Honda Bmw 5 Service Manual

Different automatic  transmissions are used,  depending on 
model  and model  year 
and/orproduction date. All  of the  auto- 
matic  transmissions  are electrohydraulically  controlled  with 
five forward  speeds. Automatic  transmission applications are 
given  in the table  below. 
Automatic transmission  applications  Model  Year  Engine  Transmission 
526 from 911 999 M52 TU ASS 360R 
5251 from 312001  M54 ASS 3252 
5301 to 312001  M54 ASS 390R 
530i from 312001 M54 ASS 3252 
540i 
from 111 997...

The lubricant used varies, depending on transmission and 
model  year. Fluid application information is clearly marked on 
a  label  on transmission. 
On manual transmission, either  ATF (orange  label reads 
ATF-Oil)  or a special BMW lubricant (yellow label  reads MTF- 
LT 
I) is  used.  See 230  Manual Transmission. 
Automatic  transmission  is filled with either Dexron 
Ill ATF 
(black transmission  ID plate  reads  ATF-Oil),  or special  life- 
time  oil (green transmission ID plate  reads...

210 Clutch 
........................... General .21 0.2 
........................ Special tools  .21 0.2 
Clutch  Hydraulics ................. .21 0.4 
Clutch hydraulic  system. 
bleeding and flushing 
................. .21  0.4 
Clutch master cylinder. replacing 
........ .21 0.6 
Clutch  slave cylinder.  replacing ......... .21 0.8  Flywheel. removing 
and installing 
................... (6 cylinder engine)  210-12 
Flywheel. removing and installing 
(V-8 engine) ....................... 21 0-1 3...

1 Clutch 
This repair group covers replacement of clutch mechanical 
and  hydraulic components. 
BMW 5 Series models with manual transmission use a single 
disc hydraulically actuated clutch. 
Twoversions of  the clutch 
are used: 
1997 
5281 (6 cylinder)  uses traditional clutch  components. 
All  540i (V-8)  and 1998  and later 
6 cylinder models use a 
self-adjusting clutch (SAC). 
NOTE- 
See 200 Transmission-General for  transmission applica- 
tion information. 
Special tools 
Some special tools and...

4 Tom T60 socket  for V-8  flywheel bolt removal 
(Tool No.  1 1 4 180) 
4 Hose clamping tool 
(Tool No.  13 3 
01 0) 
4 Clutch  disc lining  gauge 
(Tool  No. 21 2 080) 
4 Clutch  disc centering  mandrels (non-SAC  clutch) 
(Tool  No. 21 2 
141,21 2 142,21 2 200,21 2 201) 
4 Clutch  disc alignment tools  (SAC clutch) 
(Tool  No. 00 5  500 (handle).  21 2 130  (drift)) 
4 SAC  tensioning  tool 
(Tool No.  21 2 170) 
4 SAC  locating ring 
(Tool No.  21 2 180)   

Tool for bleeding clutch  hydraulics (Tool No. 21 5 030) 
21 5 030 I 
The clutch  is hydraulically actuated by  the master and  slave 
cylinders.  With the self-adjusting  clutch 
(SAC), clutch disc 
wear is automatically  taken up through  the self-adjusting 
pressure plate  springs, making  pedal feel consistent through- 
out  the life  of the  clutch. 
A soft  or spongy  feel to the clutch  pedal, long pedal free-play, 
or  grinding  noises 
from the gears while shifting  can all indi- 
cate problems...

Anach pressure  brake bleeder to fluid reservoir  and  pump 
bleeder  a few  times  to pressurize hydraulic fluid system. 
CAUTION- 
* Do not  exceed 2 bar (29 psi) pressure at  the fluid resenfoil 
when bleeding or  flushing the hydraulic system. 
Brake fluid is poisonous, highly corrosive and danger- 
ous to  the environment.  Wear safety  glasses and 
rub- 
bergloves  when working with brake fluid.  Do not  siphon 
brale  fluid  with  your mouth. Immediately clean  away 
any fluid  spilled on painted...

21 0-6 
1 Clutch 
Hydraulic system, bleeding 
(using 
BMW special  tool 21 5 030) 
4 Working underneath  transmission,  remove slave cylinder 
mounting  nuts (arrow)  from clutch  housing and remove 
cylinder. Leave fluid  line attached. 
4 Use  BMW  special  tool 21 5 030 to press slave cylinder push- 
rod completely  into slave cylinder. 
Hold  slave cylinder so that bleeder valve is  at highest point. 
Open  bleeder valve and allow brake fluid  to expel  until 
clean  fluid comes out, free  of air...

21 0-7 
Clutch 
- Remove brake fluid reservoir  cap. Using a clean syringe. 
remove brake  fluid from reservoir to below  level of clutch 
hydraulic supply  hose. 
- Detach clutch  hydraulic supply  hose from  brake fluid reser- 
voir.  Plug reservoir outlet and hose. 
4 Remove lower dash  trim panel fasteners (A) and (B). 
Lower trim panel  and disconnect wiring harnesses  on back 
side of panel. 
Remove trim  panel. 
4 Working under dash, remove clutch master cylinder pushrod 
retaining clip (arrow)...

21 0-8 
Clutch 
4 Remove hydraulic line locking clip (1) and  pull line (2) off 
master cylinder. 
CAUTION- 
. To  prevent brake fluidspill,  wrap clutch master cylinder  with 
shop rags  when removing hydraulic fluid lines from master 
cylinder. 
* Brake  fluid damages  paint andstains  carpets. Clean off 
any brake  fluid on or 
in the  car  immediately. 
- Remove  master cylinder  with supply  hose 
4 Remove switch  module from master cylinder. 
Press  locking button 
(A) to  release  harness...