steering BMW M3 1998 E36 Service Manual

320-2



STEERING
AND
WHEEL
ALIGNMENT

3
.
Carefully
remove
airbag
from
front
of
steering
wheel
.

See
721
Airbag
System
(SRS)
.
Store
airbag
unit
in
a

safe
place
.

WARNING-

Improper
handling
of
theaírbag
could
cause
seri-
ous
ínjury
.
Store
theaírbag
with
the
horn
pad
facing
up
.
If
stored
facing
down,
accidental
deployment
could
propel
it
vlolently
into
the
air,
causíng
ínjury
.

4
.
Remove
steering
wheel
center
bolt
.
Lightly
punch
mark

or
scribe
position
of
steering
wheel
to
steering
column

shaft
.
See
Fig
.
1
.

0012687
Fig
.
1
.
Steering
wheel
center
bolt
(arrow)
.



Power
steering
pump,

removing
and
installing

POWER
STEERING
SYSTEM

5
.
Unlock
steering
wheel
by
turning
ignition
key
on
.
Re-
move
steering
wheel
.

WARNING-

The
SRS
contact
reel
ís
mounted
to
the
rear
of
the
steering
wheel
hub
.
The
contact
reel
ís
a
wound
coil
ofwirethat
ensures
continuous
electrícal
contact
for
the
air
bag
unit
Once
the
steering
wheel
mounting
nut
or
bolt
is
removed
the
contact
reel
is
locked
in
the
center
position
and
its
position
must
not
be
al-
tered
.

6
.
Insta¡¡
steering
wheel
while
aligning
matching
marks
.
Make
sure
airbag
contact
ring
locking
pin
engages
cutout
in
contact
reel
.
Insta¡¡
steering
column
center
nut
.
Do
not
over-torque
.
See
Fig
.
2
.

7
.
The
remainder
ofinstallation
is
reverse
of
removal
.
Carefully
install
airbag
from
front
of
steering
wheel
.
See
721
Airbag
System
(SRS)
.

Tightening
Torque

"
Steering
wheel
to
steering
column
spindle
...
..
..
.
..........
63
Nm
(46
ft-Ib)

Fig
.
2
.



Insta¡¡
steering
wheel
so
that
locking
pin
in
column
aligns
with
cutout
in
contact
reel
(arrow)
.
Contact
reel
on
late
model
steering
wheel
may
vary
from
that
shown
.

POWER
STEERING
SYSTEM

Power
assist
is
províded
by
a
belt-driven
pump
on
the
lower

left
front
of
the
engine,
just
below
the
alternator
.
The
power

steering
fluid
resenroir
is
located
on
the
lower
left
front
of
the
engine
.

1
.
Empty
power
steering
fluid
reservoir
usingclean
sy-

ringe
.
Do
not
reuse
fluid
.

2
.
Raise
front
of
car
.

WARNING

Make
sure
thecar
is
firmly
supportedon
jack
stands
designed
for
the
purpose
.
Place
the
jack
stands
be-
neatha
structural
chassis
point
.
Do
not
place
jack
stands
undersuspension
parts
.

3
.
Remove
fluid
hoses
frbm
pump
.
Plug
openings
in
pump
and
in
hose
ends
.

4
.
Remove
drive
belt
from
power
steering
pump
.
See
020
Maintenance
Program
.

5
.
Remove
pump
mounting
bolts
and
remove
pump
.
See
Fig
.
3
.

Fig
.
3
.



Power
steering
pump
and
pulley
mounting
bolts
.

6
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Make
sure
al¡
thread
bores,
bolts,
nuts,
fluid
couplings

and
mating
surfaces
are
clean,
and
that
inside
surface

of
multi-ribbed-belt
is
free
of
grease
and
dirt
.

"
Use
new
sealing
washers
when
reattaching
power

steering
pressure
lines
.

"
Make
sure
hoses
have
adequate
clearance
from
chas-

sis
.
Do
not
over-torque
banjo
bolts
.

"
Fill
and
bleed
power
steering
system
as
described
be-

low
.

Power
steering
system,

bleeding
and
filling

1
.
Wíth
engine
off,
fill
power
steering
fluid
reservoir
with

clean
fluid
.
Fill
levelto
MAX
mark
on
dipstick
.

STEERING
AND
WHEEL
ALIGNMENT



320-
3

STEERING
GEAR
A
cutaway
of
the
power-assisted
rack-and-pinion
power

steering
gear
is
shown
in
Fig
.
4
.
The
rack
is
designed
to
be

maintenance
free
.

