Abs BMW 530i 2001 E39 Workshop Manual

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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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1 Brakes
- Remove precharge pump mounting bracket fasteners and re-
move pump.
- Installation is reverse of removal, noting the following:
Be sure to replace rubber pump mounts if damaged
01
worn.
Bleed brakes as described earlier.
Tightening torque Brake line
to precharge pump 18 Nrn (13 ft-lb)
DSC pressure sensor (1 999 - 2002 models)
On 1999 and later DSC systems, the DSC pressure sensor is
screwed into the DSC hydraulic unit (right rear of engine com-
partment).
WARNING-
* €39 cars require special BMW service equipment to prop-
erly bleed the brakes. Removal of the
DSCpressure sensor
is not recommended unless this equipment is available. For
safety reasons, the brake system on cars with ABS must be
bled using the procedures described in this repair group.
Switch off ignition and remove
key to male sure brake
system cannot be activated.
- Disconnect electrical harness connector at switch.
- Use BMW special tool 34 5 160 to remove and install sensor.
Inspect threads and sealing surfaces for damage.
* Work quicltly to avoid excessive brake fluid leakage.
Tightening torque
Pressure sensor
to hydraulic 19 Nrn (14ft-lb)
unit
- Reconnect harness connector
- Bleed front brakes as described earlier.
- Press on brakes and check for leaks at sensor.
- Turn on ignition and firmly depress brake pedal. Check that
DSC warning light does not come on.

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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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400-4
I Bodv-General
Bumpers
The front and rear bumpers are clad in high quality
deform-
able plastic and, at solid barrier impact speeds of 4 kph (2.5
mph), provide protection with virtually no damage to the
bumper
orthe vehicle. In addition to hydraulic dampeners.
which absorb the initial impact energy, these bumpers are
backed by compressible tubes. These deform in a controlled
manner at impact speeds greaterthan that
forwhich bumpers
and hydraulic dampeners are designed. This helps avoid ex-
pensive damage to the body at impact speeds up to 14 kph (9
mph).
The E39 Sport Wagon was introduced to the US market in
911 998 (model year 1999). It shares many components with
the E39 sedan and is identical to it from the B-pillar forward.
US
marltet 5 Series Sport Wagons are available in two vari-
ants:
6-cylinder
(5251, 528i) powered by the 2.8 liter M52 TU en-
gine (1 999) or the 2.5 liter M54 engine (2000 and later)
* V-8 (540i) powered by the 4.4 liter M62 TU engine
The wheelbase of the Sport Wagon is the same as the sedan.
Howeverthe body is 30
mm (1.2 in) longer and 10 mm (0.4 in)
higher.
The Sport Wagon rear suspension was redesigned to elimi-
nates the upper rear spring strut mounting on the E39 sedan.
The use of separate coil springs and
shoclc absorbers results
in a flat, wide floor in the cargo area. See
300 Suspension,
Steering and Brakes-General.
The self-leveling air spring suspension system (electronic
height control or EHC) is standard on Sport Wagon V-8 mod-
els and optional on 6-cylinder models.
Sport Wagon cargo capacities are shown below.
Sport Wagon load capacities
Cargo capacity
Rear seat up 909 liters (32.1 cu ft)
Rear seat folded down I809 liters (63.9 cu ft)
Load limit
Cargo compartment
460 Kg (1014 lb)
Roof
I00 Kg (220 lb)

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Body-General
SAFETY AND SECURITY FEATURES
A number of new or improved safety and security features are
incorporated in
E39 cars.
Safety cage
4 The body safety cage is a continuation of an established
BMW concept for passenger protection. Tubular impact
structures built into the body provide protection against pas-
senger injury during front or rear impacts.
Door locks and door handles
4 The door handles allow easy door opening, but are secure in
accidents.
Electrical components in the locks are fully encapsulated and
cannot be picked easily. The door handles, latches and
loclc
assemblies offer reliability and security against theft.
Door position and
loclc condition are detected by hall sensors.
Roof padding
In addition to the side and head protection airbags, there is
supplementary padding at the roof pillars and along the roof
above the doors. This is positioned to present energy absorb-
ing
surlaces to passengers thrown around by side impact
forces.
Seat belts
Each front seat belt assembly has a height-adjustable anchor
at the 8-pillar.
An automatic pyrotechnic (explosive charge) tensioner tight-
ens the front belt at the buckle upon impact, snugging up lap
and shoulder segments of the belt. The tensioners are de-
signed to automatically tension the belts by about
2 inches
(55 mm) in the event ofa collision.
A force limiter puts an upper limit on the amount of iorce each
belt can exert on the passenger.

