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+.
Remove snap ring from steering shaft. - Slide steering angle sensor off steering shaft < Installation is reverse of removal, noting the following. Take care to line up loclting pin (arrow) with mount hole in sensor. Perform steering angle offset test using BMW scan tools DISplus, GT1, or MoDiC. Once calibrated, the sensor sends a confirmation ID code to the DSC control module to indicate proper calibration. DSC precharge pump, removing and installing (1 998 models) 1998 V-8 cars with Bosch DSC Ill v. 5.3 are equipped with a DSC precharge pump mounted in the engine compartment. There is no separate precharge pump in the Bosch DSC Ill v. 5.7 system (1999 models and later). WARNING- E39 cars require special BMWservice equipment to properly bleed the brakes. Removal of hydraulic components is not recommended unless this equipment is available. For safety reasons, the brake system on cars with ABS must be bled us- ing the procedures described in this repair group. - Using a clean syringe, empty brake fluid reservoir. CAUTIOI\C Brake fluid is highly corrosive and dangerous to the environ- ment. Disoose of it orooerlv. Working at precharge pump, disconnect hydraulic lines (A) and electrical harness connector (6). Clean up dripping fluid. hydraulic unit. Label all con-
1 Brakes - Remove precharge pump mounting bracket fasteners and re- move pump. - Installation is reverse of removal, noting the following: Be sure to replace rubber pump mounts if damaged 01 worn. Bleed brakes as described earlier. Tightening torque Brake line to precharge pump 18 Nrn (13 ft-lb) DSC pressure sensor (1 999 - 2002 models) On 1999 and later DSC systems, the DSC pressure sensor is screwed into the DSC hydraulic unit (right rear of engine com- partment). WARNING- * €39 cars require special BMW service equipment to prop- erly bleed the brakes. Removal of the DSCpressure sensor is not recommended unless this equipment is available. For safety reasons, the brake system on cars with ABS must be bled using the procedures described in this repair group. Switch off ignition and remove key to male sure brake system cannot be activated. - Disconnect electrical harness connector at switch. - Use BMW special tool 34 5 160 to remove and install sensor. Inspect threads and sealing surfaces for damage. * Work quicltly to avoid excessive brake fluid leakage. Tightening torque Pressure sensor to hydraulic 19 Nrn (14ft-lb) unit - Reconnect harness connector - Bleed front brakes as described earlier. - Press on brakes and check for leaks at sensor. - Turn on ignition and firmly depress brake pedal. Check that DSC warning light does not come on.
340-31 Brakes ABS 1 traction electronic control module (1 997 -1 998 models) 4 The traction control electronic control module in 1997- 1998 models is located to the left of the glove compartment. NOTE- In both ASC and early DSC systems this location is used for the electronic control unit. - Before removing the traction control electronic module, read any fault codes in memory. ABS I DSC control module (1 999 - 2002 models) The DSC electronic control unit in 1999 and later models (from 911998) is bolted to the DSC hydraulic unit in the right rear of the engine compartment. - Before removing the traction control electronic module, read any fault codes in memory. - Install electronic control unit using new screws. Tightening torque DSC electronic control unit to 2.9 Nrn (26 in-lb) hydraulic unit (use new screws) - Code newly installed module using either DIS or MoDiC. - Adjust steering angle sensor using menu item Service func- tion in DIS or MoDiC. ABS I traction control hydraulic unit, removing and installing WARNING - E39 cars require special BMWsewice equipment to properly bleed the brakes. Removal of the hydraulic unit is not recom- mended unless this equipment is available. For safety rea- sons, the brake system on cars with ABS must be bled using the procedures described in this repair group. NOTE- Before starting this procedure, read control module mem- ory and print out diagnostic record. DSC system: Adjust steering angle sensor using either DISplus, GTI, or MoDiC. After completing work, function test control module.
