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
340-
8
BRAKES
Fig
.
10
.
Brake
fluid
linesat
master
cylinder
(arrows)
.
6
.
If
fluid
reservoir
was
removed,
install
it
carefully
using
new
sealing
grommets
.
7
.
Mount
master
cylinder
to
brake
booster
using
a
new
0-
ring
and
new
self-locking
nuts
.
CAUTION-
Use
cave
not
to
over-torque
the
master
cylinder
mounting
nuts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.
0012164
8
.
Connect
all
brake
fluid
lines
.
Connect
hydraulic
clutch
hose
to
brake
fluid
reservoir
.
9
.
Reconnect
fluid
leve¡
sender,
and
bleed
entire
brake
systemas
described
earlier
.
BRAKE
BOOSTER
BRAKE
BOOSTER
The
brake
booster
is
mounted
to
the
bulkhead
on
the
driver
sideofthe
engine
compartment,
directly
behind
the
brake
master
cylinder
.
See
Fig
.
11
.
0015225
Fig
.
11
.
Brake
booster
(arrow)
.
A
is
vacuum
hose
from
intake
mani-
fold
.
B
is
one-way
valve
.
Intake
manifold
vacuum
acts
ona
large
diaphragm
in
the
brake
booster
to
reducebrake
pedal
effort
.
Brake
booster,
removing
and
installing
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
vi¡¡
.
Tightening
Torque
"
Brake
master
cylinder
to
2
.
Using
a
clean
syringe,
empty
brake
(luid
reservoir
.
brake
booster
.....
..
.
..
.........
26
Nm
(18
ft-Ib)
WARNING-
"
Brake
fluid
hose
to
caliper
....
17-19
Nm
(13-14
ft-Ib)
Brake
fluid
is
highly
corroslve
and
dangerous
to
the
environment
.
Dispose
of
it
properly
.
3
.
Remove
brake
fluid
level
sender
connector
from
reser-
voir
cap
.
4
.
Disconnectbrake
fluid
lines
from
master
cylinder
.
Plug
openings
.
5
.
Disconnect
engine
vacuum
hose
from
brake
booster
.
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
7
.
Turn
on
ignition
.
Check
that
light
comes
on
as
soonas
4
.
Remove
parkíng
brake
shoes
as
described
above
.
lever
is
pulled
up
.
5
.
Disconnect
cable
from
parking
brake
actuator
and
then
8
.
Install
parking
brake
lever
boot
.
Install
road
wheel
lug
remove
parking
brakecable
from
cable
holder
on
trail-
bolts
.
ing
arm
.
See
Fig
.
17
.
Tightening
Torque
"
Road
wheel
to
hub
.
..
......
100±10
Nm
(74±7
ft-Ib)
Parking
brake
shoes,
removing
and
installing
1.
Raise
rear
of
car
andremove
road
wheels
.
WARNING
-
Make
sure
the
car
is
firmly
supportedon
jack
stands
designed
for
the
purpose
.
Place
the
jack
stands
be-
neath
a
structural
chassis
point
.
Do
not
place
jack
stands
undersuspension
parts
.
2
.
Without
disconnecting
brake
fluid
hose,
remove
rear
brake
calipers
from
trailing
arms
.
Remove
rear
brake
rotors
.
See
Brake
Pads,
Calipers
and
Rotors
.
CA
UTION-
Do
not
let
the
brake
caliper
assembly
hang
from
the
brake
hose
.
Support
caliper
from
chassis
with
strong
wire
.
3
.
Unhook
upper
return
spring
from
brake
shoes
.
Remove
shoe
retainers
bypushing
them
in
and
rotating
1
/4turn
.
BMW
special
tool
no
.
344
000
can
beused
to
remove
retainers,
if
needed
.
4
.
Spread
shoes
apart
and
lift
them
out
.
7
.
Installation
is
reverse
of
removal
.
Adjust
parking
brake
as
described
earlier
.
