ABS BMW 323i 1993 E36 Service Manual

Brake
rotor,
removing
and
installing
.
.
.
.
.
.
.
.
340-7

MASTER
CYLINDER
............
.
.
.
.
.
.
.340-7

Master
cylinder,
removing
and
installing
.
...
.
340-7

GENERAL



TROUBLESHOOTING

WARNING
-

"
Although
semi-metallic
and
metallic
Brake
friction
materials
in
Brake
pads
or
shoes
no
longer
con-
tain
asbestos,
they
produce
dangerous
dust
.
"
Brake
fluid
is
poisonous,
highly
corrosive
and
dangerous
to
the
environment
Wear
safety
glasses
and
rubber
gloves
when
working
with
Brake
fluid
.
Do
not
siphonBrake
fluid
with
your
mouth
.
Immediately
clean
away
any
fluid
spilled
on
painted
surfaces
and
wash
with
water,
asBrake
fluid
will
remove
paint
.

"
Always
use
new
Brake
fluid
froma
fresh,
un-
opened
container
.
Brake
fluid
will
absorb
mois-
ture
from
the
air
.
This
canlead
to
corrosion
problems
in
the
brakingsystem,
and
will
also
low-
er
the
Brake
fluid's
boiling
point
.
Dispose
of
Brake
fluid
properly
.

"
Do
notreuse
self-locking
nuts,bolts
or
fasteners
.
They
are
designed
to
be
used
only
once
and
may
failif
reused
.
Always
replace
them
with
new
self-
locking
fasteners
.

BMW
E36
models
areequipped
with
vacuum
power-assist-

ed
four-wheel
disc
brakes
with
an
integral
Antilock
Brake
Sys-

tem
(ABS)
.
Single-pistoncalipers
act
on
solid
or
vented
front
rotors
and
solid
rear
rotors
.
A
brake
pad
wear
sensor
for
each

axle
indicates
when
brake
padsneed
replacement
.
The
dual

drum-type
parking
brakesystem
is
integrated
with
the
rear
brake
rotors
.

NOTE-

M3
models
havevented
directional
Brake
rotors
on
the
rearaxle
as
well
ason
the
front
.

340
Brakes

BRAKES
340-1

GENERAL
.
.
.
.
.
.
.........
.
.
.
..........
340-1



BRAKE
BOOSTER
.........
.
.
.
.
.
...
.
.
.
.
340-8

TROUBLESHOOTING
.......
.
......
.
...
340-1



Brake
booster,
removing
and
installing
....
.
.
340-8

PARKING
BRAKE
.
.....
.
...
.
.
.
.....
.
.
.
340-10
BLEEDING
BRAKES
.
.
.
.
.
.
.
.
..........
340-3



Parking
brake,adjusting
.
.
.
.
.
.
.
.
.
.
.....
.
340-10
Pressure
bleeding
brakes



Parking
brake
shoes,
removing
and
installing
.
340-11(except
cars
with
AST)
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.340-3



Parking
Brake
cable,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
340-11

BRAKE
PADS,
CALIPERS,



ANTILOCK
BRAKE
SYSTEM
(ABS)
.
.
.
.340-11
AND
ROTORS
..........
.
.......
.
.
.
.
.
.
.
340-3



ABS
System
Inspection
.
...
.
.......
.
.
.
..
340-12
Brake
pads,
replacing
............
.
.
.
.
.
.
.
340-4
ABS
wheel
speed
sensors,
replacing
.
.
.
.
..
340-12
Brake
caliper,
removing
and
installing
.
..
..
.
340-6

TABLES

a
.
Brake
System
Troubleshooting
.....
...
.
.
.....
.340-2
b
.
Brake
Rotor
Reconditioning
Specifications
.
.....
.340-7

Brakeperformance
is
mainly
affected
by
three
things
:
the
leve¡
and
condition
of
the
brake
fluid,
the
system's
abilíty
to
create
and
maintain
hydraulic
pressure,
and
the
condition
of
the
friction
components
.

