Engine cooiant temperature (ECT) sensor

see 130 under appropriate iuel injection system

Engine cooling fan

see Cooiing system, electric fan

Engine hood 410-6

raising to service position 410-6

Engine troubleshooting see Engine, driveability troubleshooting

EVa~oratiVecontrol svstem 160-3

see also 130 under aDDroDriate iuel injection system

Evaporator

see N C

Evaporator temperature sensor see N C

WARNING

Your common sense, good judgement, and general alerlness are crucial lo safe and successful service ivork. Before attempling any work on your BMW be sure lo read 001 General Warnings and Cautions and the copyright page at the fronl of Ihe manual. Review these warnings and cautions each lime you prepare to work on your BMW Please also read any warnings and cautions tliat accompany Nie procedures in the manual.

Exhaust manifold see Exhaust system

Exhaust system diagrams 180.1 1

exhaust manifolds, removinglinstalling 180-4

muifier, replacing 180-8 oxygen sensors 180-8

and catalytic converter020-19 see also Fuel injection

removinglinstalling180-2 see also Maintenance

Expansion tank

see Cooling system

Expansion valve see N C

Exterior lighting see Lights

Exterior trim

BMW emblem (Roundel), removing1 installing 510-13

body side molding, replacing 510.13 grill, removinglinsialiing510-14 headlight housing trim, removing1 installing 510-14

outside mirror 510-2

EWS (electronic immobilization) 515-21

ring antenna, iemovinglinstaiting 320-11

Fan

see Cooling system

Fan clutch

see Cooling system, cooling fan

Fault codes OBD-2

storage 100-4. 600.10

Fender

front, rernovinglinstailing410-2

Filters

see Maintenance

Final drive

lubricant speciiicatiorls 020-9 mounh, replacing 331-12

oil level 020-26. 331-6 removinglinslalling331-5 seals 331-7

Firing order

see Ignitionsystem

FtS

see Interior protectiorl

Flex disc

see Driveshaft

Fluids and lubricants see Maintenance

Flywheel

removinglinstalling210-13

Fogllght

see Lights

Front centering guide see Driveshatt

Front oil seal

see Crankshaftoil seals

Front suspension control arm 310-12 description 300-2 ride height 300-14

stabilizer bar, removinglinstalling 310-21

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

Fuel filter

see Maintenance

INDEX 5

Fuet injection applications 130-2

Bosch M5.2, M5.2.1 130-46 Bosch ME 7.2 130-66

fuel delivery

see 130 under appropriate iuel injection system

see also Fuel pump see also Fuet tank

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

Siemens MS 42.0. MS 43.0 130-23

Fuel injector

see 130 under appropriate fuel injectionsystem

Fuel level sender 160-15

see also Fuei pump

Fuel pressure 160-10

see also Fuel pump

Fuel pump 160-3

electrical circuit, testino 160-7

Gaskets

and seals 010-9

Gearshift

automatic transmission adjusting 250-7

shift interiock. checkino function

"

250-9

shiftloclc. checicino- function 250-8 manual transmission

gearshift lever, removingiinstalling 250-5

steptronic 250-7

General module (GM Ill) 600-8

see also Central locking

Generator

see Battery, starter, alternator

Glass

see Door window

Glove compartment 513-16

see also

Global positioning system (GPS) 620-9

Grill

see Exterior trim

Grounds

100-5

Guide link

see Rear suspension, suspension arms

Halogen headlight 630-5

Hand brake

see Brakes, pariring brake

Handle, door see Door locks

Hatch

seeTailgate

Hazard warning switch see Switches

Headlight housing trim

see Exterior trim washer611-17 see also Lights

Headlight spray nozzle 611-17

Headlight switch see Switches

Heater core see Heating

Heater valve see Heating

Heating

lieater core, replacing 640-18 lheater core temperature sensor, removingiinstalling640-12 heater valve, replacing 640-17 IHKA housing, removinglinstallin~ 640-21