Pinion

Fig
.
4
.



Cutaway
of
rack-and-pinion
steering
gear
.

Tightening
Torques

"
Hydraulic
hoses
to
power
steering
pump



?he
steering
gear
and
linkage
require
no
maintenance
oth-

M10
banjo
bolt
.........
..
.
...
...
.
12
Nm
(9
ft-Ib)



er
than
alignment
and
a
periodic
inspection
for
worn
compo

M14
banjo
bolt
..............
..
..
35
Nm
(26
ft-Ib)



nents
.

M16
banjo
bolt
..............
...
.
40
Nm
(30
ft-Ib)

"
Power
steering
pump
to
bracket



Steering
gear
rack,
removing
and
installing
(self-locking
nuts)
.............
..
.
22
Nm
(16
ft-Ib)

"
Power
steering
pump
bracket
to
engine



1
.
Empty
power
steering
fluid
reservoir
using
clean
sy-

block
or
oil
pan
(self-locking
nuts)
...
22
Nm
(16
ft-lb)



ringe
.
Do
not
reuse
fluid
.

2
.
Disconnect
negative
(-)
cable
from
battery
and
cover

terminal
with
insulating
material
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery

disconnection
cautions
given
at
the
front
of
this

manual
on
page
viii
.

2
.
Start
engine
.
Slowly
turn
steering
wheelfrom
lock
to

lock
a
minimum
of
two
times
.



3
.
Carefully
remove
airbag
from
frontof
steering
wheel
.
See

721
Airbag
System
(SRS)
.
Store
airbag
unit
in
a
sale

3
.
Turn
engine
off
and
check
fluid
leve¡,
adding
fluid
if
nec-



place
.

essary
.
4
.
Make
sure
front
wheelsare
pointed
straight
ahead
.

5
.
Remove
outer
tie
rod
ball
joínt
nuts,
thenseparate
outer

tie
rod
ends
from
steering
arms
using
appropriate

press
tools
.

6
.
Disconnect
power
steering
hose
from
fluid
reservoir
.

STEERING
GEAR

320-
4



STEERING
AND
WHEEL
ALIGNMENT

7
.
Remove
fluidline
banjo
bolt
from
steering
gear
.
See



9
.
Remove
steering
gearmounting
bolts
.
See
Fig
.
7
.
Re
Fig
.
5
.



move
steering
gear
from
subframe
crossmember
by

pulling
it
forward
.

CAUTION-

Plug
the
openings
in
the
pump
and
hoseends
to
prevent
dirt
from
entering
the
hydraulic
system
.

NOTE-
It
may
be
necessary
to
remove
other
components
to
gain
access
to
the
steering
gear
.

"
Make
sure
al¡
thread
bores,
bolts,
nuts,
splines
and
mating
surfaces
are
clean
.
Use
new
self-locking
nuts
wherever
applicable
.

"
Use
marks
made
during
removal
to
reassemble
steer-
ing
column
universal
jointto
steering
stub
shaft
.
Make
sure
wheels
are
straight
ahead
.

"
Use
a
new
sealing
washer
on
banjo
fitting
.
Do
not
over-

Fig
.
5
.



Fluid
hoses
and
banjo
bolts
at
steering
gear
(arrows)
.



torque
banjo
bolt
.
"
Install
airbag
to
the
steering
wheel
as
described
in
721
Airbag
System
(SRS)
.
8
.
Remove
lower
steeringshaft
universal
joint
pinch
bolt,



"
Fill
and
bleed
power
steering
system
as
described
ear-
then
pull
universal
joint
half
way
off
steering
gear
shaft
.



lier
.
Mark
relationship
between
shaft
and
universal
joint,



"
Have
thecar
professionally
aligned
.
then
remove
universal
joint
from
steering
gear
.
See
Fig
.
6
.

0013231
Fig
.
6
.



Steering
column
universal
joint
pinch
bolt
(arrow)
.
Mark
U-
joint
to
shaft
before
disconnecting
.
With
wheels
in
straight
ahead
position,
mark
on
steering
gear
(A)
should
align
with
split
seam
in
universal
joint
(B)
.

STEERING
GEAR

Fig
.
7
.



Steering
gear
mounting
bolts
(arrows)
.