Air
in
the
Brake
fluid
will
make
the
Brake
pedal
feel
spongy

during
braking
or
will
increase
the
Brake
pedalforce
required

to
stop
.
Fluid
contaminated
by
moisture
or
dirt
can
corrode
the

system
.
Inspect
the
Brake
fluid
inside
the
reservoir
.
Ifit
is
dirty
or
murky,
or
is
over
a
year
old,
the
fluid
should
be
replaced
.

Visually
check
the
hydraulic
system
startingat
the
master

cylinder
.
To
check
the
function
of
the
master
cylinder
hold
the

brake
pedal
down
hard
with
the
engine
running
.
The
pedal

should
feelsolid
and
stay
solid
.
If
the
pedal
slowly
falls
to
the

floor,
either
the
master
cylinder
is
leaking
internally,
or
fluid
is
leaking
externally
.
If
no
leaks
canbe
found,
the
master
cylin-
der
is
faulty
and
should
be
replaced
.
Check
all
Brake
fluid
lines

and
couplings
for
leaks,
kinks,
chafing
and
corrosion
.

Check
the
Brake
booster
by
pumping
the
Brake
pedal
ap-

proximately
10
times
with
the
engine
off
.
Hold
the
pedal
down
and
start
the
engine
.
The
pedal
should
fa¡¡
slightly
.
If
not,
check

for
any
visiblefaults
before
suspecting
a
faulty
brake
booster
.

Check
for
strong
vacuum
at
the
vacuum
hose
fitting
at
the

booster,
and
check
the
non-retum
valve
for
one-way
flow
.

Worn
or
contaminated
brake
pads
will
cause
poor
braking

performance
.
Oil-contaminated
or
glazed
pads
will
cause

stopping
distances
to
increase
.
Inspect
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
byworn
suspension
components
.

TROUBLESHOOTING

340-2
BRAKES

When
troubleshooting,
keep
in
mind
that
tire
inflation,
wear

and
temperature
can
affect
braking
and
suspension
.
See310

Front
Suspension
for
more
information
on
front
suspension

parts
inspection
.

Table
a
lists
symptoms
of
brake
problems,
their
probable

causes,
and
suggested
corrective
actions
.

Table
a
.
Brake
System
Troubleshooting

Symptom



1



Probable
cause



1



Repairs

Brake
squeal



a
.
Incorrectly
installed
brake
pads
or



a
.
Check
component
installation
.
parking
brake
shoes
b
.
Brakepad
carriers
dirty
or
corroded



b
.
Remove
brake
pads
and
clean
calipers
.
c
.
Brake
pad
anti-rattle
springs
faulty
or



c
.
Install/replace
anti-rattle
springs
.
missing
d
.
Brakepads
heat-glazed
or
oil-soaked



d
.
Replace
brake
pads
.
Clean
rotors
.
Replace
leaking
calipers
as
required
.
e
.
Wheel
bearings
worn
(noise
most



e
.
Replace
worn
bearings
.
See310
Front
Suspension
pronounced
when
turning)



or
330
Rear
Suspension
.

Pedal
goes
to
f
loor
when
braking



a
.
Brake
fluid
leve¡
low
due
to
system



a
.
Check
fluidlevel
and
inspect
hydraulic
system
for
leaks



signs
of
leakage
.
Fill
and
bleed
system
.
b
.
Master
cylinder
faulty



I
b
.
Replacemaster
cylinder
.

Low
pedal
after
system
bleeding



1
a
.
Master
cylinder
faulty



1
a
.
Replace
master
cylinder
.

Pedal
spongy
or
brakes
work
only



a
.
Air
in
brake
fluid



a
.
Bleedsystem
.
when
pedal
is
pumped



b
.
Master
cylinder
faulty
(interna¡
return



b
.
Replacemaster
cylinder
.
spring
weak)
c
.
Leaking
line
or
hose
unions



c
.
Repair
or
replace
lines
and
hoses
.
Bleed
system
.

Excessive
braking
effort



a
.
Brake
pads
wet



a
.
Use
light
pedal
pressure
to
dry
pads
while
driving
.
b
.
Brake
pads
heat-glazed
oroil-soaked



b
.
Replace
brake
pads
.
Clean
rotors
.
Replace
leaking
calipers
.
c
.
Vacuum
booster
or
vacuum
hose
con-



c
.
Inspect
vacuum
lines
.
Test
vacuum
booster
and
re
nections
to
booster
faulty



place
as
required
.
Test
vacuum
non-return
valve
for
one-way
air
flow
.