340-32 Brakes The procedure for removing the ABS I ASC or ABS I DSC hy- draulic unit is similar for all models. The unit is located at the right rear of the engine compartment. - Using a clean syringe, empty brake fluid reservoir. CAUTION- Brake fluid is highly corrosive and dangerous to the environ- ment. Dispose of it properiw 4 Disconnect electrical harness connector (A) at hydraulic unit (1998 DSC hydraulic unit in V-8 model shown). Where applicable, detach electrical harness connector to DSC pressure sensor. Mark brake lines (arrows) in relation to their placement on hydraulic unit. Detach lines from unit using appropriate sized flare wrench. Seal open brake fluid lines and bores with suitable plugs to prevent contamination. - Carefully push aside brake lines from retainerslgrommets that may be in the way of hydraulic unit removal. Use care not to kink brake lines. - Remove hydraulic unit mounting screws. Remove hydraulic unit. - If necessary, separate hydraulic unit from control module. - Installation is reverse of removal, noting the following: Check rubber mount for hydraulic unit/control module. Re- place if damaged. Make sure all nuts, fluid couplings, thread bores and mat- ing surfaces are clean. Avoid bending pins on control module harness connector when reattaching. Make sure brake lines are securely seated in grommets before installing brake lines in hydraulic unit bores. Bleed brakes using BMW Service Testeras described earlier. Tightening torques Brake lines to hydraulic unit 18 Nm (13 ft-lb) DSC electronic control unit to hydraulic unit 2.9 Nrn (26 in-lb) (use new screws) Hydraulic unit to body 8 Nm (6 ft-ib) Mounting bracket to hydraulic unit 8 Nrn (6 ft-lb)
400 Body-General ........................ General ........................... .40 0.2 Roof paddin~ 400-7 Body Assembly ................... .40 0.2 Body dimensions (in inches) ............ .40 0.2 Bodyshell ........................... 400-3 Exterior and aerodynamics ............. .40 0.3 Sport Wagon ...................... .40 0.4 Tailgate ............................ .40 0.5 Tailgate lock system .................. .40 0.5 Rear wiper system ................... .40 0.6 Antenna and sound system ............ .40 0.6 Safety and Security Features ....... .40 0.7 Safety cage ......................... .40 0.7 Door locks and door handles ........... .40 0.7 . ........................... Seat belts 400-7 Airbags ............................ 400-8 Battery safety terminal (BST) ........... 400-9 Security ............................ 400-9 Interior Features ................... 400-9 ............................. Seats 400-10 Instruments and controls .............. 400-10 Central body electronics .............. 400-1 1 Heating and Air Conditioning (IHKA) ............... 400-12
400-2 Body-General This chapter covers system descriptions and general infor- mation for the repair groups found in sections 4 Body and 5 Body Equipment. Body dimensions (in inches) E39 sedan E39 Sport Wagon
Body shell Exterior and aerodynamics Crash behavlor -frontal impact -side impact Body -rear impact Structural body components -rigidity -rollover -strength -vibrations -acoustics Bumpers compartment lid -bendable Seets,.steerlng system .dents -vibrations bars -vibration patterns Fenders -aerodvnamic With its traditional styling features, such as the ltidney grille. circular headlights behind a glass cover (for reasons of streamlining), and the kiclt in the rear most roof pillar (C-pil- lar), the E39 can be immediately recognized as a BMW. The BMW 5 Series chassis is a unibody design constructed of high strength steel. Attaching parts, such as the front fenders, rear quarter panels, doors, trunk lid and hood are also con- structed of steel. Computer aided design (CAD) techniques have been used in refining the E39 body to reduce vehicle weight while retaining strength and increasing torsional rigidity. For good handling purposes, the more rigid the structure the more precisely the suspension can operate. Wind resistance Windows bonded flush to the body and the guided flow of cooling air into the engine compartment provide the carwith a good coefficient of drag (Cd). E39 cars have been designed for balanced aerodynamics but not necessarily an extremely low Cd. See table below. Windshield wipers are designed for effectiveness at speeds up to and beyond 200 ltph (124 mph). Coefficient of aerodynamic drag (Cd) 6-cylinder sedan 0.30 V-8 sedan 0.31 6-cylinder Sport Wagon 0.31 V-8 Sport Wagon 0.33 Fenders The exterior panels are corrosion-resistant zinc coated (gal- vanized) steel. The front fenders are bolted on. For front fend- er replacement information, see 410 Fenders, Engine Hood.