see also N C

Hood

410-6

Hood latch and release 410-10

Hydraulic valve lifters

see Cylinder head and valvetrain

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

idle speed control valve

see 130 under appropriate fuel injection system

Idle stabilizer

see 130 under appropriate fuel injection system, idie speed controi valve

idler arm 320-30

lgnition coll

see lgnition system

lgnition interlock 320-13

lgnition lock cylinder removingiinstalling320-11. 612-4

lgnition switch seeSwifches

Ignition system diagnosis

checking for spark 120-10 disabling ignition system 120-10 misfire detection 120-6 oscilioscope diagrams 120.6 troubleshooting 120-6

camshaft position sensors 120-14 coils 120.10

crankshaft speed sensor 120-12 firing order 120-9

knoclc sensors 120-16

IHKA

see N C

IHKR

see N C

Injector

see 130 under appropriate fuel injection system, luel injector

Input shaft oil seal

see Manual transmission, oil seals

Inspection

see Maintenance

Instruments GPS

see Global positioningsystem (GPSI

layout 6202 removingiinstalling620-8 self-testing 620-6

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

Intake manifold removingiinstalling

6-cvlinder enoine- 110-10. 113-8. 113-22

V-8 engine (M62) 113-56

Integral link

see Rear suspension, suspension arms

lnterior lights see Lights

lnterior protection (FISIUIS) 515-25

lnterior trim 513-13

lnterior ventilation microfilter see NC, ventilation microfiller

WARNING

Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your BMW, be sure to read 001 General Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your BMW. Please also read any warnings and caulions that accompany /he procedures in the manual.

Jack stands 010-16

Jump starting 010-19

Keys

515-11

Knock sensor

see Ignition system

Leak detection, fuel tanlr

see Fuel tank, leak detection unit

Leather upholstery

see Maintenance,leather upholstery and trim

LDP (leak detection pump)

see Fuel tanir, leal( detection unit

Level sender see Fuel tank

see also Fuel pump

License plate iight 630-11

Lifters

see Cylinder head and vaivetrain

Lifting the car 010-5

Lights

bulb applications 630-2 control module (LCM) 630-3 foglights 630-8

headiighls 630-4

automatic headlight adjustment (LWR) 630-7

vertical aim system 630-8 interior lights 630-12

bulb applications 630-13 side turn signal 630-9 taillight 630.10

trunk light bulb 630-14

turn signals, taillights 630-12

LOClCS

see Central loci(ing see also Door loclrs

Lubrication system

oil level warning switch, replacing 119-20

oil pan, removinglinstalling 6-cylinder 119-10

V-Elower 119-13 V-8 upper 119-15

oil pressure checiring 119-4

warning system, testing 119-5 warning switch, replacing 119-20

oil pressure reliel valve 6-cylinder 119-26 V-8 119-27

oil pump, removinglinstalling 6-cylinder 119-22

V-8 119-4 troubieshooting119-3

Luggage compartment seeTrunk

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

INDEX 7

Maintenance

accelerator linkage 020-14 air filter 020-14

automatic transmission 020-29 battery 020-22

body lubrication 020-31 body and interior 020-31 braire fluid 020-24

brake padlrotor wear 020-24 brake system 020-25

clutch fluid 020-26 cooling system 020-15 CV ioint boots 020-27 differentialoil level 020-26 drive bells 020-16

engine comparlmenl 020-14 engine cooling system 020-16 engine oil 020-11

exhaust system 020-27 exterior washing 020-31

fluid and lubricant specifications 020-9 fuel lilter 020-27

fuel lanir and fuel lines 20-28 idle speed 020-19 inspection 020-5

interior care 020-31

lealher upholslery and trim 020-31 maintenance tables 020-6

manual transmission oil 020-30 microiilter 020-22

oxygen sensors 130-72, 180-8 parlcing brake 020-25

power steering fluid level 020-20 seat belts 020-32

service indicator 020-3 spark plugs 020-20 special cleaning 020-32 suspension, front 020-29 suspension, rear 020-29 tires 020-29

washing 020-32 waxing 020-32

windshield wiper blade 020-33 wheels, aligning 020-30

Malfunction indicator iight (MIL) OED-2

Manifold, exhaust see Exhaust system

Manifold, intake

see Intake maniiold

Pitman arm see Steering

Power steering see Steering

Power steering fluid see Maintenance

Power window switch 512-3

see also Switches

PWG

see Pedal position sensor (PWG)