Outer
tie
rod
end,
replacing

10
.
Installation
is
reverse
of
removal,
noting
the
following
:

Tightening
Torques

"
Outer
tie
rod
end
to
steering
arm
.
.
..
45
Nm
(33
ft-Ib)

"
Steering
column
universal
joint
to
steering
gear
shaft
(self-locking
nut)
....
..
..
19
Nm
(14
ft-Ib)

"
Steering
gear
to
subframe
crossmember
M10
bolt
..............
.
...
.....
42
Nm
(32
ft-Ib)

"
Steering
fluíd
lines
M10
banjo
bolt
..
..
..
........
.....
12
Nm
(9
ft-Ib)
M14
banjo
bolt
..
..
..
...
..
...
....
35
Nm
(26
ft-lb)
M16
banjo
bolt
..
.......
..
..
.....
40
Nm
(30
ft-Ib)

1
.
Raise
car,
remove
outer
tie
rod
ball
joint
nut,
and
press
out
outer
tie
rod
end
ball
joint
as
described
above
.

2
.
Make
a
reference
measurement
of
outer
tie
rod
end
to
tie
rod
.
See
Fig
.
8
.
Record
measurement
.

NOTE-
Accurate
measuring
of
the
tie
rod
end
in
reference
to
the
tie
rod
will
help
approximate
correct
wheel
align-
mentwhen
new
parts
are
installed
.

Fig
.
8
.



Measuring
tie
rod
end
position
(for
reference
only)
.

3
.
Loosen
outer
tie
rod
end
lock
nut
.
See
Fig
.
9
.

Lock
nut

4
.
Unscrew
tie
rod
end
from
steering
gear
.

0012143

"
Make
sure
all
threaded
parts
are
clean
.
Replace
self-

locking
nuts
and
inner
tie
rod
lockplate
.
"
Install
outer
tie
rod
end
to
new
tie
rod
using
reference

measurement
recorded
earlier
.

Fig
.
9
.



Outer
tie
rod
end
lock
nut
(arrow)
.



"
Have
car
professionally
aligned
.

5
.
Installation
is
reverse
of
removal
.
Make
sure
all
thread-

ed
parts
are
clean
.
Have
thecar
professionally
aligned
.

Tightening
Torques

"
Outer
tie
rod
end
losteering
arm
....
45
Nm
(33
ft-Ib)

"
Outer
tie
rod
end
lock
nut
..
.......
.
35
Nm
(26
ft-Ib)

Tie
rod,
replacing

1
.
Raise
car,
remove
outer
tie
rod
end
ball
jointnut,
and

press
out
outer
tie
rod
end
ball
joint
as
described

above
.

2
.
Make
a
reference
measurement
of
outer
tie
rod
end
to

tie
rod
.
See
Fig
.
8
.
Record
measurement

NOTE-
Accurate
measuring
of
the
tía
rod
end
in
reference
to
the
tie
rod
will
help
to
approximate
wheel
alignment

when
new
parts
are
installed
.

STEERING
AND
WHEEL
ALIGNMENT



320-
5

3
.
Loosen
rack
boot
bellows
clamp
and
slide
bellows

back
.
Inspect
boot
for
any
signof
damage
.
Replace
if

necessary
.

4
.
Unlock
inner
tie
rod
end
lockplate
using
pliers
.

5
.
Using
special
tool,
unscrew
inner
tie
rod
end
from

steeringrack
.
See
Fig
.
10
.

WHEEL
ALIGNMENT

Caster
and
Camber

Fig
.
10
.
Special
tool
(arrow)
installed
on
inner
tie
rod
end
.

6
.
Installation
is
reverse
of
removal,
noting
the
following
:

Tightening
Torques

"
Outer
tie
rod
end
to
steering
arm
..
.
.
45
Nm
(33
ft-Ib)

"
Outer
tie
rod
end
lock
nut
..........
35
Nm
(26
ft-Ib)

"
Inner
tie
rod
to
steering
gear
.......
71
Nm
(52
ft-Ib)

Proper
handling,
stability,
tire
wear,
and
driving
ease
de-

pendupon
the
correct
alignment
of
al¡
four
wheels
.
The
front

axle
is
aligned
in
relation
to
the
rear
axie,
then
the
front
wheels

are
aligned
in
relation
to
one
another
.
This
is
known
as
a
four-

wheel
or
thrust-axis
alignment
.

The
BMW
E36
uses
a
sophisticated
multi-link
suspension

at
the
front
and
rear
of
the
car
.
Proper
alignment
requires

computerized
alignment
equipment
.

Front
and
rear
caster
and
Camber
are
both
fixed
by
the
de-

sign
of
the
car
.
Any
deviations
are
usually
the
result
of
worn
or

damaged
suspension
or
body
parts
.