Brakes
pulsate,
chatter
or
grab



a
.
Warped
brake
rotors



a
.
Resurface
or
replace
rotors
.
b
.
Brake
padsworn



b
.
Replace
brake
pads
.
c
.
Brake
pads
heat-glazed
or
oil-soaked



c
.
Replace
brake
pads
.
Clean
rotors
.
Replace
leaking
calipers
.

Uneven
braking,
car
pulís
to
one



a
.
Incorrect
tire
pressures
or
worn
tires



a
.
Inspect
tire
condition
.
Check
and
correct
tire
pres-
side,
rear
brakes
lock



sures
.
b
.
Brake
pads
on
one
side
of
car
heat-



b
.
Replace
brake
pads
.
Clean
rotors
.
Replace
leaking
glazed
or
oil-soaked



calipers
.
c
.
Caliper
or
brake
pads
binding



c
.
Clean
and
recondition
brakes
.
d
.
Worn
suspension
components



d
.
Inspect
for
worn
or
damaged
suspension
compo-
nents
.
See
310
Front
Suspension
or
330
Rear
Sus-
pension
.

Brakes
drag,
bind
or
overheat



a
.
Brake
caliper
or
brake
pads
binding



a
.
Clean
or
replace
caliper
.(
b
.
Master
cylinder
faulty



b
.
Replacemaster
cylinder
.

WARNING
-

On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
ABS/AST
system
.
For
safety
reasons,
the
brake
system
on
carswith
ABS/AST
must
not
be
bled
using
the
procedures
described
inthis
repair
group
.

BLEEDING
BRAKES

Brake
bleeding
is
usually
done
for
one
of
two
reasons
:
Ei-
ther
to
replace
oíd
brake
fluid
as
part
of
routine
maintenance
or
to
expel
trapped
air
in
the
system
that
resulted
from
open-
ingthe
brake
hydraulic
system
during
repairs
.

BLEEDING
BRAKES

Alwaysuse
new
brake
fluid
from
an
unopened
container
.It

is
important
to
bleed
the
entire
system
when
any
part
of
the

hydraulic
system
has
been
opened
.
On
cars
not
equipped
with
traction
control
(AST),
brake
system
bleeding
should
be

done
with
a
pressure
bleeder
.
On
cars
with
AST,
brake
bleed-

ing
should
be
done
by
an
authorized
BMW
dealer
.

WARNING
-

On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
requíred
to
properly
bleed
the
ABS/AST
system
.
For
safetyreasons,
the
brake
system
on
carswith
ABS/AST
must
not
be
bled
using
the
procedures
described
inthís
repair
group
.

6
.
Remove
brake
pads
from
caliper
.
Where
applicable,
carefully
pry
pad
wear
sensor
from
pad
.
See
Fig
.
5
.

Fig
.
5
.



Removing
brake
pad
wear
sensor
.

7
.
Inspect
brake
caliper
for
signs
of
leakage
.
Check
that
the
caliper
piston
slides
smoothly
into
caliper
.
Replace
caliper
if
any
faults
are
found
.

CAUTION-

With
the
pads
removed,
residual
hydreulic
pres-
sure
may
cause
the
caliper
piston
to
slide
out
.
Use
a
wooden
block
to
hold
the
piston
in
place
.

8
.
fnsert
brake
pad
wear
sensor
into
cutout
in
new
pad

where
applicable
.

14
.
Place
inner
brake
pad
(with
locating
spring)
ontobrake
NOTE-



caliper
piston
.
Route
pad
wear
sensor
wiring
through
lf
the
brake
lining
indicator
light
illuminated
prior
to



caliper
opening
and
bleeder
dust
cap
.
brake
pad
replacement,
the
wear
sensor
should
be
re-
placed
.



15
.
The
remainder
of
installation
is
reverse
of
removal
.

