Honda Bmw 5 Service Manual

							
331-17 
Final ~rivel 
4 Remove staked collar  nut and  press output  shaft out of wheel 
hub  with special 
BMW tool 33 2 11 111 161117. 
- Remove  drive axle 
- Installation  is reverse  of removal,  noting the  following: 
* Use a  new  collar nut. 
- Apply  a  light coating  of oil  to contact  face of collar nut  and 
install it  loosely. 
Install  road wheel  and lower  car to ground. 
* With  an assistant applying brakes, tighten  drive axle  collar 
nut  to its  final torque. 
Stake  collar nut. 
Tightening 
torques 
Drive  axle collar  nut to drive flange M24 
300 Nrn (221 ft-lb) 
Drive axle collar nut to drive flange M27 
300 Nrn (221 ft-lb) 
Drive axle to  differential flange 
M10x20 rnrn blaclc Torx bolt 83 Nrn (61 it-lb) 
- M10x20 rnrn silver Torx bolt loo Nrn (74 ft-lb) 
Road  wheel  to hub 
120 Nrn+lO (89tt-lbi-7) 
CV joint boots 
NOTE- 
When  replacing  a CVjoint  boot, use a complete  CVjoint 
boot  repair  kit. The  lit will include  a new  boot,  clamping 
bands,  special  lubricant,  and a new  inner  CV joint  circlip. 
The  lit is available  from an authorized 
BMW dealerparts 
department. 
The  outer  CVjoint  cannot be removed  from the axle 
shaft 
In order  to replace  the outer  CV boot,  it is  necessary  to re- 
move  the inner  joint and boot  first. 
If  the 
CVjoints are  worn  or defective, a complete  rebuilt 
axle  shaft  is available  from an authorized 
BMW dealer 
parts  department. 
- Remove appropriate  axle shaft.  See Drive axle, removing 
and  installing  (sedan), or Drive  axle, removing and in- 
stalling  (Sport Wagon). 
- Working with  axle shaft at bench,  cut off old  boot  clamps and 
remove  boot. Clean  old grease  off joint and shaft.  Use new 
grease from  CV joint boot kit. 
4 Remove  dust cover  from CV joint and remove circlip  (arrow) 
retaining  joint inner hub  to axle shaft.   
						

							
I Final Drive 
4 Support inner hub with  BMW  special tools 26 1 110 and 
press axle shaft out  of joint  using  BMW  special tool  21 2 120. 
- Clean  all  old lubricant  off shaft splines  and inner joint  splines. 
If  the  CVjoint  must be disassembled  for cleaning  and inspec- 
tion,  be sure  to matchmark inner and  outer race and interme- 
diate ball cage. This allows  reassembly 
ofparfs in their 
original positions. 
NOTE- 
To  inspect  a CVjoint,  clean away the grease and loolc forgall- 
ing, pitting,  and other signs  of wear  orphysical  damage. Pol- 
ishedsurfaces or visible ball traclts alone are  not necessarily 
cause  forreplacement.  Discoloration due to overheating indi- 
cates 
laclt of  lubrication. 
- Slide  CV joint  boot  onto axle  shaft 
- Apply LoctiteO270 or an equivalent heavy-duty loclting corn- 
pound  to drive  axle splines.  Position new CV joint  on shaft  so 
that  raised  or taller  side of hub  is facing  shaft. 
WARNING- 
Do not  let the locking compound contact  the balls  in the  joint. 
Apply  only a thin coat  to cover  the splines. 
While  supporting axle  shaft with BMW  special  tool 
33 2 130 
press  inner hub of CV joint  onto shaft.  Install  a new  circlip. 
- Install  new boot  clamps. 
- Use sealing  gel to seal dust cover  to CV  joint  prior  to reinstal- 
lation. 
NOTE- 
* Do  not let the ball  hub pivot  too  far in the outer  ring of the 
joint. 
Tlie balls  will fa1 out. 
Before installing  each small boot clamp  be sure to 
burpthe 
boot by flexing  the CVjoint. A small screwdriver inserted be- 
tween  the boot  and the axle  shafl  will help  the process. 
CV joint lubricant  capacity 
Wheel  hub end 
80 gram (2.8 oz) 
Differential  end 
85 gram (3.0 oz)   
						

