2002 BMW 530i E39 Service and Repair Manual

BMW 3- & 5-Series Service and Repair Manual A K Legg LAE MIMI and Larry Warren Models covered 3-Series (E30) 316 (83 to 88), 316i (88 to 91), 318i (83 to 91), 320i (87 to 91), 325i (87 to 91). Also Touring and Convertible versions of these models 5-Series (E28) 518 (81 to 85), 518i (85 to 88), 525i (81 to 88), 528i (81 to 88), 535i (85 to 88), M535i (85 to 88) 5-Series (E34) 518i (90 to 91), 520i (88 to 91), 525i (88 to 91), 530i (88 to 91), 535i (88 to 91) Engines covered 1596 cc, 1766 cc, 1795 cc, 1990 cc, 2494 cc, 2788 cc, 2986 cc & 3430 cc Does not cover Diesel, dohc or V8 engines, or four-wheel-drive models © Haynes Publishing 1997 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. ISBN 1 85960 236 3 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,Somerset BA22 7JJ, England Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Editions Haynes S.A. 147/149, rue Saint Honoré, 75001 PARIS, France Haynes Publishing Nordiska AB Box 1504, 751 45 Uppsala, Sweden (1948-256-11AA3) ABCDE FGHIJ KLMNO PQRST 1 2 3

LIVING WITH YOUR BMW Introduction Page 0•4 Safety First! Page 0•6 Anti-theft audio system Page 0•7 Instrument panel language display Page 0•7 Roadside Repairs Jacking, towing and wheel changing Page 0•8 Jump starting Page 0•9 Identifying leaks Page 0•10 ROUTINE MAINTENANCE Routine Maintenance and Servicing Page 1•1 Lubricants and fluids Page 1•3 Maintenance schedule Page 1•4 Weekly checks Page 1•7 Every 6000 miles Page 1•11 Every 12 000 miles Page 1•16 Every 24 000 miles Page 1•23 Every 60 000 miles Page 1•26 Contents

REPAIRS & OVERHAUL Engine and Associated Systems In-car engine repair procedures Page 2A•1 General engine overhaul procedures Page 2B•1 Cooling, heating and air conditioning systems Page 3•1 Fuel and exhaust systems Page 4•1 Engine electrical systems Page 5•1 Engine management and emission control systems Page 6•1 Transmission Manual transmission Page 7A•1 Automatic transmission Page 7B•1 Clutch and driveline Page 8•1 Brakes Braking system Page 9•1 Suspension Suspension and steering systems Page 10•1 Body Equipment Bodywork and fittings Page 11•1 Electrical Body electrical systems Page 12•1 Wiring Diagrams Page 12•10 REFERENCE MOT Test Checks Checks carried out from the driver’s seat Page REF•1 Checks carried out with the vehicle on the ground Page REF•2 Checks carried out with the vehicle raised Page REF•3 Checks carried out on your vehicle’s exhaust emission system Page REF•4 Tools and Working Facilities Page REF•5 General Repair Procedures Page REF•8 Fault Finding Page REF•9 Conversion factors Page REF•17 Automotive chemicals and lubricants Page REF•18 Buying spare parts and vehicle identification numbers Page REF•19 Glossary of Technical Terms Page REF•20 Index Page REF•25 Contents

0•4 Introduction The E30 3-Series range first became available in the UK in March 1983, and continued in production until April 1991, when the revised E36 3-Series range (not covered by this manual) was introduced. Convertible and Touring (Estate) models were introduced for 1988, and these models have continued in E30 form to date. The E28 5-Series models were introduced in October 1981, and were superseded in June 1988 by the revised E34 5-Series range, Touring versions of which became available from March 1992. Throughout this manual, E28 models are also referred to as “old- shape”, while E34 models are designated “new-shape”. The models covered by this manual are equipped with single overhead cam in-line four- and six-cylinder engines. Early 316 and 518 models are fitted with carburettors, but all other models are fitted with fuel injection systems. Transmissions are a five-speed manual, or three- or four-speed automatic. The transmission is mounted to the back of the engine, and power is transmitted to the fully-independent rear axle through a two- piece propeller shaft. The final drive unit is bolted solidly to a frame crossmember, and drives the rear wheels through driveshafts equipped with inner and outer constant velocity joints. The front suspension is of MacPherson strut type, with the coil spring/shock absorber unit making up the upper suspension link. The rear suspension is made up of coil spring- over-shock absorber struts, or coil springs and conventional shock absorbers, depending on model. The brakes are disc type at the front, with either drums or discs at the rear, depending on model. Servo assistance is standard on all models. Some later models are equipped with an Anti-lock Braking System (ABS). All models are manufactured to fine limits, and live up to the BMW reputation of quality workmanship. Although many of the models covered by this manual appear complex at first sight, they should present no problems to the home mechanic. Note for UK readers The greater part of this manual was originally written in the USA. Some of the photographs used are of American-market models, but the procedures given are fully applicable to right-hand-drive models (or have been amended where necessary). Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. Technical writers who contributed to this project include Robert Maddox, Mark Ryan and Mike Stubblefield. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. Project vehicles The main project vehicle used in the preparation of this manual for the UK market was a 1988 BMW 318i with an M40/B18 engine. Introduction to the BMW 3- and 5-Series BMW 320i Saloon (E30)

0•5 Introduction BMW 518i (E28) BMW 325i Touring (E30) BMW 535i (E34) BMW 325i Convertible (E30)

2002 BMW 530i E39 Service and Repair Manual

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