"
Do
not
lubricate
guide
boits
.
9
.
Slowly
press
piston
back
into
caliper
.
Use
cace
not
to



"
Once
brake
assembly
is
installed
depress
brakepedal
damage
piston
dust
sea¡
.
See
Fig
.
6
.



severa¡
times
before
driving
vehicle
.

NOTE-

"
Open
caliper
bleeder
screw
when
pressing
piston



Tightening
Torques

back
into
caliper
.
Catch
expelled
fluidin
appropriate



"
Brake
caliper
to
brake
pad

container
.
This
procedure
is
highly
recommended
in



carrier
(guide
bolt)
..........
...
.
.
30
Nm
(22
ft-Ib)

the
case
of
cars
with
ABS
.



"
Road
wheel
to
hub



.....
.
..
100±10
Nm
(74±7
ft-Ib)

"
Open
the
bleeder
screw
only
when
applying
force
to
the
piston
.
Do
not
allow
airto
be
drawn
in
through
the
bleeder
screw
.

"
Pressing
the
caliper
piston
in
may
cause
the
brake
flu-
id
reservoir
to
overflow
.
To
prevent
this,
use
a
clean
syringe
to
first
remove
some
fluid
from
the
reservoir
.

BRAKES
340-
5

0012157
Fig
.
6
.



Brake
caliper
piston
being
pressed
into
caliper
to
make
room
for
new
pads
.
Usea
rag
toprotect
caliper
piston
and
seals
.

10
.
Thoroughly
clean
inner
and
outer
surfaces
of
brake
ro-
tor
.
Inspect
rotor
for
cracks,
signs
of
overheating
and
0012156
scoring
.

11
.
Measure
thickness
of
rotor
.
See
Table
b
.
If
rotor
does
not
pass
minimum
thickness
requirements,
or
is
dam-

aged,
replace
as
described
later
.

12
.
Thoroughly
clean
all
contact
points
on
caliper
and
brake
pad
carrier
.
Clean
guide
bolts
and
make
surethey
slide
freely

13
.
Lightly
coat
pad
contact
points
with
brake
anti-squeal
paste
.
Place
outer
brake
pad
onto
caliper
.
Applya
small
amount
of
grease
to
thetop
and
bottom
contact
points
where
the
caliper
contacts
the
pad
carrier
.

BRAKE
PADS,CALIPERS,
ANDROTORS

6
.
Disconnect
ABS
electrical
connectors
.
Label
and
then

disconnect
brake
lines
from
hydraulic
brake
unit
.
Plug

openíngs
.
See
Fig
.
12
.

~
~
A
1/
B
'1v
C
~
F

lu
11
-ri
J
.

0013244
A
.
Right
front



F



Front
from
master
cylinder
B
.
Leftfront



R
.
Rear
from
master
cylinder
C
.
Rear

Fig
.
12
.
Brake
fluid
linesat
ABS
hydraulic
unit
.

WARNING
-

"
On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
Antilock
Brake
System
(ABS)
.
Removal
of
the
ABS
hydraulic
unit
is
not
recommended
un-
less
this
equipment
is
available
.
For
safetyrea-
sons,
the
brake
system
on
cars
with
ABS
must

not
be
bled
using
the
procedures
described
inthis
repair
group
.

"
Do
not
mix
up
the
fluid
fines
at
the
ABS
hydraulic
unit
Label
all
connections
before
disconnecting
.

7
.
Remove
ABS
hydraulic
unit
from
engine
compartment
.

8
.
Working
inside
car,
remove
panel(s)
frombeneath

steering
column
to
access
pedal
assembly
.
See513
In-

terior
Trim
.

12
.
Make
sure
al¡
nuts,
fluid
couplings,
thread
bores
and

mating
surfaces
are
clean
.

BRAKES
340-
9

0011261

Fig
.
13
.
Brake
pedal
clevispin
and
retaining
clip
(A)
.
Brake
booster
mounting
nuts
shown
at
arrows
.

13
.
If
necessary,
mount
master
cylinder
to
vacuum
booster

using
a
new
O-ríng
and
newself-locking
nuts
.

CAUTION-

Do
not
over-torque
the
master
cylinder
mounting
bolts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

14
.
Installation
is
reverse
of
Rmoval
.