							
General ........................... .34 0.2 
Special  Tools 
....................... .34 0.2 
E39 brake  system 
.................... .34 0.4 
Electronic braking and stability control 
.... .34  0.4 
Troubleshooting 
..................... .34  0.5 
Warnings  and cautions 
................ .34  0.7 
Bleeding  Brakes ................... .34 0.8 
Brakes, bleeding 
..................... .34  0.9 
Brake  Pads, Calipers  and Rotors ... .34 0.1 1 
Braking  system components .......... .34 0.11 
Brake pads, 
checking and replacing ..... .34  0.12 
Brake rotors, removing and installing 
.... .34  0.15 
Master Cylinder .................. .34 0.16 
Master cylinder, removing and installing 
. .34 0.17 
Brake  Booster .................... .349 0.1 
Brake  booster check valve 
............ .34 0.19 
Brake booster, removing and installing 
.. .34  0.20 
Parking  Brake .................... .34 0.22 
Parking  brake components 
............ .34 0.22 
Parking 
brake, adjusting .............. .34  0.22 
Parking bralte shoes, removing 
and  installing 
....................... .34 0.23 
Parking 
brake cable,  replacing ......... .34 0.24 
ABS  Component Replacement ..... 340-26 
Wheel  speed sensor. replacing 
......... 340-26 
ABS  impulse wheel 
.................. 340-27 
DSC lateral acceleration  or 
rotational rate (yaw) sensor. replacing 
... 340-27 
DSC  steering  angle sensor. 
removing and installing 
............... 340-28 
DSC  precharge pump. 
removing and installing (1998 models) 
... 340-29 
DSC pressure sensor 
(1 999 - 2002  models) ................ 340-30 
ABS  /traction  electronic control 
module 
(1 997  -1 998 models) .......... 340-31 
ABS 
/ DSC control module 
(1  999 
- 2002  models) ................ 340-31 
ABS 
/ traction control hydraulic  unit. 
removing and installing 
............... 340-31   
						

							
This repair group covers brake service: 
Brake pads, calipers,  and disks 
Master cylinder, bralte booster, and parking brake 
ABS 
1 ASC  and ABS / DSC  component replacement 
ABS 
1 ASC  and ABS 1 DSC system  descriptions are covered 
in 
300 Suspension,  Steering and Brakes - General. 
Special  Tools 
BMW requires  the use  of either the DIS  or the MoDiC diag- 
nostic tool to safely and completely bleed the 
brak~ng and 
traction control  systems. Read all procedures through before 
beginning a  job. 
< Parking bralte cable adjusting tool 
(Tool  No.  BMW 34 
1 030) 
4 Brake  piston  expander 
(Tool  No. BMW  34 
1 050) 
4 Bralte caliper bolt tool (7 mrn Allen) 
(Tool  No. BMW  34 
1 080) 
34 I 000 
34 1 090 < Steel wire brush 
7 (Tool No.  BMW 34 1 090)   
						

							
, Brake caliper bolt tool 
4 ASC bleeder wrench 
(Tool No.  BMW 34 
3 110) 
4 Brake line flare wrench  set (12 mm, 14 mm, 17 mm, 19 rnm) 
(Tool  No. BMW  34 3  150) 
34 3 152 
34 3 153 
34 3 154 
4 DSC Dressure sensor  installation socltet 
4 ABS IASC  or ABSI DSC control  unit 42-pin  harness  adapter 
(break-out adapter) 
(Tool  No. BMW  34 5 240) 
0 
(Tool NO. BMW  34 5 160)   
						

							
E39 brake system 
BMW E39 models are equipped with vacuum power-assisted 
four-wheel disc brakes with  an integral 
Antilock Brake System 
(ABS).  Single-piston calipers  act on vented  front and rear  ro- 
tors. A  brake pad wear sensor  for each axle indicates when 
brake  pads need replacement. The dual  drum-type parking 
brake system is integrated with the rear brake  rotors. 
Electronic braking and stability control 
E39 models were introduced with  Automatic Stability Control, 
a  computer controlled  traction control system  that uses  the 
AB5 system  in conjunction  with engine management controls 
to  control wheel spin during  take-off and maintain  vehicle sta- 
bility while braking. 
Added  in the 
1998 model  year was  Dynamic Stability Control 
(DSC).  This system implements wheel speed modulation 
throughout all  stages of driving.  For example, DSC is able  to 
reduce understeer by applying differing amounts  of braking 
force  to each  wheel,  or it can  override the  engine manage- 
ment  system during  hard cornering. 
A  summary  of distinguishing  characteristics  of the various 
systems is shown  in the table 
E39 electronic  braking and 
stability  control systems. 
For  ABS, ASC  and DSC system  and component  descriptions, 
see 
300 Suspension, Steering  and Brakes-General. 
WARNING- 
A car  with  electronic stability control  is still  subject  to normal 
physical  laws. Avoid  excessive speeds for  the road  conditions 
encountered. 
E39 electronic  braking and stability  control systems 
Year  (model) 
manuf.  up to 911998 
(528i, 540i) 
manuf.  from 911999 
(540i optional)* 
From 
911 999 
(ail  models)  System 
Automatic  Stability Control  (ASC) Identifiers 
Electronic control  module next to glove  compartment 
Hydraulic unit  in right  rear of engine  compartment 
No  precharge  pump 
Dynamic  Stability Control 
(Bosch  DSC 
Ill v. 5.3) 
Dynamic 
Stabil~ty Control 
(Bosch  DSC 
Ill v. 5.7)  Electronic 
control module  next to glove  compartment 
Hydraulic unit in  right rear of engine compartment 
Precharge  pump in left  front  of engine  compartment,  below steering 
fluid reservoir 
Separate  rotational  rate (yaw)  and lateral  acceleration  sensors 
Control 
modulelhydraulic unit in right rear  of engine compartment 
No  precharge  pump 
Combined  rotational rate (yaw)  and lateral  acceleration sensors   
						

