Torque wrench BMW 528i 1998 E39 Owner's Manual

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21 0-1 8
Clutch
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model)
or
11 2 070 (V-8 model).
- Install SAC pressure plate on dowel pins at flywheel. lnstall
clutch mounting bolts and tighten each one turn at a time until
pressure plate is fully seated. Torque to specification.
Tightening torques Clutch to flywheel
- M8 (8.8 grade)
MB 110.9 orade)
24 Nm (1 8 it-lb)
34 Nm (25
ft-lb)
Use 14 mm Allen wrench to unscrew (clocltwise or counter-
clockwise) lock plate in center of pressure plate.
NOTE-
The spring lockplate may make snapping noises while being
unscrewed.
Using large bolt, pull out clutch centering tool
Remove flywheel locking tool
4 Inspect and clean release bearing lever. Apply a thin coat of
grease to release bearing lever lubrication points. lnstall re-
lease bearing. Bearing tabs
(A) align with contact points (B)
on release lever.
- Clean release bearing guide sleeve.
CAUTIOG
Do not grease guide sleeve. Ifguide sleeve is greased, re-
lease bearing may stick to it.
- Clean and lightly lubricate clutch disc splines and transmis-
sion input shaft splines.
- lnstall transmission. See 230 Manual Transmission.
Tightening torques
- - - Transmlsslon to engine -
. MB (Torx) 22
Nm (16 it-lb)
MI0 (Torx) 43 Nm (32 it-lb)
* M12 (Torx) 72 Nm (53 it-lb)
.-

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31 0-8
Front Suspension
Slide strut assembly out of steering lknucltle pinch collar. If
necessary use pry bar.
CA UTIOI\C
Do notpullstrut out of steering knuckle with twisting motion.
This can scratch and damage the strut.
Disassemble and reassemble strut assembly as described
later.
When installing new strut, be sure to align locator letter (A)
on strut body with slot in steering
lknuckle pinch collar (6).
Struts are marked with L for left and R for right.
Remainder of installation is reverse of removal.
Make sure strut shoulder (below locator letter) bottoms out
in steering knuckle pinch collar.
Use new self-locking nuts and bolts.
When attaching stabilizer
lrnk to strut, use a thin wrench to
counterhold
link ball joint while t~ghtening nut.
- Have car professionally al~gned when job IS complete.
Tightening torques
Brake caliper to steering knuckle
110 Nm (81 ft-ib)
Road wheel to hub 120 ti0 Nm (89 t7 ft-lb)
Stabilizer bar
link to strut 65 Nm (48 It-lb)
Steering knucltle pinch bolt at strut 81 Nm (60 It-lb) - mountlng collar
Steering tle rod to steerlng knuckle 65 Nm (48 it-lb)
Strut assembly top to strut tower 24 Nm (18 it-lb)
- - -

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31 0-22
I Front Suspension
Stabilizer bar, removing and installing
On E39 models the front stabilizer bar links attach to the strut
assemblies.
- Raise car and support safely.
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 jaclc stands under
suspension parts.
< Remove slaol zer bar connecring I nk rnounl ng nLts (A) from
r~glit and eft s~des of slaol lzer bar C~~nIerhol~ ball ]olnl (6)
with flat wrench
NOTE-
Use a thin wrench to counterhold shaft of stabilizer bar link
ball joint while removing mounting nut.
< Remove stabilizer bar anchor bushing nuts (arrows) on right
and left sides and remove bar.
- Installation is the reverse of removal, noting the following.
Use new self-locking nuts on stabilizer bar links.
Installation of stabilizer bar is easiest with car level (front
wheels at the same height).
Tightening torques Stabilizer bar to stabilizer link
59 Nm (44 ft-lb)
Stabilizer anchor to subframe 22 Nm (16 ft-lb)

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Brakes
- Open bleeder screw. Carry out bleeding procedure with
BMW Service Tester until clear, bubble-free fluid flows.
Models with DSC: After BMW Service Tester bleeding rou-
tine has finished, press brake pedal to floor
5 times until
clear, bubble-free fluid runs out. Close right rear bleeder
valve.
Models with ASC: Close right rear bleeder valve.
- Repeat procedure at left rear brakes.
- Repeat BMW Service Tester bleeding at right front brakes.
Models with DSC: After
BMW Service Tester bleeding rou-
tine has finished, press brake pedal to floor
5 times until
clear, bubble-free fluid runs out. Close right front bleeder
valve.
Models with ASC: After BMW Service Tester bleeding rou-
tine has finished, press brake pedal to floor
12 times until
clear, bubble-free fluid runs out. Close right front bleeder
valve.
- Repeat procedure at left front brakes.
- Remove brake bleeding apparatus and disconnect BMW
Service Tester. Top up brake fluid. Check to make sure
brake 1
fluid reservoir cap seal is intact.
Tightening torques Bleeder screws (wrench size)
- 7 rnrn screw
3.5 - 5 Nrn (2.5 - 3.7 ft-lb)
11 rnrn screw 12-16Nrn(9-12ft-lb)

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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)