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411-3
Doors
4 Pull up on locking clip and remove connector.
4 With door fully open, unscrew pin bolts (arrow) from top and
bottom hinges.
Disconnect door
check by squeezing mounting pin tabs
(arrow) and driving pin up.
Remove door by lifting up off lower hinge halves.
CAUJION-
Be careful not to damage door or otherpainted body surfac-
es.
Make sure no load is placed on wirinq harness.
Installation is reverse of removal. Keep in mind the following:
Mount and align rear doors first, followed by the front
doors.
Align door so that panel gaps are equal on either side, see
specifications at the end of this procedure. If necessary,
adjust door hinges. See Door hinge adjustment.
* Adjust door striker so that trailing edge of front door is
slightly higher
(I mm 10.04 in.) than leading edge of rear
door. See
515 Central Locking and Anti-Theft.
Repair any paint damage and paint any exposed metal.

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Doors
~obr adjustment
Front fender to
4.25 mm i 0.25 mm (0.17 i- 0.01 in)
front door gap
Front
door to 4.5 mm i 0.25 mm (0.18 i 0.01 in)
rear door gap
Rear door to rear fender 4.0 mm i 0.25 mm (0.16 i 0.01 in)
Permissible deviation 1 .O mm (0.04 in)
from
~arallel
Tightening torque
Door hinge to door frame
20 Nm (15 it-lb)
Door check, replacing
WARNING -
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures relating to the
airbag system.
- Close door window completely.
- Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnecting the batter)! read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove interior door panel. See Door trim panels, remov-
ing and installing.
- Where applicable, remove side-impact airbag from door. See
721 Airbag System (SRS). Remove door vapor barrier.
Disconnect door
check by
(arrow) and removing pin. squeezing I mounting
pin tabs

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Trunk Lid, ~ail~atel
4 Loosen lower tailgate lock fasteners (arrows) so that tailgate
lock can center itself.
CAUTION-
The lower section of tailgate lock must not scrape against
the upper section.
The eccentric pin on the lower section of the tailgate
loclc rotates
when being locked from upper section of
tailgate lock.
- Disconnect tailgate latch actuator motor by squeeze locking
tabs on electrical harness connector and disconnecting.
CAUTION-
Eccentric pin in lower section of trunk lid lock must be at
lower dead center.
After disconnecting plug connector from actuator mo-
tor, tailgate is opened by electric
unloclcing fixture of up-
per section of tailgate loclc.
. For this reason, the cable connections to the upper
section of the tailgate loclc must remain connected.
Othe~tise the tailgate can only be opened by the emer-
gency handle. Eccentric pin of lower section of tailgate
loclc remains at bottom dead center point after unlock-
ing.
Tailgate alignment, height adjustment
4 Loosen left and right tailgate hinge fasteners (arrows) to al-
low tailgate to be adjusted.
CAUTION-
. When the hinge screws for the tailgate are released, the
position of the overall assembly changes with respect to
the body.
The position of the rear window frame to the tailgate re-
mains unchanged.
- Close tailgate carefully and check gap dimensions. See Tail-
gate alignment specifications below.
- Tighten hinge screws when gap dimensions are correct.

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51 0 Exterior Trim. Bumpers
General ........................... .51 0.2 Exterior Trim ...................... 51 0-1 3
Outside Rear View Mirrors
Outside mirror glass. replacing
Outside mirror housing.
removing and installing
......
Outside mirror assemblv .
BMW emblem. removing and installing ... 510-13 .......... .51 0.2
Body side molding. replacing ........... 51 0-13 .......... .51 0.2
Radiator grill. removing and installing .... 51 0-1 4
Headlight housing trim panel.
.......... .51 0.3
removing and installing ............... 510-14 . .
removing and installing ................ .51 0.4
Bumpers ......................... .51 0.5
Front bumper assembly
............... .51 0.6
Front bumper, removing and installing
.... .51 0.7
Front bumper impact absorber. replacing
. .51 0.8
Rear bumper assembly ............... .51 0.9
Rear bumper. removing and installing
... .51 0.10
Rear bumper impact absorber. replacing
. .51 0.1 1
Front bumper height. adjusting
......... .51 0.12