WHEEL
ALIGNMENT

320-
6



STEERING
AND
WHEEL
ALIGNMENT

Front
Toe-in
andToe
Difference
Angle



Wheel
Alignment
Specifications

Toe-in
is
the
difference
in
the
distance
between
the
front
of



Alignment
specificationsfor
the
E36
are
listed
in
Table
a

the
front
wheels
and
the
rear
of
the
front
wheels
.
It
is
adjusted



and
Table
b
.
The
specifications
only
apply
under
the
following

by
altering
the
length
of
the
outer
tie
rods
.



conditions
:

Toe-in
adjustments
should
only
be
made
on
alignment
equipment
with
the
car
in
normalloaded
position
as
described

below
under
Wheel
Alignment
Specifications
.

Toe
difference
angledetermines
the
progressively
different

pathstaken
by
the
front
wheelsas
the
car
is
turning
.
It
is
fixed
by
the
steering
gear,
but
depends
on
accurate
setting
of
the
toe-in
.

Rear
Toe-in

There
is
no
provision
for
routinerear
wheel
toe-in
adjust-

ment
.
If
any
alignment
angles
deviate
from
specifications,
carefully
inspect
the
rear
trailing
arms,
rear
suspension
sub-
frame
and
al¡
associated
bushings
and
flexible
mounts
for
wear
or
damage
.
After
replacing
any
parts
that
appear
worn
or
damaged,
re-check
thetoe
measurements
.

WHEEL
ALIGNMENT

Table
a
.
Front
Wheel
Alignment
Specifications

"
Correct
wheels
and
tires
are
installed,
in
good
condition,
and
are
at
the
correct
inflation
pressures
.

"
Al¡
steering
and
suspension
parts
and
bushings
areun-

damaged
and
show
no
signs
of
abnormal
wear
.

"
Wheel
bearings
are
in
good
condition
.

"
Ride
height
is
in
accordance
with
specifications
.

See
310
Front
Suspension
and330
Rear
suspension
.

"
Car
isin
normal
loaded
position
.

Normal
loaded
position

"
Each
front
seat
.....:.............
68
Kg
(150
lb)

"
Rear
seat
(center)
................
68
Kg
(150
lb)

"
Trunk
.
.
.
..
.......................
21
Kg
(46
lb)

"
Fueltank
.
........................
...
.
..
..
full

3181325
Model



3181325



sport



M3
3
.0
liter



M3
3
.2
liter
suspension

Toe
angle
(total)



0°
18'±8'



0°
18'±8'



0°
10'
±5'



0°
10't5'

Camber

To
1995



-0°
40'±30'



-0°
58'±
30'



-0°55'±30'



-

1995
on



-0°
30'
±30'



-0°
51'±30'



-0°55'±30'



-0°
46'±30'

Caster

10°
wheel
lock



3°
41'±30'



3°
50'±30'



6°
38'±30'



9°
35'±30'

20°
wheel
lock



3°
52'±30'



3°
57'
t30'



6°
52'±30'



7°
50'±30'

Front
Wheel
Displacement



0°
t15'



0°t15'



0°
±15



0°
±15'

Table
b
.
Rear
Wheel
Alignment
Specifications

3181325
Model



3181325



sport



M3
3
.0
liter



M3
3
.2
liter
suspension

Toe
angle
(total)



0°
24't6'



0°
24'±6'



0'30'
.-t6'



0°
30't6'

Camber



-l'
40'
t15'



-2°
0'
t15'



-1
°
45'
t10'



-1'45'±10'

Maximum
allowabledeviation
between
sides



0°
±3'



0°
±3'



0°
t3'



0°
t3'

GENERAL
.......
.
.
.
.
.
.
.
.
.
.......
.
...
.330-1



CV
boot,
replacing
........
.
.
.
.........
.
.330-8

RIDE
HEIGHT
....
.
.
.
.
.
...
.
...
.
.
.
.
.
...
.
330-1



REAR
SUSPENSION
ARMS
.
.
.
.
.
.
.
.
.
..
.
330-9

Trailing
arm,
removing
and
installing
.
.
.
....
330-10

SHOCK
ABSORBERS
AND
SPRINGS
.
.
.
330-2



Trailing
arm
bushing,
replacing
.
...
.
.
.
.
.
..
330-11

Rear
shock
absorber,
removing
and
installing
330-3



Upper
control
arm,
removing
and
installing
.
.330-12

Coil
spring,
removing
and
installing
.
.
.
.
.
.
.
.
330-4



Lower
control
arm,
removing
and
installing
.
.330-12

REAR
WHEEL
BEARINGS
....
.
...
.
.
.
..
330-4

Rear
wheel
bearing,
replacing
.......
.
....
330-5



Final
drive
carrier,
removing
and
installing
.
.330-12

DRIVE
AXLES
..
.
.
.
.
.
.
.
.
.
.............
330-6



TABLE
a
.
Rear
Ride
Height
Specifications
..
.
............
330-1
Drive
axle,
removing
and
installing
.........
330-6

GENERAL

Special
service
tools
are
required
for
some
of
the
work
de-
scribed
in
this
repair
group
.
Read
the
procedures
through
be-
fore
beginning
any
job
.

