Seat BMW 525i 2001 E39 Repair Manual

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Rear Suspension
- Remove exhaust system. See 180 Exhaust System.
- Detach driveshaft from differential. See 260 Driveshaft.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect brake fluid hose. See
340 Brakes.
- Remove left and right ABS sensors from wheel bearing car-
riers.
Disconnect parking brake cable from brake shoe expander.
See 340 Brakes.
Remove heat shield from above driveshaft
If equipped, remove ride height sensor connectors
CAUTION-
Models with air springs: Disable air supply pump by discon-
necting electrical plug before performing any repairs. Pump is
locatedbeneath a coverunder
thespare tire in the floorof the
carqo compartment.
Models with air springs: Loosen compressed air pipes (ar-
rows) at air distribution assembly to release system pres-
sure.
WARNING -
Vehicle will lower when the air pipes are opened. 1
- Working underneath rear suspension, lift wheel bearing car-
rier to relieve rear spring tension. Then unbolt air spring
mounting bolt from seat on wheel bearing carrier.
4 Support final drive unit from below using transmission jack
(BMW special tools 00 2 030 and 33 4 390 or equivalent).
NOTE-
Special tool 33 4 390 will need modifications to cradle the fi-
nal drive properly
4 Remove right and left suspension trim panels (arrow),

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330-30
I Rear Suspension
Remove right and left lower strut mount bolts (arrow).
Remove rear suspension subframe by removing 4 mounting
bolts
(arrows).
Carefully lower rear suspension subframe away from body to
remove.
To install, jack
subframe into position. Install and t~ghten sub-
frame mounting bolts. Note that on each bolt, rubber-coat-
ed detent plate
(arrow) must be installed at rear in driving
direction.
Models
w~th coil springs: Fit springs correctly in lower
spring seats.
Models with air suspension: Fit eccentric lug at bottom of
air
sprlng in recess of wheel carrier spring seat.
Tightening torques
-
Air spring to wheel bearing carrier 20 Nm (1 5 ft-lb)
Rear subframe to body (M12) 163 Nm (120 ft-lb)
-

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330-36
l~ear Suspension
- Working underneath rear suspension, lift wheel bearing car-
rier to relieve rear spring tension. Then unbolt air spring
mounting bolt from seat on wheel bearing carrier.
- Models with rear coil springs: Remove cargo compartment
floor carpet.
Working at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside
coii
spring from under car.
< Working from underneath, position BMW special tool 33 2
301
between 2nd and 3rd spring coii from bottom.
Make sure tooi recess faces upward.
Working in cargo compartment, guide
BMW special tooi 33
2 304
from above and thread into special tool 33 2 301.
4 Working 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 coil
lifts off sprrng seat on wheel
bearing carrier.

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330-39
I Rear suspension1
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Models with coil springs: Fit spring correctly in lower spring
seat.
* Models with air suspension: Fit eccentric lug at bottom of
air spring in recess of wheel carrier spring seat.
Always use new self-locking nuts.
- Make sure all threaded bolts, nuts and mating surfaces are
clean.
a Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Stake axle collar nut afler tightening.
Tightening torques
ABS pulse sensor to wheel bearing 8 Nm (6
ft-lb)
carrier
Air spring to wheel bearing carrier 20 Nm (15 ft-lb)
Brake rotor to hub 16 Nm (12
it-lb)
Rear axle shaft to hub (M27) 300 Nm (221 ft-lb)
Rear brake pad carrier (caliper) to wheel 65 Nm (48 ft-lb)
bearing carrier
Road wheel to hub
120ilONm
(89 k7 ft-lb)
Swing arm to wheel bearing carrier 256 Nm (189 it-lb)
Upperfrontcontrol arm (traction strut) to 65 Nm (48 ft-lb)
wheel carrier
Upper rear control arm to wheel carrier 142 Nm (105 ft-lb)
Rear wheel bearing, replacing
< The rear wheel bearing is integrated with its mounting flange.
1. Torx bolt
2. Wheel bearing and mounting flange
3. Wheel hub
4. Collar nut
- Raise rear end of car and remove wheel.
WARNING -
Make sure the car is firmly supported on jaclc stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.

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/Final Drive
4 Remove final drive input flange using BMW special tools 31
2 101,31 2 102,31 2 103 and 31 2 104 or equivalent.
Using BMW special tool
00 5 010 or equivalent remove seal
from final drive housing.
1
4 Drive new seal into place until its fully seated using BMW
special tools
00 5 500, 33 3 440 and 33 3 470 or equivalent.

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Final Drive
Front final drive mount
4 Remove front final drive mount using BMW special tools 33
3312,333314, 333315,334161
and334162.
I i 4 Coat bearing sleeve in rear axle carrier and rubber mount
with
~ircolight~ anti-friction agent.
Slide rubber mount from side with large diameter into
BMW special tool 33
4 165.
Milled recess
(A) makes firm contact with rear axle carrier
when top rubber mount is tightened down.
The
slolled srde ot r11e rubber mounl must be ar r#ghl angles
lo
rhe groove rn specal roo/ 33 '1 165 and shoulo be lrghrened
I down ~ransversely across the vehicle axis. I
Draw rubber mount in firmly with BMW special tools 33 3
314,333315,334164,334165and334166.
NOTE-
Male sure special tool 33 4 166 is properly seated.
0 Rubber mount must locate flush in rear axle carrier. If nec-
essary, rotate special tool
33 4 164 through 90" and draw
in overlap.
- Remainder of installation is reverse of removal

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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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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

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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 driver's
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 driver's seat.
- Remove driver's seat. See 520 Seats.
- Lateral acceleration sensor (1 998 models): Remove lower
lefl door pillar trim (driver's
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.

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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)