Honda Bmw 5 Service Manual
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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 M62 TU ASS 4402 Automatic transmission identification metal ID plate is mount- ed to body of transmission. 4 GM transmission ID tag (arrow) is on left side of transmission housing, behind transmission selector cable, just above transmission pan. < ZF transmission ID tag (arrow) is on left rear of transmission, just above transmission pan.
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 Life-Time Oil). See 240 Automatic Transmission. CAUTION-- If in doubt as to the type of fluid installed in a particular trans- mission, consult an authorized BMW dealer service depari- ment for the latest in operating fluids.
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 Transmission pilot bearing. replacing .... 210-1 5 Clutch. installing (non-SAC components) . 210-1 6 Clutch. installing (new SAC components) . 21 0-17 Clutch. install in^ (used SAC components) 210-19 Clutch Mechanical ................. .21 0.9 self-adjusting crutch (SAC). breaking in : . 210-21 ..................... Clutch variations .21 0.9 ................... Clutch. removing .21 0.1 1 Clutch components. inspecting ........ .21 0.1 1
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 techniques are required for clutch re- pairs. Be sure to read a procedure through before beginning a job. < Flywheel loclting tool (V-8 models) 1 (Tool NO. 11 2 070) - 4 Flywheel loclting tool (6 cylinder models) (Tool No. 1 1 2 170) - < Pilot bearino removal tools 11 11 2350 < pilot bearing instaation (Tool No. 11 2 350) tool
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 with the clutch hydraulics. In these circum- stances it is best to star? with a clutch fluid flush, followed, if necessary, by replacement of the hydraulic parts. NOTE- The clutch hydraulic system shares the fluid reservoir and flu- id with the brake hydraulic system. Clutch hydraulic system, bleeding and flushing If the clutchlbralte fluid is murky or muddy, or has not been changed within the last two years, flush the system and change the fluid. Flushing the old fluid from the clutch lines is done using a bralte system pressure bleeder. - Remove brake fluid reservoir cap. Using a clean syringe, re- move brake fluid from reservoir. Refill reservoir with clean DOT 4 bralte fluid. Worlting inside engine compartment, remove left interiorven- tilation filter housing: Release 3 plastic taps (A) on duct. Earlier models use a single release latch. Rotate duct inward to remove. Disconnect electrical harness to hood position switch. Remove filter housing cover. Release spring lock (B) on interior ventilation housing and remove housing.
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 surfaces and wash with wa- ter, as brale fluid will remove paint. Always use new brake fluid from a fresh, unopened container. Brake fluid will absorb moisture from the air. This can lead to corrosion problems in the clutch and brake hydraulic systems, ;nd will also lower the brake fluid boiling point. Dispose of brale fluid properly. - Raise and safely support vehicle. WARNING- Make sure the car is stable and well supported at all times. Use a professional automotive lift orjackstands designed for the purpose. A floor iack is not adequate support. - If necessary, remove transmission splash shield. Hydraulic system, bleeding Worlting underneath transmission, connect a hose from clutch slave cylinder bleeder valve (arrow) to a container. Open bleeder valve and allow bralte fluid to expel until clean fluid comes out, free of air bubbles. Close bleeder valve and disconnect pressure bleeding equipment from fluid reservoir. Slowly operate clutch pedal about 10 times. Fill reservoir with clean fluid as necessary. CR* .,,, .rP,ll,h.:I,,~,~mn.lI,i,,i
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 bubbles. * Close bleeder valve and disconnect pressure bleeding equipment from fluid reservoir. Slowly unscrew and detach special tool 21 5 030 from slave cylinder. CAUTION- Do not remove tool if hydraulic system is pressurized. - Reinstall slave cylinder. Tightening torque Slave cylinder to transmission case 22 Nm (1 6 ft-lb) - Slowly operate clutch pedal about 10 times. Fill reservoir with clean fluid as necessary. Clutch master cylinder, replacing The clutch master cylinder is mounted to the pedal assembly directly above the clutch pedal. Working inside engine compartment, remove left interior ventilation filter housing: Release 3 plastic taps (A) on duct. Earlier models use a single release latch. Rotate duct inward to remove Disconnect electrical harness to hood position switch. Remove filter housing cover. Release spring loclc (B) on interior ventilation housing and remove housing.
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) and pin from clutch pedal. 4 Remove master cylinder mounting bolts (arrows)
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 connector. Pull harness connector (8) off switch module. Use screwdriver to lever off switch module (C). - Installation is reverse of removal. CA UTlON- Switch module must snap firmly into place on the master cyl- inder during installation. Tightening torques Clutch master cylinder to pedal cluster 10 Nm (89 in-lb) Fluid line to master cylinder or slave cylinder 17 Nm (13 ft-lb) - Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as described earlier. Clutch slave cylinder, replacing 4 Working inside engine compartment, remove left interiorven- tilation filter housing: Release 3 plastic taps (A) on duct. Early models: release latch. Rotate duct inward to remove. Disconnect electrical harness to hood position switch. Release spring lock (B) on interior ventilation housing and remove housing. - Pinch off brake fluid supply hose to clutch master cylinder us- ing BMW special tool 13 3 01 0 or equivalent hose clamping tool.