brake rotor BMW 525i 2001 E39 Workshop Manual

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020 Maintenance
General ........................... .02 0.2
Special tools ........................ .02 0.2
Service Interval Indicator (Sll) ........... .02 0.3
Service Interval Indicator (Sll), resetting ... .02 0.3
Inspection I, Inspection 11 ............... .02 0.5
Maintenance Tables ................ .02 0.6
Fluid and Lubricant Specifications .. .02 0.9
Fluids and lubricants ................. .02 0.10
Engine Oil Service ................ .02 0.1 I
Engine oil. checking level ............. .02 0.12
Engine oil and filter. changing .......... .02 0-13
Engine Compartment Maintenance . .02 0.14
Accelerator and linkage ............... .02 0.14
Air filter. replacing ................... .02 0.1 4
Cooling system service ............... .02 0.15
Engine drive belt service .............. .02 0.16
Idlespeed .......................... 020-19
Catalytic converter and oxygen sensors .. .02 0.19
Power steering fluid, checking level ..... .02 0.20
Spark plugs ........................ .02 0.20
Spark plugs, replacing ................ .02 0.21
Interior ventilation microfilter, replacing ... .02 0.22
Other Mechanical Maintenance ..... .02 0.22
Battery, checking. cleaning. and replacing .02 0-22
Brake fluid. replacing ................. .02 0-24
Brake pad 1 rotor wear. checking ........ .02 0.24
Brake system, inspecting ............. .02 0.25
Parking brake. checking ............... 020-25
Clutch fluid. checking ................. 020-26
Differential oil level. checking ........... 020-26
Drive axle joint (CV joint) boots. inspecting 020-27
Exhaust system. inspecting ............ 020-27
Fuel filter. replacing .................. 020-27
Fuel tank and fuel lines. inspecting ...... 020-28
Suspension. front. inspecting ........... 020-29
Suspension. rear. inspecting ........... 020-29
Tires. checking inflation pressure ........ 020-29
Tires. rotating ....................... 020-29
Transmission service. automatic ........ 020-29
Transmission service. manual .......... 020-30
Transmission fluid. checking and filling
(manual transmission)
................ 020-30
Wheels. aligning ..................... 020-30
Body and Interior Maintenance ..... 020-31
Body and hinges. lubricating ........... 020-31
Exterior washing ..................... 020-31
Interior care ........................ 020-31
Leather upholstery and trim ............ 020-31
Polishing ........................... 020-32
Seat belts .......................... 020-32
Special cleaning ..................... 020-32
Washing chassis ..................... 020-32
Waxing ............................ 020-32
Windshield wiper blade maintenance ..... 020-33

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020-24
Maintenance
tions. In general, replacement batteries should always be
rated equal or higher than the original battery.
The battery is held in place by a single hand screw and plate.
A secure battery hold-down is important in order to prevent
vibrations and road shoclt from damaging the battery.
CAUTION-
Prior to disconnecting the baitem read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
NOTE-
Always disconnect the negative (-) cable first, and connect
it last. While changing the battery, clean away any corro-
sion in or around the battery tray
More battery and charging system information is in 121
Battery, Alternator, Starter.
Brake fluid, replacing
Brake fluid absorbs moisture easily, and moisture in the fluid
affects bralte performance and reliability. This is why
BMW
strictly recommends replacing the bralte fluid every two
years. When replacing or adding bralte fluid, use only new
fluid from previously unopened containers. Do not use brake
fluid that has been bled from the system, even
if it is brand
new. Use only DOT
4 brake fluid.
NOTE-
See 340 Brakes for brake fluid flushing procedures.
Brake pad 1 rotor wear, checking
Disc brakes are fitted at all four wheels. Although the brakes
are equipped with a brake pad warning system, the system
only monitors one wheel per axle. Pad thickness should be
checked whenever wheels are off or brake
worlt is being
done.
4 Disc brake pad wear can be checked through opening in
caliper:
Measure distance
(A) of brake pad "eai' to bralte rotor.
See
340 Brakes. Compare to specification below.