NOTE-
When
removing
the
brake
shoes
the
shoe
expander
pivot
pin
in
the
brake
actuator
may
fall
out
.
Two
versions
of
the
Antilock
Brake
System
(ABS)
are
in-
5
.
Inspect
shoe
expander
to
make
sure
it
functions
prop-
stalled
onthe
cars
coveredby
this
manual
.
Early
cars
use
the
erly
.
Apply
a
thin
coat
of
grease
tosliding
parts
and
Teves
Mark
IV
G
ABS
.
Later
cars
use
the
Teves
Mark
20-I
pins
.
ABS
.
The
main
difference
between
the
two
systems
is
that
the
Mark
20-I
system
integrates
the
ABS
control
module
into
the
6
.
Installation
is
reverse
of
removal
.
Be
sure
to
adjust
hydraulic
unit
as
a
single
component
.
parking
brake
cables
as
described
earlier
.
ABS
is
designed
to
be
maintenance
free
.
There
are
noad
Parking
brake
cable,
replacing
justments
that
canbe
made
to
the
system
.
Repair
and
trouble-
shooting
of
the
major
ABS
components
requires
special
test
1
.
Raise
rear
of
car
and
remove
road
wheels
.
equipment
and
knowiedge
and
should
be
done
by
an
autho-
rized
BMW
dealer
.
2
.
Remove
rear
brake
caliper
and
rotor
.
See
Brake
Pads,
Calipers
and
Rotors
.
3
.
Working
inside
car,
lift
parking
brake
lever
boot
out
of
console
.
Remove
cable
adjusting
nut
.
Refer
to
Fig
.
15
.
Fig
.
17
.
Parking
brake
cable
insertion
point
in
rear
trailing
arm
(arrow)
.
6
.
Slide
cable
out
of
housing
.
NOTE
-
BRAKES
340-
1
1
On
some
models
it
may
be
necessary
to
remove
rear
muffler
to
access
the
brake
cabes)
.
ANTILOCK
BRAKE
SYSTEM
(ABS)
0013209
ANTILOCK
BRAKE
SYSTEM
(ABS)
ELE-50
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FRONT
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LEFT
LOW
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WASHER
WASHER
BEAM
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THEFT
TEMPERATURE
PRESSURE
FOG
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FAN
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BEAMBEAM
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FOG
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RIGHT
PUMP
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1995-96
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WASHER
WASHER
FLUID
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AUXILIARY
WASHER
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LEVEL
WIPER
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BLOWER
TURNMODULE
FLASHER
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MODULE
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RADIO
RADIO
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INDEX
Brakes
(cont
.)
pressure
bleeding
brakes
(except
cars
wíth
AST)
340-3
troubleshooting
340-1
Brushes,
alternator
See
Battery,
starter,
alternator
Bulbs
See
Exterior
lighting
See
also
Instruments
Bumpers
See
Exterior
trim,
bumpers
C
CamberSee
Steering
and
wheel
alignment
Camshaft
See
Cylinder
head
and
valvetrain
Camshaft
position
sensor
See
Ignition
system
Camshaft
timing
chain
general
information
117-1
camshaft
timingchain,
4-cylinder
117-
2
camshaft
timing
chains,6-cylinder
117-6
camshaft
timing
chain,
removing
(4-cylinder
engines)
117-2
camshaft
timing
chains,
removing
(6-cylinder
engines)
117-7vanos
(variable
valve
timing)
117-14
control
unit,
removing
117-16system
operation,
testing
117-14
Caster
See
Steering
andwheel
alignment
Catalytic
convertor
See
Exhaustsystem
Cautions
viü
Center
bearing
See
Driveshaft
Center
console
See
interior
trim
Central
body
electronics
(ZKE
IV)
515-8
Central
locking
system
(ZVM)
515-7