NOTE
-

A
general
description
of
the
rear
suspension
and
a
troubleshooting
guide
can
be
found
in
300
Suspen-
sion,
Steering
and
Brakes-General
.

RIDE
HEIGHT

Rear
suspension
ride
height
is
controlled
by
the
rear

springs
.
If
the
rear
ride
height
is
not
within
the
specifications

listed,
the
rear
springs
should
be
replaced
.

Ride
height
is
measured
from
the
lower
edge
of
the
wheel

arch
to
the
bottom
edge
of
the
wheel
rim
.
See
Fig
.
1
.

Table
a
lists
rear
suspension
ride
height
specifications
.



ooy

98
These
specifications
apply
to
a
car
in
a
normally
loaded
posi-

tion
.
When
checking
ride
heightor
installing
suspension
com-



Fig
.
1
.



Ride
height
measurement
(A)
is
taken
from
center
of
wheel

ponents,
load
the
caras
follows
:



archto
bottom
of
wheel
rim
.

Normal
loaded
position

"
Each
front
seat
..
...
.
.
.............
68kg
(150
lb)

"
Rear
seat
(center)
..
.
.
.............
68
kg
(150
lb)

"
Trunk
.........
.
.
.
.
.
..............
21kg
(46
lb)

"
Fue¡
tank



.....



.
..



.
.
.
................



.



..
..
.
full

NOTE-

M3
ride
height
is
measured
with
the
car
unladen
.

330
Rear
Suspension

REAR
SUSPENSION



330-1

FINAL
DRIVE
CARRIER
.
.......
.
.
.
.
.
..
330-12

Table
a
.
Rear
RideHeight
Specifications

Wheel
size



318,323,325,



M3
modeis
328
modeis

15
inch
std
.
suspension



518
mm
(20
.39
in)
sport
suspension



~
507
mm
(19
.96
in)

16
inch
std
.
suspension



531
mm
(20
.91
in)
sport
suspension



~
520
mm
(20
.47
in)

Continued

RIDE
HEIGHT

Brake
rotor,
removing
and
installing
.
.
.
.
.
.
.
.
340-7

MASTER
CYLINDER
............
.
.
.
.
.
.
.340-7

Master
cylinder,
removing
and
installing
.
...
.
340-7

GENERAL



TROUBLESHOOTING

WARNING
-

"
Although
semi-metallic
and
metallic
Brake
friction
materials
in
Brake
pads
or
shoes
no
longer
con-
tain
asbestos,
they
produce
dangerous
dust
.
"
Brake
fluid
is
poisonous,
highly
corrosive
and
dangerous
to
the
environment
Wear
safety
glasses
and
rubber
gloves
when
working
with
Brake
fluid
.
Do
not
siphonBrake
fluid
with
your
mouth
.
Immediately
clean
away
any
fluid
spilled
on
painted
surfaces
and
wash
with
water,
asBrake
fluid
will
remove
paint
.

"
Always
use
new
Brake
fluid
froma
fresh,
un-
opened
container
.
Brake
fluid
will
absorb
mois-
ture
from
the
air
.
This
canlead
to
corrosion
problems
in
the
brakingsystem,
and
will
also
low-
er
the
Brake
fluid's
boiling
point
.
Dispose
of
Brake
fluid
properly
.

"
Do
notreuse
self-locking
nuts,bolts
or
fasteners
.
They
are
designed
to
be
used
only
once
and
may
failif
reused
.
Always
replace
them
with
new
self-
locking
fasteners
.

BMW
E36
models
areequipped
with
vacuum
power-assist-

ed
four-wheel
disc
brakes
with
an
integral
Antilock
Brake
Sys-

tem
(ABS)
.
Single-pistoncalipers
act
on
solid
or
vented
front
rotors
and
solid
rear
rotors
.
A
brake
pad
wear
sensor
for
each

axle
indicates
when
brake
padsneed
replacement
.
The
dual

drum-type
parking
brakesystem
is
integrated
with
the
rear
brake
rotors
.