400-4 I Bodv-General Bumpers The front and rear bumpers are clad in high quality deform- able plastic and, at solid barrier impact speeds of 4 kph (2.5 mph), provide protection with virtually no damage to the bumper orthe vehicle. In addition to hydraulic dampeners. which absorb the initial impact energy, these bumpers are backed by compressible tubes. These deform in a controlled manner at impact speeds greaterthan that forwhich bumpers and hydraulic dampeners are designed. This helps avoid ex- pensive damage to the body at impact speeds up to 14 kph (9 mph). The E39 Sport Wagon was introduced to the US market in 911 998 (model year 1999). It shares many components with the E39 sedan and is identical to it from the B-pillar forward. US marltet 5 Series Sport Wagons are available in two vari- ants: 6-cylinder (5251, 528i) powered by the 2.8 liter M52 TU en- gine (1 999) or the 2.5 liter M54 engine (2000 and later) * V-8 (540i) powered by the 4.4 liter M62 TU engine The wheelbase of the Sport Wagon is the same as the sedan. Howeverthe body is 30 mm (1.2 in) longer and 10 mm (0.4 in) higher. The Sport Wagon rear suspension was redesigned to elimi- nates the upper rear spring strut mounting on the E39 sedan. The use of separate coil springs and shoclc absorbers results in a flat, wide floor in the cargo area. See 300 Suspension, Steering and Brakes-General. The self-leveling air spring suspension system (electronic height control or EHC) is standard on Sport Wagon V-8 mod- els and optional on 6-cylinder models. Sport Wagon cargo capacities are shown below. Sport Wagon load capacities Cargo capacity Rear seat up 909 liters (32.1 cu ft) Rear seat folded down I809 liters (63.9 cu ft) Load limit Cargo compartment 460 Kg (1014 lb) Roof I00 Kg (220 lb)
400-5 Body-General Tailgate The E39 Sporl Wagon tailgate is large with a low sill for easy cargo loading. The tailgate opens to an angle of 88 mea- sured from the rear roof pillar (D-pillar) and to a height of 2029 mm (79.8 in) measured from the ground to the upper edge of the raised tailgate. The rear window is bonded to a load bearing frame and can be opened separately from the main tailgate. Tailgatesupport gas springs are recessed into cavities in the roof. Tailgate lock system A mechanical tailgate lock cylinder is not used; the tailgate is opened by the unlock pad above the license plate, the remote tailgate switch located in the drivers kick panel, or via FZV (Iteyless entry) control. 4 An emergency release mechanism is incorporated into the latch assembly to open the hatch from the vehicle interior if a malfunction occurs. The tailgate lock assembly includes an automatic soft close (SCA) feature. The electrical operation of SCA is a function of central body electronics (ZKE Ill). The SCA actuator is locat- ed in the rear cowl panel below the tailgate. The actuator is controlled by a load relay in the General Module. A locking cam is mounted on an eccentric that is driven by the actuator. 4 The SCA cam always turns in the same direction to open or close the tailgate. The cam turns 180 to open or to close. When the cam turns in the up direction the notch in the cam SCA actuator pushes on a lever on the back of the latch in the tailgate. This mechanically unlocks the latch. The tailgate is raised up and can be opened.
. I Body-General 1 Rear wiper system The rear wiper assembly on the E39 Sport Wagon is a self- contained unit. The control electronics are integrated into the gear drive that is part of the motor assembly. The control elec- tronics contain two hall sensors, one forthe park position and one forthe end stop or to signal reverse direction of the wiper motor. - Wiperlwasher stalk switch / 4 - 3 502400100 4 The rear wiper is controlled through the stalk switch on the steering column. The switch includes the following functions: Intermittent rear window wiping Programmed rear window wiping interval Operation of rear window washer The wiper system automatically controls the following safety and convenience features: * Wiper interrupted when rear glass is opened Wiper interrupted if wiper arm is blocked Continuous wiping when vehicle is shifled into reverse Antenna and sound system 4 There are two diversity FM antenna amplifiers: FMI amplifier located in the rear window frame FM2 / FZV amplifier located in the lefl D-pillar The radio amplifier and CD changer are behind the side ac- cess panels in the cargo compartment: CD changer on lefl side Sound system subwoofer on right side The subwoofer has a hold down knob and is mounted on a hinge. It can be swung out to access the batteryand fuse pan- el by unscrewing the knob.