Ac system BMW 540i 1998 E39 Workshop Manual

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Final Drive
Final drive, removing and installing
- Raise rear of car.
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the jaclc stands beneath struc-
tural chassis
~oints. Do not i lace iaclc stands under
( suspension barfs.
Remove exhaust system. See 180 Exhaust System.
Disconnect drive shaft from final drive. See
260 Driveshaft.
Remove drive axle CV joint bolts (arrows) at left and right
sides. Suspend drive axles from body using stiff wire.
4 Support final drive with BMW special tool 33 4 390.
* Remove front final drive mounting bolt.
Remove rear final drive mounting bolts
(2).
Carefully lower final drive unit.
- To install, use BMW special tool 33 4 390 to lift final drive into
place.
CA UTIOP&
The following sequence must be used when installing the fi-
nal drive to prevent torsion stress on the final drive during in-
Install mounting bolts and finger tighten only.
Remove final drive support.
Tighten both rear mounting bolts.
Tighten front mounting bolt.
NOTE-
Use new self-locking nuts.
- Check differential oil level. See Differential oil level, check-
ing.
- Remainder of installation is reverse of removal.

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Final Drive
Final drive input shaft seal, replacing
- Remove exhaust system. See 180 Exhaust System
- Remove drive shaft. See 260 Driveshaft.
< Lift out collar nut locking plate (arrow).
4 While counterholding drive flange with special BMW tool 23
23 0 020 0 020 loosen and remove collar nut.

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. .
Final Drive Final drive output shaft seals, replacing
- Remove exhaust system (if necessary). See 180 Exhaust
System.
Remove drive axle
CV joint bolts
axle from body using stiff wire. (arrows).
Suspend drive
4 Drive out final drive output flange using soft faced hammer.
4 Remove seal using BMW special tool 00 5 010 and 32 1 060
or equivalent.

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331-16
I Final Drive
Worlting at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring.
4 Worlting from underneath, position BMW special tool 33 2
301
between 2nd and 3rd spring coil from the bottom.
Make sure tool recess faces upward.
Worlting in cargo compartment, guide BMW special tool
33
2 304
from above and thread into special tool 33 2 301.
4 Worlting in cargo compartment, attach BMW special tools 33
2 302.33
2 303 and 33 2 305 to special tool 33 2 304.
- Use special tool 33 2 306 to compress spring.
Tighten until lower spring end lifts off spring seat on wheel
bearing carrier.
- Model with air springs: Loosen compressed air pipes at air
distribution assembly to release system pressure.
WARNING-
The vehicle will lower when tlie airpipes are loosened.
- Remove final drive. See Final drive, removing and install-
ing.

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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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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)

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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
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.

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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.

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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)