NOTE-

M3
models
havevented
directional
Brake
rotors
on
the
rearaxle
as
well
ason
the
front
.

340
Brakes

BRAKES
340-1

GENERAL
.
.
.
.
.
.
.........
.
.
.
..........
340-1



BRAKE
BOOSTER
.........
.
.
.
.
.
...
.
.
.
.
340-8

TROUBLESHOOTING
.......
.
......
.
...
340-1



Brake
booster,
removing
and
installing
....
.
.
340-8

PARKING
BRAKE
.
.....
.
...
.
.
.
.....
.
.
.
340-10
BLEEDING
BRAKES
.
.
.
.
.
.
.
.
..........
340-3



Parking
brake,adjusting
.
.
.
.
.
.
.
.
.
.
.....
.
340-10
Pressure
bleeding
brakes



Parking
brake
shoes,
removing
and
installing
.
340-11(except
cars
with
AST)
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.340-3



Parking
Brake
cable,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
340-11

BRAKE
PADS,
CALIPERS,



ANTILOCK
BRAKE
SYSTEM
(ABS)
.
.
.
.340-11
AND
ROTORS
..........
.
.......
.
.
.
.
.
.
.
340-3



ABS
System
Inspection
.
...
.
.......
.
.
.
..
340-12
Brake
pads,
replacing
............
.
.
.
.
.
.
.
340-4
ABS
wheel
speed
sensors,
replacing
.
.
.
.
..
340-12
Brake
caliper,
removing
and
installing
.
..
..
.
340-6

TABLES

a
.
Brake
System
Troubleshooting
.....
...
.
.
.....
.340-2
b
.
Brake
Rotor
Reconditioning
Specifications
.
.....
.340-7

Brakeperformance
is
mainly
affected
by
three
things
:
the
leve¡
and
condition
of
the
brake
fluid,
the
system's
abilíty
to
create
and
maintain
hydraulic
pressure,
and
the
condition
of
the
friction
components
.

Air
in
the
Brake
fluid
will
make
the
Brake
pedal
feel
spongy

during
braking
or
will
increase
the
Brake
pedalforce
required

to
stop
.
Fluid
contaminated
by
moisture
or
dirt
can
corrode
the

system
.
Inspect
the
Brake
fluid
inside
the
reservoir
.
Ifit
is
dirty
or
murky,
or
is
over
a
year
old,
the
fluid
should
be
replaced
.

Visually
check
the
hydraulic
system
startingat
the
master

cylinder
.
To
check
the
function
of
the
master
cylinder
hold
the

brake
pedal
down
hard
with
the
engine
running
.
The
pedal

should
feelsolid
and
stay
solid
.
If
the
pedal
slowly
falls
to
the

floor,
either
the
master
cylinder
is
leaking
internally,
or
fluid
is
leaking
externally
.
If
no
leaks
canbe
found,
the
master
cylin-
der
is
faulty
and
should
be
replaced
.
Check
all
Brake
fluid
lines

and
couplings
for
leaks,
kinks,
chafing
and
corrosion
.

Check
the
Brake
booster
by
pumping
the
Brake
pedal
ap-

proximately
10
times
with
the
engine
off
.
Hold
the
pedal
down
and
start
the
engine
.
The
pedal
should
fa¡¡
slightly
.
If
not,
check

for
any
visiblefaults
before
suspecting
a
faulty
brake
booster
.

Check
for
strong
vacuum
at
the
vacuum
hose
fitting
at
the

booster,
and
check
the
non-retum
valve
for
one-way
flow
.

Worn
or
contaminated
brake
pads
will
cause
poor
braking

performance
.
Oil-contaminated
or
glazed
pads
will
cause

stopping
distances
to
increase
.
Inspect
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
byworn
suspension
components
.

TROUBLESHOOTING

340-
6BRAKES

bolt~



Guide
bolt

caps
covers
Brake
caliper
Shoe
retaining
píns

Parking
brake
cable

Fig
.
7
.



Rear
brake
caliper
assembly
.

Caliper
guide



Brake



ad
bolts
,



Bleeder
valve



i
_
~wear
sénsor
®



and
dust
cap



(right
wheel
V
.
.,,,

Brake
caliper,
removing
and
installing

1
.
Raise
car
and
remove
wheel
.

WARNING
-

Make
sure
the
car
is
firmly
supported
on
jack
standsdesigned
for
the
purpose
.