"
Bleed
brakes
as
described
earlier
.

"
Check
and,
if
necessary,
adjust
brake
light
switch

above
brake
pedal
.

Tightening
Torques

"
Brakemaster
cylinder
to

brake
booster
...........
.
..
..
...
26
Nm
(18
ft-Ib)

"
Brake
booster
to
bulkhead
.
.
..
..
...
22
Nm
(16
ft-Ib)

"
Brake
fluidline
to
master
cylinder
or

ABS
hydraulic
unit
.......
.
..
17-19
Nm
(13-14
ft-lb)
9
.
Remove
clip
and
clevis
pin
from
brake
booster
pushrod

and
disconnect
it
from
brakepedal
.
Remove
brake

booster
mounting
nuts
.
See
Fig
.
13
.
NOTE-

10
.
Working
in
engine
compartment,
remove
brake
booster



When
replacing
the
brake
booster
one-way
valve
or
together
with
master
cylinder
.



vacuum
hose,
install
the
valve
so
that
the
molded
arrow

is
pointing
toward
the
intake
manifold
.
Use
new
hose

11
.
If
booster
or
master
cylinder
O-ring
is
being
replaced,



clamps
.

disconnect
master
cylinder
from
brake
booster
.

BRAKE
BOOSTER

7
.
Turn
on
ignition
.
Check
that
light
comes
on
as
soonas



4
.
Remove
parkíng
brake
shoes
as
described
above
.

lever
is
pulled
up
.
5
.
Disconnect
cable
from
parking
brake
actuator
and
then

8
.
Install
parking
brake
lever
boot
.
Install
road
wheel
lug



remove
parking
brakecable
from
cable
holder
on
trail-

bolts
.



ing
arm
.
See
Fig
.
17
.

Tightening
Torque

"
Road
wheel
to
hub
.
..
......
100±10
Nm
(74±7
ft-Ib)

Parking
brake
shoes,

removing
and
installing

1.
Raise
rear
of
car
andremove
road
wheels
.

WARNING
-

Make
sure
the
car
is
firmly
supportedon
jack
stands

designed
for
the
purpose
.
Place
the
jack
stands
be-

neath
a
structural
chassis
point
.
Do
not
place
jack

stands
undersuspension
parts
.

2
.
Without
disconnecting
brake
fluid
hose,
remove
rear

brake
calipers
from
trailing
arms
.
Remove
rear
brake

rotors
.
See
Brake
Pads,
Calipers
and
Rotors
.

CA
UTION-

Do
not
let
the
brake
caliper
assembly
hang
from

the
brake
hose
.
Support
caliper
from
chassis
with
strong
wire
.

3
.
Unhook
upper
return
spring
from
brake
shoes
.
Remove

shoe
retainers
bypushing
them
in
and
rotating
1
/4turn
.

BMW
special
tool
no
.
344
000
can
beused
to
remove

retainers,
if
needed
.

4
.
Spread
shoes
apart
and
lift
them
out
.



7
.
Installation
is
reverse
of
removal
.
Adjust
parking
brake

as
described
earlier
.

NOTE-

When
removing
the
brake
shoes
the
shoe
expander
pivot
pin
in
the
brake
actuator
may
fall
out
.

Two
versions
of
the
Antilock
Brake
System
(ABS)
are
in-

5
.
Inspect
shoe
expander
to
make
sure
it
functions
prop-



stalled
onthe
cars
coveredby
this
manual
.
Early
cars
use
the

erly
.
Apply
a
thin
coat
of
grease
tosliding
parts
and



Teves
Mark
IV
G
ABS
.
Later
cars
use
the
Teves
Mark
20-I

pins
.



ABS
.
The
main
difference
between
the
two
systems
is
that
the

Mark
20-I
system
integrates
the
ABS
control
module
into
the

6
.
Installation
is
reverse
of
removal
.
Be
sure
to
adjust



hydraulic
unit
as
a
single
component
.

parking
brake
cables
as
described
earlier
.