Racic and pinion steering see Steering

Radiator

see Cooling system

Radiator cooling fan seeCooling system, cooling fan

see also Cooling system, electric fan

Radiator grill

see Exterior trim

Radio 650-2

see also Antenna see also Speakers

Rain sensor 611-6

Raising car safely 010-5

Readiness codes

OED-6

Rear door window see Door window

Rear main seal

see Crankshaltoil seals

Rear parcel sheif 513-16

WARNING

Your common sense, good judgemenl, and general alerlness are crucial lo seie end successful service ivork. Beiore attempting any work on your BMW be sure to read 001 General Warnings and Cautions and llle copyright page at lhe iron1of the manual. Review Niese warnings and caulions each lime you prepare lo work on your BMW Please also read any warnings and caulions lllal accompany the procedures in the manual.

Rear suspension ball joints 330-19 bushings 330-13 control arms

seesuspension arms, below description 300-5

electronic height control (EHC) 330-44

ride height 300-14

ride height sensor 330-46

shoclr absorbers end springs 330-9 stabilizer bar 330-42

struts and springs 330-5 subframe 330.13 suspension arms 330-13 variations 330-4

wheel bearing, replacing 330-32 see also Maintenance

see also Drive axles see also Final drive

Rear window (Sport Wagon) see Tailgate

Rear window defroster 610-17

Receiverldrter

see N C

Relay positions

see Electrical component tocations table 610-3

Remote entry (FZV) see Central locking

Reversing light switch see Baclc-up light switch

Ride height 300-14

Steering description 300-10 liuid

see Maintenance gearbox 320-25 idler arm 320-30 lock 320-12 pitman arm 320-28

power steering pump 320-17 rack & pinion 320-19 steering column 320-10

motors 320-16 removinglinstalling320-14 trim 320-10

steerino wheei 320-7 tie rods-

6-cvlinder, reelacinq320-22

V- center tie'rod, replacing 320-32 variations 310-5

Steering box

see Steering, gearbox

Steering column switches see Switches

Steering column see Steering

Steering lock see Steering

Steering wheei switches see Switches

Stepper motor see AIC

Steptronic transmission see Gearshift

Strut

see Front suspension see also Rear suspension

Subframe

see Rear suspension

Sunroof

initializing 540-2

adiustinq 540-5

. .

cornponents, removingiinstailing 540-9

emergency closing 540-4

Suspension, front

see Front suspension

see also Aluminum suspension cornponents

Suspension, rear

see Rear suspension

see also Aluminum suspension cornponents

Swing arm

see Rear suspension, suspension arms

Switches ASCIDSC 612-12 back-ue

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

center console switches 612-11 central ioci(ing 612-11

hazard 612-1I headlight 612-9

ignition cylinder 320-11. 612-6 outside mirror 612-11

pedal cluster switches 612-8 seat heater 612.12

steering column positioning612-7 steering column switches 612-6 steering wheel switches 612-2 turn signaliheadlightdimmer 612-6 window 612-11

wipers 612-6

Tailgate 412-6

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

taiigatelrear window loclring 515-14 see also Trunldtaiioate- ioclr

see also Central ioclcing

Taillights

see Lights

Tape player 650-3

TCM (transmission control module) see Automatic transmission

Tension strut

see Front suspension

Thermostat

see Cooling system

see also Electrically heated thermostat

Throttie body

see 130 under appropriate fuel injection system

Throttie cable 130-38

Throttie position sensor

see 130 under appropriate luel injection system

Throw-out bearing

see Clutch, mechanical

Thrust arm

see Front suspension

Tie rod

see Steering

Tightening fasteners 010-8

Tilt sensor 515-24

Timing chain

see Camshaft timing chain

Tire, changing 010-18

Tires 300-11

see also Maintenance

Toe

320-34

Tools

010-13