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Old 07-20-2012, 09:17 AM
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bluebee bluebee is offline
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Location: San Jose, California
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Mein Auto: 02 BMW 525i M54 auto 130K
For the cross-linked record, In addition to post #146 of this thread here is another text DIY, this one for a 2003 530i posted here today:
- E39 (1997 - 2003) > 530i Alternator Replacement Help !

Originally Posted by jotscan View Post
Disconnect the negative battery terminal.

Disconnect connector and positive battery terminal from alternator.

Move the air intake muffler / hot film mass meter unit:
Remove the bolt (10mm hex socket) holding the air intake muffler to the car body. Loosen 2 big clamps holding the hoses, one at the engine end (hot film mass meter) and one at the bumper end (air intake muffler).

Disconnect the electrical connector from the hot-film mass meter.

Difficult to remove the vacuum control hoses, best left alone.

Gently jiggle the rubber parts out of their positions.

Rotate the assembly on top of the engine.

Only the air intake muffler / hot film mass meter was moved out of the way to access the alternator.

It is best to remove the shroud and impeller to provide more room and prevent damage to the driver side headlight. Damage to the headlight is a high probability since the access is at this side.

Off load the belt from the alternator using a Torx T50 socket driver (Snap-On Tools #FTX50SE) and short ratcheting wrench turning clockwise (push down) on the tensioner pulley.

Remove alternator’s top and bottom bolts using 16mm or 5/8” hex sockets.
Top bolt is 150mm (approximately 6”) long (idler support). Part #071 199 046 77

Bottom bolt is 125mm (approximately 5”) long (sliding bushing nut). Part #071 199 006 30
PD (Pitch Diameter) shank with captive washer.

Remove bottom bolt first using the long 16mm socket.
It may be difficult to remove the top bolt since the sliding bushing nut was clamped down tight on the clevis caused when the bolt was tightened down.

Retract the sliding bushing nut using a puller.
Puller parts list:
30mm Socket- ½” Drive (Snap-On #TWM30)
M10-1.5 fully threaded hex bolt of the appropriate length. Length based on the thrust bearing washer thickness used. 75mm long bolt used for this system
Washers and thrust bearing.

Remove top bolt.

Pull alternator out. It should be easy. If it is tight, the sliding bushing nut may still be against the clevis fitting.

Ensure the sliding bushing nut is flush with the alternator clevis hole. Slide the alternator in and install the lower bolt. There should be some play before the bolt is tightened. When the bolt is tightened, it will pull the sliding bushing nut to close the gap. Do not tighten.

Install and tighten the top bolt.

Tighten the bottom bolt.

Attach the alternator electrical connections.

Install the belt. Check to make sure belt was installed correctly.

Install the air box assembly, clamps and bolt.

Connect the hot-film mass meter electrical connector.

Partial list of tools used:
Torx T50 socket – 3/8” drive
16mm socket (1 inch long) – 3/8” drive
5/8” socket (2-1/2 long) – 3/8” drive
(5/8 = .625; 16mm = .630”)
Flex handle socket wrench driver – 3/8” drive
16mm ratcheting box wrench
16 mm box wrench
Attached Thumbnails
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Please read the suggested threads and add value, either by pictures or by descriptions, so the next person stands on your shoulders.
See also: E39 Bestlinks & How to easily find what you need
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