ABS Modul BMW 525i 2001 E39 User Guide

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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

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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

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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-
85'C (185°F) for Ions periods of time (approx. 2 hours)

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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-

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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.

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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)

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520-5
Seats
1
4 Release mounting tabs (arrows) and remove switch module.
Front seat, removing and installing
- Turn ignition switch to OFF position.
Remove front and rear rail trim panels:
Raise center of trim panel
(A) to release loclting pin.
Unlock and lift out inner mounting clips tabs
(6).
Slide trim panel off rail (arrow) to remove.
< Remove seat belt mounting fastener (arrow) from seat
frame.

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INDEX 'tl
WARNING
Your common sense, good
judgemenl, and general alertness are
crucial to sale and successiul service
worlr. Belore attempting any work on
your
BMM be sure lo read 001
General Warnings and Cautions
and the
copyriglll page at the front 01
the manual. Review these warnings
and
caulions each lime you prepare
lo work on your BMW. Please also
read any warnings and cautions that
accompany
tile procedures in the
manual.
312-way valve (running losses)
see Fuel tank
Abbreviations, commonly used 600-14
ABS (antilock brake system)
see
Bral(es
A/C air distribution motors
see stepper motors (below)
blower final stage (resistor pack),
replacing
640-16
blower, removinglinslalling
640-1 5
compressor, replacing
640-24 condenser, replacing 64045
control panellmodule, removing1
installing
640-1 1
evaporakr, removinglinstalling 640-29
evaporator temperature sensor
640-12 expansion valve, removinglinstailing
640-27
IHKA/ IHKR system description 640-5
receiveridrier, replacing 640-26
stepper motors 640-1 3 ventilation microiilter, replacing
020-22. 640-17
see also Heating
Accelerator
iinlcage
see Maintenance
Activated carbon canister
see Fuel tank
ADS (auxiliary throttle valve)
130-57
Air compressor
330-44
Air conditioning
see
AIC
Air distribution (flap) motors
seeNC, stepper motors
Air filter see Maintenance
Air spring
300-6, 330-12
Airbag system (SRS)
2-stage
airbag 721-4
control module, replacing 721-7 driver airbag, removinglinstalling
721-8
iiead protection airbag 721-12 components 721-1 1
indicator
lighl721-4
passenger airbag, removinglinstalling
721-9 side-impact airbags crash sensor,
replacing
721-7
Airflow sensor see 130 under appropriate
fuel
injection system
Air pump
see 130 under appropriate fuel
injection system, secondary air
injection system
Air suspension
see Electronic height control
(EHC)
Alarm
see Anti-theft alarm
Alignment see
Wheei alignment
Aluminum suspension components
300-2
Antenna 650-6
Alternator see Battery, starter, alte rnator
Amplifier
650-4
Anti-theft alarm (DWA)
515-24 emergency disarming 515-31
Antifreeze (engine coolant)
see Maintenance
see also Cooling system
Antilock brake system (ABS) see Brakes
ASC see Brakes
ATF (automatic transmission fluid)
see Automatic transmission
see also Cooling systern
Automatic headlight adjustmenl
(LWR) see Lights
Automatic seat belt tensioner
720-4
Automatic shiftloclc
see
Gearshift
Automatic transmission
applications
200-3, 240-4
ATF 020-10, 200-4
capacity 240-8 checking 240-6
drainingifilling 240-7
heat exchanger 170-5
fluid pan and strainer 240-9 gearshift
see Gearshift
ID tag
200-3 range switch 610-6
removaliinstallation 240-10
steptronic see Gearshift
Auxiliary cooling fan
see
Coollng system, electric Ian
Auxiliary throttle valve (ADS)
130-57
Axle joint
see Drive axle
Back-up light switch
automatic transmission see Automatic transmission. range switch
- .~.~~~
manual transmission 230-8 -
- I

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2 INDEX
Battery, starter, alternator
alternator (generator)
121-10
6-cylinder engine, removingi
installing 121-15
M62 engine 121-16
M62 TU engine (water cooled)
121-18
battery
121-5 charging 121-9
safety terminal 121-3
testing 121-5 charging system, troubleshooting
121-12
starter
121-1 9
6-cylinder engine, removingi instaliinq 121-20 . V-8 engine, rernovinglinsialiing
121-21
solenoid, removinglinstalling
121-23 troubleshooting 121-19
see also Maintenance
Bearing, wheel
see Front suspension
see also Rear suspension
Belts see Maintenance, drive belts
Blade, wiper
see Wipers and Washers
Blower motor see
A/C
BMW emblem
see Exterior trim
BMW special tools 010-18 see also special tools section at
beginning
of each repair group
Body dimensions 400-2
interior features
400-9 salety and security 400-7
Body side molding
see Exterior trim
Bonnet see Engine hood
Boot see Trunk
Brake fluid
020-24, 340-8
Brake fluid pressure sensor
340-30
Brakes
ABS, ASC or DSC system
300-12
component replacement 340-26
ASCIDSC switch
see Switches
bleeding
bralces 340-8
brake booster 340-1 9 bralce Dads. caiioers and rotors ,., 340-1 1
descriotion 300-10
e~ectrdnic brake & stability 300-11
light switch
see Switches
master cylinder
340-16 pariking brake 340-22
troubleshooting 340-5
Bulbs see Lights
Bumper
lront 510-6 height, adjusting 510-12
rear 510-9
Bus system
600-4
Camber
320-33
Camshaft
removingiinslaiiing
M52 engine 116-12
M52 TU
/ M54 engine 116-1 9 M62 engine 11 6-39
wear
116-6
Camshaft position sensors
see ignition system
Camshaft timing chain
adjusting M52 engine
117-22
M52 TU I M54 engine 117-43
M62 engine 117-79 removinglinstalling
M52 engine 117-26
M52TU 1 M54 engine 113-46.116-
28
M62 engine 117-66
Capacities, fluid
020.10
Car rnemorvlicev memorv . . 600-10
see also Centrai
lociking
Carbon canister, activated
see Fuel
tank
Caster
320-33
Catalytic converter and oxygen sensor 020-19
see also Exhaust system: exhaust
manilolds
Cautions
001-3
CD changer
650-4
Center bearing, driveshaft
see Driveshait
Center brake light
sedan
630-13
Center console
513-3
Centrai body electronics (ZKE 111)
600-6
Central locking
car memoryiey memory 515.12 general module iunctions 515-2
remote entry (FZV) 515-8
remote lkey initialization 515-10 single lociddouble ioclk 515-6
switch 515-4
Chain
see Camshaft liming chain
Characteristic map (electrically heated) thermostat
see Electrically heated thermostat
Charging system
see Battery, starter, alternator
Cluster see instruments
Clutch fluid see Maintenance
hydraulics
210-4
mechanical 210-9
switch
see Switches, pedal ciuster
variations
210.10
Codes, fault OED-1
Coil
see Ignition system
Coil spring
see Front suspension
see also Rear
suspe nsion