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7 Maintenance
< Unbolt caliper from steering arm to properly inspect:
Brake pad thickness
(A)
Brake rotor
Condition of caliper seal
(B)
Condition of caliper slider bolts (C)
NOTE-
Brake caliper removal and installation procedures are given
in
340 Brakes.
Brake pad lining minimum thickness
Dimension
A 3.0 mm (0.12 in)
Brake system, inspecting
Routine maintenance of the brake system includes maintain-
ing the brake fluid in the reservoir,
checking bralte pads for
wear, checking parking brake function, and inspecting the
system for fluid lealts or other damage:
- Check that bralte hoses are correctly routed to avoid chafing
or
Itinking.
- lnspect unions and brake calipers for signs of fluid leaks.
- lnspect rigid lines for corrosion, dents, or other damage.
- Inspect flexible hoses for cracking
- Replace faulty hoses or lines as described in 340 Brakes.
WARNING-
Incorrect installation or overtightening hoses, lines, and
unions may cause chafing
orlealage. This can lead to partial
Parking brake, checking
The parking brake system is independent of the main braking
system and may require periodic adjustment depending on
use. Adjust the parking brake if the brake lever can be pulled
up more than
8 clicks. Check that the cable moves freely. A
description of the parking brake and
parlting bralte adjust-
ment can be found in
340 Brakes.

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300-1 0
/Suspension, Steering and Brakes - General
The steering system features variable power assist provided
by an engine-driven hydraulic pump.
Rack and pinion steering
6-cylinder models
(525i, 5281, 5300
Two types of steering systems are used in E39 models. 6-
cylinder (525i, 5281, 530i) models are equipped with a steer-
ing rack system. V-8
(540i) models are equipped with a re-
circulating ball and nut steering gearbox.
Rack-and-pinion steering
Steering components in 6-cylinder models consist of a rack-
and-pinion type steering gear and connecting linltage to the
road wheels.
The steering linkage connects the rack-and-pinion unit
through tie rods to the steering knucltles. The tie rod ends al-
low the wheels to pivot and react to suspension travel.
Recirculating ball and nut steering
V-8 models
(540i)
I
Recirculating ball and nut steering
Recirculating ball and nut steering in V-8 models consists of a
steering box with integrated hydraulic control valve and con-
necting linkage to the road wheels.
Thesteering linkageconnects the steering gearbox through a
pitman arm to the wheels. An idler arm maintains correct toe
angle. The tie rod allow the wheels to pivot and react to sus-
pension travel.
E39 cars are equipped with power disc brakes with integral
antilock brakes (ABS). The parking bralte is a dual-drum sys-
tem integrated with the rear brake rotors.
Power assist is provided by a vacuum booster when the en-
gine is running. The brake pedal
pushrod is connected direct-
ly to the master cylinder, so failure of the vacuum booster
does not normally result in total
bralte failure.
Each disc bralte uses a caliper with a single hydraulic cylin-
der. Brake pads in the left front and right rear contain wear
sensors. When brake pads need replacement, the sensors il-
luminate a light on the dashboard.

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/~ront Susaension
Front suspension arms FRONT SUSPENSION ARMS
Scyllnder models (5251,5281,530i)
Control arms and tension struts are attached to the front sub-
Front suspension arms V-8 models (5401)
frame through rubber bushings and to the steering ltnuckles
by ball joints.
NOTE-
Tension struts are sometimes called thrust arms or thrust
rods.
Control arms or tension struts are sometimes called lower
front arms or lower rear arms.
Inspect ball joints for wear and looseness. lnspect bushings
for wear or fluid
lealts. The ball joint can only be replaced as
part of an entire suspension arm assembly. Some suspen-
sion arm
bushinas are available as re~lacement Darts. Al-
ways replace in pairs
NOTE-
Steering wheel vibration during braking (usually at road
speeds of
50 to 60 m.p.h.) are often causedby faulty suspen-
sion arm bushings, not out-of-true brake rotors.
Some special tools may be required to remove suspension
arms and to replace bushings. Read procedures through be-
fore beginning the job.
Control arm, removing and installing
(6-cylinder models)
- Raise car and remove wheel
Male sure
that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension
parfs.
Cars equipped with vertical headlight adjustment system:
Disconnect control arm from level sensor.
Remove control arm fasteners (arrows). Lightly tap inner
control arm mounting bolt out of subframe.