							
Brakes 
Troubleshooting 
Brake performance is mainly affected by three things: 
Q Level  and condition  of brake fluid 
Ability  of bralte system to create and maintain pressure 
Condition  of friction  components 
Air  in bralte  fluid will 
make the brake  pedal feel spongy  during 
braking 
orwill increase  the bralte pedal force required  to stop. 
Fluid contaminated by moisture or dirt  can corrode  the sys- 
tem.  lnspect the brake  fluid inside the reservoir.  If it is dirty  or 
murky,  or is more  then two years old, replace fluid. 
To 
check the  function  of the  master cylinder  hold the bralte 
pedal  down hard with the engine running.  If the  pedal  slowly 
falls  to the  floor, either  the master cylinder  is leaking internal- 
ly,  or fluid is  leaking externally. 
lnspect the  rotors for glazing, discoloration and scoring. 
Steering  wheel vibration while  braking at speed  is often 
caused  by warped rotors, but  can also  be caused  by worn 
suspension components. 
When troubleshooting, keep  in mind that tire inflation, wear 
and temperature  can all have  an affect  on braking.  See 
300 
Suspension, Steering  and Brakes-General  for additional 
suspension  and brake  system troubleshooting. 
The  table  Brake system  troubleshooting  lists symptoms of 
brake  problems, probable causes, and suggested corrective 
actions. Unless  noted otherwise, relevant repairs  are de- 
scribed later in  this repair group.   
						

							
340-6 
1 Brakes 
Brake system troubleshooting 
/symptom I Probable  cause 1 Repairs 
Brake  squeal 
Pedal  goes to floor  when 
bralting 
Low pedal  after system bleeding 
Pedal spongy  or brakes work 
only when pedal  is pumped 
Excessive  braking effort 
Brakes pulsate, chatter  or grab 
Uneven 
bralting, car pulls  to one 
side,  rear braltes 
loclt 
Brakes drag, bind or  overheat Brake 
pad carriers dirty  or corroded  or 
pads loose (poor  fit) in pad  carrier 
Braite  pads heat-glazed  or oil-soaked 
Wheel bearings  worn (noise most 
pronounced when turning) 
Incorrectly Installed  brake  pads, 
parking bralte shoes,  or bralte  parts 
Brake fluid loss due to system leaks 
Master cylinder  or traction control 
system  faulty 
Master cylinder  faulty 
Air  in braite  fluid 
Master cylinder  or traction control 
system  faulty 
Brake  pads wet 
Brake pads 
heat-glazedorfluid-soalted 
Vacuum  booster or vacuum  hose 
connections  to booster  faulty 
--- Warped  brake rotors 
Brake  pads worn 
Brake pads heat-glazed  or oil-soaked  Remove 
brake pads and clean  calipers. Use original 
equipment  pads for proper fit and  use BMW  anti-squeal 
compound during  installation, 
Replace  brake pads. Ciean  rotors.  Replace leaking  caliper: 
as  required. 
Replace  worn bearings.  See 310 Front  Suspension 
or33C 
Rear Suspension. 
Check component  installation. Checldreplace anti-rattle 
springs. 
Checlt fluid  level  and inspect for signs  of leakage. 
Replace master cylinder. Diagnose  traction control system 
using factory  or compatible  diagnostic  tool. 
Replace master  cylinder. 
Bleed  system using  factory or compatible  diagnostic  tool. 
Replace master  cylinder. Diagnose  traction control system 
using factory  or compatible  diagnostic  tool. 
Use  light  pedal pressure  to dry pads while  driving. 
Replace 
bralte pads  and rotors.  Replace  leaking calipers. 
lnspect  vacuum lines.  Test vacuum booster and replace  as 
required.  Test vacuum  non-return  valve for one-way  flow. 
Resurface  or replace  rotors. 
Replace brake  pads. 
Clean  rotors.  Replace  leaiting calipers. 
Incorrect  tire pressures  or worn  tires 
Brake  pads on one side  of car heat- 
glazed  or fluid-soaked 
Caliper  or brake  pads binding 
Worn suspension components 
Brake  caliper  or brake  pads binding 
Master cylinder  or traction  control 
system  faulty  lnspect 
tire  condition.  Checlt  and correct tire  pressures. 
Replace  brake pads. Clean rotors.  Replace leaking 
calipers. 
Clean  and recondition  brakes. 
Inspect  for worn or  damaged suspension  components. See 
310  Front Suspension  or 330 Rear  Suspension. 
Ciean  or  replace caliper. 
Replace master  cylinder. Diagnose traction  control system 
using  faclory or  compatible  diagnostic  tool.   
						