ABS
is
designed
to
be
maintenance
free
.
There
are
noad
Parking
brake
cable,
replacing



justments
that
canbe
made
to
the
system
.
Repair
and
trouble-

shooting
of
the
major
ABS
components
requires
special
test

1
.
Raise
rear
of
car
and
remove
road
wheels
.



equipment
and
knowiedge
and
should
be
done
by
an
autho-

rized
BMW
dealer
.

2
.
Remove
rear
brake
caliper
and
rotor
.
See
Brake
Pads,

Calipers
and
Rotors
.

3
.
Working
inside
car,
lift
parking
brake
lever
boot
out
of

console
.
Remove
cable
adjusting
nut
.
Refer
to
Fig
.
15
.

Fig
.
17
.
Parking
brake
cable
insertion
point
in
rear
trailing
arm
(arrow)
.

6
.
Slide
cable
out
of
housing
.

NOTE
-

BRAKES
340-
1
1

On
some
models
it
may
be
necessary
to
remove
rear

muffler
to
access
the
brake
cabes)
.

ANTILOCK
BRAKE
SYSTEM
(ABS)

0013209

ANTILOCK
BRAKE
SYSTEM
(ABS)

340-
1
2
BRAKES

ABS
is
self-tested
by
the
ABS
diagnostic
unit
each
time
the
car
is
started
.
Once
the
test
is
complete,
the
ABS
dashboard
light
tucos
off
.
If
the
light
remains
lit
or
comes
on
at
any
time
during
driving,
a
system
fault
has
occurred
and
ABS
is
elec-
tronically
disabled
.
The
conventional
braking
systemremains
fully
functioning
.

ABS
Inspection

A
visual
inspection
of
the
ABS
may
help
to
locate
system
faults
.
If
no
visual
faults
can
befound
and
the
ABS
light
re-
mains
on,
have
the
system
diagnosedbyan
authorized
BMW
dealer
.

Carefully
inspect
the
entire
ABS
wiring
harness,
particularly

the
pulse
sensorharnesses
and
connectors
near
each
wheel
.

Look
for
chafing
or
damage
due
to
incorrectly
routed
wires
.

Carefully
remove
the
wheelspeed
sensors
.
Clean
the
sen-



Fig
.
18
.
Front
ABS
pulse
sensor
mounting
bolt
(arrow)
.
sor
tips
.
Inspect
the
toothed
wheel
on
thewheel
hub
.
Check
for
missing,
clogged
or
corroded
teeth,
or
other
damage
that
could
alter
the
clearance
between
the
sensor
tip
and
the
toothed
wheel
.

NOTE-

If
a
toothed
ring
is
damaged,
the
entire
wheel
hub
mustbe
reptaced
.
See
310
Front
Suspension
or330
Rear
Suspension
.

ABS
wheel
speed
sensors,
replacing

1
.
Raise
applicable
end
of
car
.

WARNING
-

Make
sure
thecar
is
firmly
supportedon
jack
stands
designed
for
the
purpose
.
Place
the
jack
stands
be-
neath
a
structural
chassis
point
Do
not
place
jack
stands
under
suspension
parts
.

2
.
Unscrew
wheelspeed
sensor
mounting
bolt
.
Remove
sensor
from
its
housing
.
See
Fig
.
18
.
Remove
harnessfrom
retaining
mounts
.

3
.
Front
ABS
sensor
:
Working
in
front
wheel
housing,
dis-
connect
and
remove
sensor
.
See
Fig
.
19
.

4
.
Rear
ABS
sensor
:
Working
in
rear
wheel
housing,
dis-
connect
andremove
sensor
.

5
.
During
installation,
apply
thin
coat
of
Molykote
0
Long-
term
2
or
an
equivalent
grease
to
pulse
sensor
and
housing
.

ANTILOCK
BRAKE
SYSTEM
(ABS)

0012122
Fig
.
19
.
Front
ABS
wheel
speed
electrical
connector
(arrow)
in
wheel
well
.

6
.
Installation
is
reverse
of
removal
.

