Honda Bmw 5 Service Manual
Have a look at the manual Honda Bmw 5 Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 328 Honda manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
Brakes The brake booster is mounted to the bulkhead on drivers side of the engine compartment, directly behind the brake master cylinder. Intake manifold vacuum acts on a large diaphragm in the brake booster to reduce brake pedal effort. Brake booster check valve The checlc valve in the bralte booster vacuum line prevents contamination from engine backfires and other sources from entering the bralte booster. Location of check valve varies, depending on year and mod- el. 4 6-cylinder models (528i): 1. Intake manifold 2 Hose clamp 3. Vacuum line 4. Upper hose bracket 5. Grommet 6. From 911998: Check valve in grommet in booster. Remove left ventilation filter housing for access. 7. To 911 998: Check valve in vacuum hose. Remove left ventilation filter housing, peel back trim rubber below housing and unclip upper hose brackets to access hose clamps and valve. 8. Lower hose bracket 9. Brake master cylinder 10. Brake booster < 6-cylinder models (525i, 530i): Remove left ventilation filter housing to access checlc valve. 1. Vacuum hose 2. Hose clamp 3. Hose bracket 4. Check valve in grommet in booster 5. Braite master cylinder 6. Grommet 7. Brake booster 4 V-8 models (540i) to 911998: Check valve (arrow) in vacuum line behind left cylinder head. - V-8 models (540i) from 911998: Checkvalve in brake booster. Remove left ventilation filter housing to access valve.
Brakes - Pump brake pedal a few times to reduce vacuum in brake booster. This makes removal of check valve easier. - Remove or loosen hose clamp(s) at check valve. - Disconnect hoses. Remove valve to test or replace. NOTE- If valve is pressed into grommet in vacuum booster, pry it out carefully. - Reinstall valve using new hose clamps NOTE- Install the valve so that the molded arrow is pointing toward the intake manifold. Brake booster, removing and installing CAUTIO& All E39 vehicles sold in the USA are equipped with Antiloclc Braking System (ABS) and either Automatic Stability Control (ASC) or Dynamic Stability Control (DSC). In order for the bralchg and stability controls to work properk if brake fluid lines are disconnected and reconnected, male sure that the brake system is bled by an authorized BMW dealer or other qualified repair facility using the BMW Service Tester: See Brake Bleeding earlier in this group. - Disconnect negative (-) cable from battery. I CAUTION- I Prior to disconnecting the battery read the battery discon- nection cautions given in 001 General Cautions and I Warnings. I - Remove bralte master cylinder as described earlier. - Disconnect engine vacuum hose from bralte booster.
1 Brakes Pull down panel If applicable, disconnect electrical harness rows) from 16-pin OBD-ll plug. Remove panel from interior. connectors (ar- Working above and in front of pedals, remove locking clip (A) and slide brake booster pushrod off bralte pedal pin. Remove brake booster mounting nuts (6). Working in engine compartment, carefully separate bralte booster from engine compartment bulkhead. CAUTION- Do not use force on booster when separating from bulkhead. This can damage booster and pushrod. Remove booster by tilting out in direction of engine. Lift booster up and out of engine compartment. - Installation is reverse of removal, noting the following: Make sure all nuts, fluid couplings, thread bores and mat- ing surfaces are clean. Replace bralte booster self-locking mounting nuts. Replace sealing O-ring between master cylinder and bralte booster. Bleed bralte system as described earlier. CAUTION-- Do not over-torque tlie master cylinder mounting bolts. This could damage the bralce booster and prevent proper vacuum build-up. After 30 minutes of use recheclc the torque on bralce booster mounting nuts. Tightening torques Brake master cylinder to brake booster 26 Nm (19 it-lb) Brake booster to bulkhead 22 Nm (16 it-lb) (Recheck torque after 30 minutes of use.) Brake fluid line to master cylinder 18 Nm (13 it-lb) NOTE- When replacing the brake booster check valve or vacuum hose, install the valve so that the molded arrow is pointing to- ward the fntalce manifold. Use new hose clamps