Centrallocking
and
anti-theft
general
information
515-1
door
handles
and
Iocks
515-1
door
striker,
replacing
515-6
front
door
handle,
removing/
installing
515-3
front
door
lock,
removing/installing
515-1
rear
door
handle,
removing/installing
515-5
rear
door
lock,
removing/installing
515-4
EWS
II
control
module,
replacing
515-10
EWS
II
ring
antenna,
replacing
515-10
EWS
II
transmitter/receiver
module,
replacing
515-11
locking
system
and
electronic
immobilization
515-7
luggage
compartment
locking
actuator,
removing/installing
515-6
Clutch
general
information210-1
clutch
hydraulic
system,
bleeding
and
flushing
210-2
clutch,
inspecting
and
installing
210-5
clutch
master
cylinder,
replacing
210-2
clutch,
removing
210-4
clutch
slave
cylinder,
replacing
210-3
transmission
pilot
bearing,
replacing
210-6
Clutch
fluid
See
Maintenance
program
Coil
See
Ignition
system
Coilspring
See
Rear
suspension
Component
locations
See
Electrical
component
locations
Compressor
See
Air
conditioning
Compressor
clutch
See
Air
conditioning
Condenser
See
Air
conditioningControl
arms
See
Front
suspension
See
also
Rear
suspension
Convertible
top
general
information
541-1
manual
convertible
top
541-1
lid
release
mechanism
541-2
replacing
541-2
visor
latch
541-1
visor
latch
píate
541-1
power
convertible
top
541-2
drive
motor,
replacing
541-7
emergency
operation
541-7
front
latching
mechanism
541-4
lid
541-9
replacing
541-5
visor
latch
541-4
visor
latch
motor541-5
visor
latch
plate
541-4
rollover
protection
system
541-9
Coolant
(Anti-freeze)
See
Maintenance
program
Coolant
pump
See
Cooling
system
Cooling
system
general
information
170-1
cooling
fan,
replacing
170-8
coolant
pump,
replacing
170-10
coolant
pump
and
thermostat170-1
coolant,
draining/filling
170-5
cooling
fans
170-2
cooling
fan,
testing
170-4
cooling
system
service
170-5
cooling
system,
bleeding
(radiator
with
integral
expansion
tank)
170-6
cooling
system
pressure
test
170-3
electric
cooling
fan,
replacing
170-8
radiator,
removing/installing
170-11
Cooling
system
(cont
.)
radiator
and
expansion
tank
170-1
radiator
service
170-11
temperature
gauge
quick
check170-3
thermostat
quick
check
170-3
thermostat,
replacing
170-9
troubleshooting
170-2
warnings
and
cautions
170-2Crankshaft
position/rpm
sensor
See
Ignition
system
Crash
sensor
See
Airbag
system
(SRS)
CV
joint
See
Maintenance
program
See
also
Rear
suspension
Cylinder
head
and
valvetrain
general
information
116-1
camshaft116-7
camshafts,
removing/installing
(M42
engine)
116-1camshafts,
removing/installing
(M44
engine)
116-3
camshafts,
removing/installing
(6-cylinder
engine)
116-4
cylinder
head,
disassembly/assembly
116-1
cylinder
head
and
valvetrain,
reconditioning
116-7
cylinder
head
116-7
hydraulic
cam
followers,
checking
and
replacing
(M42
and
al]
6-cylinder
engines)
116-9
hydraulic
valve
adjusters,
checking
and
replacing
(M44
Engine)
116-8
valve
guides
116-10
valveseats
116-12
valve
springs
116-12
valve
stem
oil
seals
116-11
valves
116-11
valves,
leak
test
116-11
valves,removing/installing
116-6
Cylinder
head
removal
and
installation
general
information
113-1
cylinder
head,
removing/installing
(4-
cylinder
engine)
113-1
cylinder
head
(6-cylinder
engine),
removing/installing
113-10
Dashboard
See
Interior
trim
Deck
lid
See
Trunk
lid
Defogger
See
Heating
Differential
See
Final
drive
DISA
(dual
resonance
intake
system)
See
Fuel
injection
See
also
Engine-general
DME
(digital
motor
electronics)
See
Ignition
system
See
alsoFuel
injection