2
.
Loosen
brake
hose
fitting
at
caliper
.
Do
not
remove
.

3
.
Remove
caliper
mounting
bolts
from
steering
arm
(Font

caliper)or
from
trailing
arm
(rear
caliper)
.
See
Fig
.
8
.

4
.
Press
piston
back
into
caliper
and
slide
caliper
off
brake

rotor
.
Spin
caliper
off
brake
hose
.

5
.
Inspect
brake
caliper
for
signs
of
leakage
.
Check
that
caliper
piston
slides
smoothly
into
caliper
.
Replace
cal-

iper
if
any
faults
are
found
.

6
.
Installation
is
reverse
of
removal
.
Bleed
entire
brake

system
before
driving
car
.
See
Bleeding
Brakes
.

Tightening
Torques

"
Front
brake
caliper
to
steering
arm
..
110
Nm
(81
ft-Ib)

"
Rear
brake
caliper
to
trailing
arm
....
67
Nm
(50
ft-Ib)

"
Brake
fluid
hose
to
caliper
....
17-19
Nm
(13-14
ft-Ib)

"
Road
wheel
to
hub



........
100±10
Nm
(74±7
ft-Ib)

BRAKE
PADS,CALIPERS,
ANDROTÓRS

Cover

Caliper



!



Brake
pad
Oringiston



carne
-
p

Circli

©
ot~
AV
~:
Z



1vo~
Spring
and
spring
retainer



uust
seas



~~



Aniráttle

j),
Brake



spring
Shoe
pads
_
_

adjuster



per
return

nf

MIL

Rotor
with
integrated
parking
brake
drum
6573

0011256

Fig
.
8
.



Front
brake
pad
carrier
mounting
bolts
(arrows)
.
Rear
caliper
mounting
bolts
are
similar
.

Brake
rotor,
removing
and
installing

Brake
rotors
shouldalways
be
replaced
in
pairs
.

Fig
.
9
.



Brake
rotor
mounting
screw
(arrow)
.

3
.
Inspect
rotor
for
excessive
grooving,
cracks,
and
warp-

ing
.
Check
rotor
thickness
.
See
Table
b
.

4
.
Installation
is
reverse
of
removal
.

"
Clean
rotor
with
brakecleaner
before
installing
.

"
If
brake
fluid
hose
veas
removed
or
loosened,
brake

systemmustbe
bled
as
described
aboveunder

Bleeding
Brakes
.

BRAKES
340-
7

5
.
Once
brake
assembly
is
instalind,
depress
brakepedal

several
times
to
adjust
caliper
and
pads
.

"
Pedal
should
feel
firm
and
be
at
proper
height
.

"
Check
fluid
leve¡
.
Top
up
if
necessary
.

NOTE-

M3
models
use
directional
brake
rotors
and
mustbe
in-



NOTE-

stalled
on
the
proper
side
.
Part
numbes
are
cast
finto



When
installing
new
rear
brake
rotors,
the
parking

therotors
.
A
part
that
ends
in
an
odd
number
is
a
left



brakeshouldbe
adjusted
.
See
Parking
Brake
.

rotor
.
One
that
ends
in
an
even
number
is
a
right
rotor
.

1.
Remove
caliper
as
described-above
and
hang
from



Tightening
Torques
chassis
using
stiff
wire
.



"
Brake
rotor
to
wheel
hub
..........
16
Nm
(12
ft-Ib)

"
Front
brake
caliper
to
steering
arm
...
110
Nm
(81
ft-Ib)

NOTE-



"
Rear
brake
caliper
to
traíling
arm
....
67
Nm
(50
ft-Ib)

Do
notloosen
caliper
brake
hose
.



"
Road
wheel
to
hub



...
..
.
100
±
10
Nm
(74
t
7
ft-Ib)

2
.
Remove
mountingscrew
holding
rotor
to
wheel
hub
.



,

See
Fig
.
9
.



Table
b
.
Brake
Rotor
Reconditioning
Specificati*M`

Front
Rear

Vented
rotor
wear
limit
(min
.
thickness)



20
.4
mm
(0
.803
in.)

Solid
rotor
wear
limit
(min
.
thickness)



8
.4
mm
(0.331
in
.)

M3
models
wear
limit
(min
.
thickness)



26
.4mm
(0
.977
in
.)



18
.4
mm
(0
.723
in
.)

Axial
runout
(max
.)
rotor
removed



0
.05
mm
(0
.002
in
.)



0
.05
mm
(0
.002
in
.)
rotor
installed



0
.20
mm
(0
.008
in
.)