Brakes Parking brake components 1. Clamp 2. Parking brake cable 3. Cable bracket 4. Grommet 5. Adjusting screw 6. Support 7. Shoe expander 8. Return springs 9. Parking brake shoe 10. Lock down spring 11. Shoe retaining pin 12. Adjuster Parking brake, adjusting The parking brake is a brake drum system integrated into the I rear brake rotors. It can be adjusted with the wheels installed, although the rear wheels will have to be raised off the ground. - Adjusting the parking bralte becomes necessary under the following circumstances: After replacing parking bralte shoes After replacing rear brake rotors Excessive stroke of parking brake handle required for ac- tuation (more then 10 clicks) After replacement of brake shoe adjuster or parking bralte cable(s) - Lift parking brake lever boot out of console. While holding ca-
340-23 Brakes - Using flat-bladed screwdriver, reach into brake drum through lug bolt hole. Turn brake adjuster until wheel no longer turns. Back adjuster off 12 notches. Parking brake adjusting (initial) Back off adjuster through wheel lug bolt hole 12 notches - Working inside car, set parking brake several times to seat cable. Then pull parking brake lever up two notches. Tighten cable adjusting nuts until it is just possible to turn rear wheels with slight resistance. - Release lever and make sure rear wheels turn freely - Turn on ignition. Pull up parlting brake lever 1 notch and make sure that parking bralte warning light comes on. if not, adjust parking bralte warning light contact switch. - Install parking brake lever boot. Install road wheel lug bolts. Tightening torque Road wheel to hub 120 i. 10 Nrn (89 i- 7 ft-lb) Parking brake shoes, removing and installing - Raise rear of car and remove road wheels. WARNING- Make sure that the car is firmly supported on jack stands de- signed for the purpose. Place jack stands beneath structural chassis points. Do not place jaclc stands under suspension parts. - Without disconnecting brake fluid hose, remove rear bralte calipers from trailing arms. Remove rear brake rotors as de- scribed earlier. CAUTION- Do not let the brake caliper assembly hang from the brake hose. Support caliper from chassis with strong wire. 4 Unhook return sprlngs (arrows) from brake shoes
340-24 Brakes 4 Remove brake shoe retaining pins using BMW special tool 34 4 000 or equivalent. Rotate retainer 114 turn to release. Spread shoes apart and lift out. 4 Note position of bralte shoe adjuster (arrow). Right side is illustrated. Left is mirror image of this. - Apply thin coat of grease to sliding parts and pins before re- assembly. - Installation is reverse of removal. Be sure to adjust parlting bralte cables as described earlier. Tightening torque Road wheel to hub 120 i lo Nm (89 i 7 ft-lb) Parking brake cable, replacing The parking brake is actuated by two separate Bowden ca- bles. Each cable can be replaced separately. - Working inside car, gain access to base of parking brake - handle by removing center console storage tray and center armrest, as necessary. 4 Use BMW special tool 34 1 030 or equivalent deep 10 mm socket to remove parlting brake cable loclc nuts (A) at base of parking brake handle. - Raise rear of car. WARNING - Male sure that the car is firmly supported on jack stands de- signed for the purpose. Place jack stands beneath structural chassis points. Do not place jaclc stands under suspension Darfs.
340-25 Brakes - Remove complete exhaust system as described in 180 Ex- haust System. - Remove center tunnel heat shield. < Pull parlting brake cable out of body guide tube (arrow) and detach from routing bracltets, noting correct routing for rein- stallation. - Remove parlting bralte shoes as described earlier. 4 Pull shoe expander (A) forward, disconnect parlting bralte cable (B) and remove expander. 4 Reroute new cable under car, attaching to bracltets (arrows). - Remainder of installation is reverse of removal. Adjust parking brake as described earlier.