GENERAL
.
.
.
.
.
.
.
.
.
...
.
..
.
...
.
.........
510-1



Front
bumper
impact
absorber,
replacing
....
510-4

Rear
bumper,
removing
and
installing



.....
.510-4

OUTSIDE
REAR
VIEW
MIRRORS
.
...
.
.....
510-1



Rear
bumper
impact
absorber,
replacing
...
.
510-6
Outside
mirrorglass,
replacing



.
.
.........
510-1



Bumper
height,
adjusting



...
.
...
.
...
.
.
.
.
.
510-6
Outside
mirror
housing,
removing
and
installing
....
.
.....
.
.
.
.
.
.
510-1



EXTERIOR
TRIM



...
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
510-6
Outside
mirror,
removing
and
installing
.
.
.
.
.
510-2



BMW
embiem,
removing
and
installing
.
.
.
.
.
.
510-7

Body
side
molding,
replacing



.
.
.
.
.
.
.
.
.
.
.
.
.
510-7
BUMPERS



.
.
.
.
.
....
.
.....
.
.....
.
.
.
.
.
.
510-3



Radiator
grille,
removing
and
installing
.
.
.
.
.
.510-7
Front
bumper,
removing
and
installing
.
.
.
.
.
.
510-3



Front
panel,
removing
and
installing
...
.
.
.
.
.
510-7

GENERAL

510
Exterior
Trim,
Bumpers

This
repair
group
includes
repair
information
for
the
outside

rear
view
mirror,
front
and
rear
bumpers,
and
the
easily
re-

movable
exterior
trim
parts
.

OUTSIDE
REAR
VIEW
MIRRORS

The
remove
controlled
mirrors
come
in
two
styles
:
heated
and
unheated
.
Many
of
the
mirror
components
are
separately

available
from
an
authorized
BMW
dealer,
including
the
glass

and
outside
plastic
housing
.

Outside
mirror
glass,
replacing

CAUTION-

Mirror
shouldbe
ator
above
room
temperature
before
removal
.
Otherwise,
small
plastic
parts
or
glass
will
break
.

1
.
Insert
thin
pry
tool
(wooden
or
tape-wrapped
screwdriv-

er)
between
bottom
mirror
edge
and
mirror
housing
and

carefully
pry
out
mirror
glass
from
housing
.
See
Fig
.
1
.

2
.
Heated
mirror
:
remove
heating
element
harness
con-

nectors
from
back
of
mirror
glass
.

3
.
Install
new
glass
into
position
by
pressing
firmly
until
it

snaps
into
place
.

EXTERIOR
TRIM,
BUMPERS



510-1

00130
..

Fig
.1
.
Prying
mirror
glass
out
of
mirror
housing
.
Note
screwdriver
shaft
wrapped
with
tape
.

Outside
mirror
housing,

removing
and
installing

1
.
Remove
mirror
glass
as
described
above
.

2
.
Remove
housing
retaining
screws
and
lift
off
rear
hous-
ing
.
See
Fig
.
2
.

3
.
Tilt
mirror
housing
forward
and
compress
plastic
retain-

ers
and
lift
off
front
housing
.
See
Fig
.
3
.

4
.
Installation
is
reverse
of
removal
.
Check
mirror
function

before
installing
covering
parts
.

OUTSIDE
REAR
VIEW
MIRRORS

BUMPERS

Front
bumper,
removing
and
installing

Refer
to
Fig
.
6
.
when
removing
and
installing
the
front
bumper
.

1
.
Raise
and
properly
support
vehicle
.

WARNING
-

Make
sure
that
the
car
is
firmly
supportedonjack
stands
designed
for
the
purpose
.
Place
the
jackstands
beneath
a
structural
chassis
point
.
Do
not
place
jack
stands
undersuspension
parts
.

2
.
Unclip
left
trim
strip
by
prying
gently
under
plastic
trim
at
front
of
bumper
.
Similarly,
unclip
towing
eyecoverfrom
right
side
.

5
.
Remove
bumper
cover
retaining
screws
in
front
wheel
3
.
Remove
four
mounting
nuts
from
bumper
mounts
(two



well
(left
and
right
sides)
.
See
Fig
.
8
.
nuts
on
eachmount)
.
See
Fig
.
7
.

4
.
Working
underneath
car,
removescrews
from
left
and
right
side
corner
trim,
then
remove
trim
.