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330-28
Rear Suspension
4 To install, jack subframe into position. Install and tighten sub-
frame mounting bolts. Note that on each bolt, rubber-coat-
ed detent plate
(arrow) must be installed at rear in driving
direction.
Tightening torques
Rear
subframe to body (M12) 163 Nm (120 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Make sure long lower strut bushing fits in hole in wheel
bearing carrier.
111 0 Tighten suspension arm and shoclc absorber fasteners to
502330036 final torque only afler vehicle has been lowered and sus-
pension has settled.
Have car professionally aligned when job is complete
Tightening torques
ABS pulse sensor to wheel bearing carrier 8 Nrn (6 ft-lb)
Brake rotor to hub
16 Nm (12 ft-lb)
Driveshaft
CV joint to final drive flange
- MI0 (Tow bolts) 70 Nm (51 ft-lb)
MB (compression nut) 32
Nm (24 ft-lb)
Rear brake pad
carrler (caliper) to wheel 65 Nm (48 ft-lb)
bear~ng carrler
Rear strut to
wheel bearlng carrler 127 Nm (94 ft-lb)
Road wheel to hub
120210Nrn
(89 57 ft-lb)
Rear axle assembly, removing and
installing (Sport Wagon models)
Incaseof damage to thesubframe, or if apressed-in bushing is
worn, remove
subframe by removing complete axle assembly.
In Sport Wagon models with conventional coil spring, lower
subframe slowly, making sure rear springs stay on spring
seats.
In models with air suspension
(EHC), disable the air supply
pump, deflate the air springs and disconnect them from the
wheel carriers before lowering the subframe.
- Raise car and remove rear wheels.
WARNING-

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Rear Suspension
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Tighten suspension arm and shock absorber fasteners to
final torque only afler vehicle has been lowered and sus-
pension has settled.
Tightening torques
ABS pulse sensor to wheel bearing carrier 8
Nrn (6 ft-lb)
Air line connection 2 Nrn (18 in-lb)
Brake rotor to hub 16
Nrn (12 ft-lb)
Driveshaft
CV joint to final drive flange
- MI0 (Torx bolts) 70
Nrn (51 ft-lb)
- MB (compression nut) 32 Nrn (24 ft-lb)
Rear
brake pad carrier (caliper) to wheel 65
Nrn (48 ft-lb)
bearing carrier
Road wheel to hub
120ilO Nrn
(89 i-7 ft-lb)
Rear subframe mounting bushings,
removing and installing
- Remove rear subframe mounting bolts as described earlier.
Lower
subframe approximately 40 - 45 mm (1 -2 in).
4 Install BMW special tools 33 4 140,33 4 151,33 4 154,33 4
155,33 4 156 as shown.
Use hot air gun with a maximum output temperature of
600°C (1100" F) to heat bushing area of subframe for no
more than
2 minutes. Remove rubber mount from sub-
frame.
CAUTION-
Aluminum suspension parts may be severely damaged
witli intense heat
* Heating for 2 minutes with the recommended heat
source is intended to
keep the temperature of the alu-
minum
parts below the safety threshold of 80°C
(1 76°F). .

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330-35
Rear Suspension
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Always use new self-loclting nuts.
Make sure all threaded bolts, nuts and mating suriaces are
clean.
Make sure long lower strut bushing fits in hole in wheel
bearing carrier.
Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Stake axle collar nut after tightening.
Tightening torques
ABS pulse sensor to wheel bearing carrier
8 Nm (6 ft-lb)
Brake rotor to hub 16 Nm (12 ft-lb)
Rear brake pad carrier (caliper) to wheel 65
Nm (48
ft-lb)
bearing carrier
Rear axle shaft to hub
(M27) 300 Nm (221 ft-lb)
Rear strut to wheel bearing carrier 127
Nrn (94 ft-lb)
Road wheel to hub
120+10 Nm
(89
i7 ft-lb)
Swing arm to wheel bearing carrier 256
Nrn (189 ft-lb)
Upper front control arm (traction strut) to 65 Nrn
(48
ft-lb)
wheel carrier
Upper rear control arm to wheel carrier 142
Nrn (105
ft-lb)
Rear wheel bearing carrier, removing and
installing (Sport Wagon models)
- Raise rear end of car and remove wheel.
WARNING-
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
Models
with air springs: Disable air supply pump by discon-
necting electricalplug
beforepedormingany repairs. Pump is
located beneath a cover under the spare tire in the floor of the
cargo compartment.
-- 4 Models with air springs: Loosen compressed air pipes (ar-
rows) at air distribution assembly to release system pres-

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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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330-40
Rear Suspension
4 With an assistant applying brakes, break free and remove
staked collar nut (arrow).
- If equipped, disconnect brake pad sensor connector at brake
caliper.
- Remove brake caliper assembly and rotor. See 340 Brakes.
Leave brake hose connected to caliper. Suspend caliper as-
sembly from chassis using stiff wire.
- Remove ABS pulse sensor at wheel bearing carrier.
Remove drive flange from bearing assembly using impact
style puller
(BMW special tools 33 2 116, 33 4 201/202/203
or equivalent).
CAUTION-
The wheel bearing is destroyed when the drive flange is re-
moved. Do not attempt to reuse bearing.
4 Remove four wheel bearing flange (Torx) bolts (arrows)