1 Brakes ABS COMPONENT REPLACEMENT CA UTIOW- If the tires on the car are of different makes, the ABS/trac- tion controlsystem may overreact. Only fit tires of the same make and treadpattern. In adverse conditions, such as trying to rock the car out of deep snow or other soft surface, or when snow chains are fitted, it is advisable to switch off traction control and allow tlie car driveline to operate conven- tionally. All E39 vehicles are equipped with Antilock Braking System (ABS). Early production models featured ABS with Automatic Stability Control (ABS I ASC). Later models came equipped with ABS and Dynamic Stability Control (ABS / DSC). This manual will refer to these systems as ABS. ASC or DSC will be specified when necessary. For ABS system and component descriptions, see 300 Sus- pension, Steering and Brakes-General. Wheel speed sensor, replacing - Raise applicable end of car. Make sure that the car is firmly supported on jack stands de- signed for the purpose. Place jack stands beneath structural chassis points. Do not place jack stands under suspension < Front sensor: Unscrew mounting bolts (arrows) at steering knuckle. 4 Rear sensor: Unscrew mounting bolt (arrows) in rear wheel bearing carrier. NOTE- ABS wheelspeed sensor application may vary depending on traction control system installed.
4 Disconnect and remove speed sensor electrical harness (ar- row) from retaining mounts. (Lefl front wheel shown). - During installation, apply thin coat of StaburagsBNBU 12/K or equivalent grease to speed sensor and housing. - Installation is reverse of removal. Tightening torque ABS wheel speed sensor to steering knuckle or 8 Nm (6 It-lb) rear wheel bearing carrier ABS impulse wheel The front and rear impulse wheels are integral with the inner wheel bearing seal and not available as separate part. See 310 Front Suspension or 330 Rear Suspension for wheel bearing replacement procedures. DSC lateral acceleration or rotational rate (yaw) sensor, replacing DSC system on 1998 cars (Bosch DSC Ill v. 5.3): Lateral ac- celeration sensor and rotational rate (yaw) sensor are sepa- rate units, both mounted underneath or in front of drivers seat. DSC system on 1999 and later cars (Bosch DSC Ill v. 5.7): Lateral acceleration sensor and rotational rate (yaw) sensor are combined into one unit, located under drivers seat. - Remove drivers seat. See 520 Seats. - Lateral acceleration sensor (1 998 models): Remove lower lefl door pillar trim (drivers kick panel) to access sensor. Pull up carpet as necessary to reach sensor harness connector or fasteners. 4 Rotational rate (yaw) sensor (1998 models): Remove plastic trim at door sill to access sensor (arrow). Pull up carpet and move insulation forward as necessary to reach sensor har- ness connector or fasteners. - Combined lateral acceleration / rotational rate (yaw) sensor (1 999 and later models): Remove plastic trim at door sill to access sensor. Pull up carpet and move insulation forward as necessary to reach sensor harness connector or fasteners. - Disconnect electrical harness connector at sensor. - Combined sensor (1 999 and later models): Remove sensor bracket mounting screws.
340-28 Brakes - Remove sensor mounting screws. Lift sensor away from bracket. - Installation is reverse of removal. CAUTION- Be sure to tighten the DSC acceleration sensor(s) and mounting bracket, if applicable, to specified torques. The sensor is vibration sensitive and subject to cause DSC malfunctions if installed improperly. a After replacing the sensor, perform sensor adjustment using either DIS or MoDiC under Service Functions menu. Tightening torques Lateral acceleration I rotational rate sensor 8 Nm (6 R-ib) to bracket Sensor bracket to body 8 Nm (6 ft-lb) DSC steering angle sensor, removing and installing 4 Remove lower dash panel mounting fasteners (A) and (5). - Remove steering column lower trim panel. See 320 Steering and Wheel Alignment. Remove steering shaft clamping bolt (arrow). Disconnect sensor wiring harness connector.