Side
brackets

Bumper
cover

Fig
.
6
.



Front
bumper
assembly
.

EXTERIOR
TRIM,
BUMPERS



510-3

Fig
.
7
.



Front
bumper
mounting
nuts
(arrows)
.
Lefttrim
andtow
eye
cover
on
right
have
been
removed
.

6
.
Disconnect
harness
connectors
at
foglight
sockets
(if
applicable)
.

Side
corner
trim



Support
bracket

Impact
absorber

o



O
Foglight
support

LBumner
bracket
bolt

License
plata



0011944
bracket

BUMPERS

510-4



EXTERIOR
TRIM,
BUMPERS

Fig
.
8
.



Bumper
cover
retaining
screws
(arrows)
in
left
wheel
weil
.

7
.
Disconnect
harnessconnectors
at
outside
temperature



0013052

sensor
at
rear
of
left
side
of
bumperand
temperatura



Fig
.
9
.



Front
bumper
impact
absorber
mounting
nuts
(A)
and

switch
at
rear
of
right
side
of
bumper
(if
applicable)
.



bumper
bracket
hardware
(B)
.

8
.
Slide
bumper
straight
off
sida
brackets
.

9
.
Installation
is
reverse
of
removal,
notingthe
following
:



When
removing
and
installing
therear
bumper
or
its
compo-

"
Slide
side
brackets
on
bumper
and
body
carefully
to-



nents,
referto
Fig
.
10
.

gether
.

"
Make
sure
tabs
on
trim
strip
engage
slots
in
bumper



1
.
Raise
and
properly
support
vehicle
.

correctly
.

Tightening
Torque

"
Bumper
to
bumper

bracket
(M8
nut)
............
...
.
.
22
Nm
(16
ft-Ib)

2
.
Working
under
bumper,
remove
screws
or
expansion

Front
bumper
impact
absorber,replacing



rivetsat
corners
and
middle
of
lower
bumper
panel
.
Pull

panel
backward,
uncoupling
it
from
bumper
cover
.
See

Thebumper
mounting
bracket
and
impact
absorber
mount-



Fig
.
11
.

ing
hardware
are
accessible
with
the
Font
bumper
removed,
as
described
above
.
See
Fig
.
9
.



3
.
Remove
bumper
cover
expansion
rivets
and
screws
in-

side
left
and
right
rear
wheel
wells
.

NOTE
-

Install
the
bumper
bracket
boltwith
thread
locking
com-
pound
suchas
Loctite
8
270
or
equivalent
.

Tightening
Torques

"
Bumper
bracket
to
impact
absorber

(M10
nut)
.
..
.
...
.............:.
55
Nm
(41
ft-Ib)
"
Impact
absorber
to
chassis
(M6
nut)
...
9
Nm
(7
ft-Ib)

BUMPERS

Rear
bumper,
removing
and
installing

WARNING
-

Make
sure
that
the
car
is
firmly
supported
on
jack

stands
designad
for
the
purpose
.
Place
the
jack

stands
beneath
a
structural
chassis
point
.
Do
not

place
jack
stands
under
suspension
parts
.

4
.
Remove
left
and
right
bumper
bracket
mounting
bolts

and
remove
bumper
.
See
Fig
.
12
.

5
.
Installation
is
reverse
of
removal
.

NOTE-

Install
the
bumper
bracket
bolt
with
thread
locking
com-
pound
suchas
Loctite®270
or
equivalent
.

Fig
.
10
.
Rear
bumper
assembly
.

0013045

Fig
.
11
.
Expansion
rivet
at
corner
of
rear
bumper
lower
panel
(arrow)
.
Some
models
usescrews
.
Pull
panel
backward
to
disengage
from
bumper
cover
.

Tightening
Torque

"
Bumper
bracket
to
impact
absorber

(M10
bolt)
.
..
...........
...
.
..
..
42
Nm
(31
ft-Ib)

EXTERIOR
TRIM,
BUMPERS



510-5

0013047
Fig
.
12
.
Inserttool
through
rear
bumper
mount
bores
to
remove
mounting
bolts
(right
side
shown)
.

BUMPERS