							
Brakes 
Warnings and cautions 
WARNING- 
. E39 cars require special BMWsen/ice equipment toprop- 
erly  bleed  the  brake  hydraulic  system. See Bleeding 
Brakes for additional information. 
Semi-metallic  and metallic brake friction materials  in 
brake pads  or shoes  may produce dangerous  dust. 
Brake fluid is poisonous, corrosive and dangerous to 
the environment.  Wear safety glasses  and rubber 
gloves when worliing with 
bralie fluid. Do not siphon 
brake fluid with your mouth. Dispose  of brake fluid 
properly 
Do not reuse self-locking nuts, bolts  or fasteners.  They 
are designed to  be used  only once  and may  fail if re- 
used. Always replace  them with new  self-locliing  fas- 
teners. 
CAUTlOI\C 
Immediately clean bralie fluid spilled  on painted  surfaces 
and  wash  with water,  as 
bralie 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 
braking sys- 
tem,  and will also  lower the fluid boiling point. 
. Plug open lines  and brake fluid ports  to prevent con- 
tamination. 
Only tighten brake hoses on  front wheels 
with wheels 
in straight ahead position. 
If  carrying  out electric welding 
worlc, be sure to discon- 
nect electrical harness connector  from electronic con- 
trol module. 
Do  not  expose electronic control modules  to high sus- 
tained heat, such  as in a paint drying booth. Maximum 
heat exposure:-95°C (203 
OF) for  short  periods  of time- 
85C (185°F) for Ions periods of time  (approx. 2 hours)   
						

							
340-8 
1 Brakes 
Brake bleeding is usually  done for one  of two  reasons:  either 
to  replace  old brake  fluid as part  of routine  maintenance  or to 
expel trapped  air in the system that  resulted 
from opening the 
brake hydraulic  system during repairs. 
Read the 
Warnings listed  below  before beginning  the bleed- 
ing procedure  an on any 
E39 car. If air enters the  ACS or DSC 
hydraulic  unit, the factory  BMW Service  Tester MUST  be 
used  in conjunction  with a bralte pressure  bleeder before the 
vehicle  is driven. 
The  BMW 
ServiceTester (DISpluslGT1iMoDiC) must  be 
used  to bleed  the braltes  if: 
Any  hydraulic  brake system components are replaced,  in- 
cluding  bralte lines. 
Air  has enter the 
ABSIASC or ABSlDSC hydraulic unit. 
WARNING - 
* The  ASC  and DSC  systems use electronic controls  and a 
sophisticated  hydraulic unit Once  air enters  the hydraulic 
unit,  it is  very  difficult  to remove  using traditional  methods. 
For  this  reason,  pressure 
brake bleeding  should be done 
in  conjunction  with the BMW 
Sewice Tester (DIS- 
plus/GTl/MoDiC). The tester electrically cycles the  hy- 
draulic  unit solenoids  in the  hydraulic  unit while 
pressurized  brake fluid is forced through  the system. 
When  flushing  the brake  fluid from the  system, use ex- 
treme  care to not  let the 
brale fluid  reservoir  run dry If 
air enters  the hydraulic  unit, the BMW  Service  Tester 
MUST  be used  to bleed  the brale  system before  the 
vehicle  is driven. 
Always use new  brake fluid from an unopened container.  It is 
important  to bleed  the entire system when  any part  of the  hy- 
draulic  system  has been  opened. Be sure  to have  the special 
equipment  needed before  beginning the job. 
When bleeding  the 
braltes, start atthe wheel farthest from  the 
master  cylinder and  progress in the following order: 
right  rear brake 
left  rear brake 
* right front brake 
left front  brake