0
.20
mm
(0
.008
in
.)

CAUTION-

M3
brake
rotors
must
not
be
machined
.

MASTER
CYLINDER

The
brake
master
cylinder
is
mounted
to
the
front
of
the
vac-

uum
booster
on
the
driver
side
bulkhead
.

Master
cylinder,
removing
and
installing

1
.
Using
a
clean
syringe,
empty
brake
fluid
reservoir
.

WARNING
-

Brake
fluid
is
highly
corrosive
and
dangerous
to
the

environment
.
Dispose
of
it
properly
.

NOTE-

On
original
equipment
rotors,
the
mínimum
allowable



2
.
Disconnect
brake
fluid
leve¡
sender
connector
from
fluid

thickness
is
stamped
on
the
rotor
hub
.
Measure
the
rotor



reservoi
r
cap
.

brakingsurface
with
a
micrometer
at
eight
to
ten
different

points
and
use
the
smallest
measurement
recorded
.



3
.
Disconnect
brake
fluid
lines
frommaster
cylinder
.
See

Fig
.
10
.
Disconnect
hydraulic
clutch
system
supply
line
.

4
.
Unscrew
mounting
nuts
and
remove
master
cylinder

from
brake
booster
.

5
.
Make
sure
all
nuts,
fluid
couplings,
thread
bores,
and

mating
surfaces
are
clean
.

MASTER
CYLINDER

6
.
Disconnect
ABS
electrical
connectors
.
Label
and
then

disconnect
brake
lines
from
hydraulic
brake
unit
.
Plug

openíngs
.
See
Fig
.
12
.

~
~
A
1/
B
'1v
C
~
F

lu
11
-ri
J
.

0013244
A
.
Right
front



F



Front
from
master
cylinder
B
.
Leftfront



R
.
Rear
from
master
cylinder
C
.
Rear

Fig
.
12
.
Brake
fluid
linesat
ABS
hydraulic
unit
.

WARNING
-

"
On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
Antilock
Brake
System
(ABS)
.
Removal
of
the
ABS
hydraulic
unit
is
not
recommended
un-
less
this
equipment
is
available
.
For
safetyrea-
sons,
the
brake
system
on
cars
with
ABS
must

not
be
bled
using
the
procedures
described
inthis
repair
group
.

"
Do
not
mix
up
the
fluid
fines
at
the
ABS
hydraulic
unit
Label
all
connections
before
disconnecting
.

7
.
Remove
ABS
hydraulic
unit
from
engine
compartment
.

8
.
Working
inside
car,
remove
panel(s)
frombeneath

steering
column
to
access
pedal
assembly
.
See513
In-

terior
Trim
.

12
.
Make
sure
al¡
nuts,
fluid
couplings,
thread
bores
and

mating
surfaces
are
clean
.

BRAKES
340-
9

0011261

Fig
.
13
.
Brake
pedal
clevispin
and
retaining
clip
(A)
.
Brake
booster
mounting
nuts
shown
at
arrows
.

13
.
If
necessary,
mount
master
cylinder
to
vacuum
booster

using
a
new
O-ríng
and
newself-locking
nuts
.

CAUTION-

Do
not
over-torque
the
master
cylinder
mounting
bolts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

14
.
Installation
is
reverse
of
Rmoval
.

"
Bleed
brakes
as
described
earlier
.

"
Check
and,
if
necessary,
adjust
brake
light
switch

above
brake
pedal
.

Tightening
Torques

"
Brakemaster
cylinder
to

brake
booster
...........
.
..
..
...
26
Nm
(18
ft-Ib)

"
Brake
booster
to
bulkhead
.
.
..
..
...
22
Nm
(16
ft-Ib)

"
Brake
fluidline
to
master
cylinder
or

ABS
hydraulic
unit
.......
.
..
17-19
Nm
(13-14
ft-lb)
9
.
Remove
clip
and
clevis
pin
from
brake
booster
pushrod

and
disconnect
it
from
brakepedal
.
Remove
brake

booster
mounting
nuts
.
See
Fig
.
13
.
NOTE-

10
.
Working
in
engine
compartment,
remove
brake
booster



When
replacing
the
brake
booster
one-way
valve
or
together
with
master
cylinder
.



vacuum
hose,
install
the
valve
so
that
the
molded
arrow

is
pointing
toward
the
intake
manifold
.
Use
new
hose

11
.
If
booster
or
master
cylinder
O-ring
is
being
replaced,



clamps
.

disconnect
master
cylinder
from
brake
booster
.

BRAKE
BOOSTER