1998 BMW 528i 340 brake

Downloaded from www.Manualslib.com manuals search engine
General ........................... .34 0.2
Special Tools
....................... .34 0.2
E39 brake system
.................... .34 0.4
Electronic braking and stability control
.... .34 0.4
Troubleshooting
..................... .34 0.5
Warnings and cautions
................ .34 0.7
Bleeding Brakes ................... .34 0.8
Brakes, bleeding
..................... .34 0.9
Brake Pads, Calipers and Rotors ... .34 0.1 1
Braking system components .......... .34 0.11
Brake pads,
checking and replacing ..... .34 0.12
Brake rotors, removing and installing
.... .34 0.15
Master Cylinder .................. .34 0.16
Master cylinder, removing and installing
. .34 0.17
Brake Booster .................... .349 0.1
Brake booster check valve
............ .34 0.19
Brake booster, removing and installing
.. .34 0.20
Parking Brake .................... .34 0.22
Parking brake components
............ .34 0.22
Parking
brake, adjusting .............. .34 0.22
Parking bralte shoes, removing
and installing
....................... .34 0.23
Parking
brake cable, replacing ......... .34 0.24
ABS Component Replacement ..... 340-26
Wheel speed sensor. replacing
......... 340-26
ABS impulse wheel
.................. 340-27
DSC lateral acceleration or
rotational rate (yaw) sensor. replacing
... 340-27
DSC steering angle sensor.
removing and installing
............... 340-28
DSC precharge pump.
removing and installing (1998 models)
... 340-29
DSC pressure sensor
(1 999 - 2002 models) ................ 340-30
ABS /traction electronic control
module
(1 997 -1 998 models) .......... 340-31
ABS
/ DSC control module
(1 999
- 2002 models) ................ 340-31
ABS
/ traction control hydraulic unit.
removing and installing
............... 340-31

Downloaded from www.Manualslib.com manuals search engine
340-6
1 Brakes
Brake system troubleshooting
/symptom I Probable cause 1 Repairs
Brake squeal
Pedal goes to floor when
bralting
Low pedal after system bleeding
Pedal spongy or brakes work
only when pedal is pumped
Excessive braking effort
Brakes pulsate, chatter or grab
Uneven
bralting, car pulls to one
side, rear braltes
loclt
Brakes drag, bind or overheat Brake
pad carriers dirty or corroded or
pads loose (poor fit) in pad carrier
Braite pads heat-glazed or oil-soaked
Wheel bearings worn (noise most
pronounced when turning)
Incorrectly Installed brake pads,
parking bralte shoes, or bralte parts
Brake fluid loss due to system leaks
Master cylinder or traction control
system faulty
Master cylinder faulty
Air in braite fluid
Master cylinder or traction control
system faulty
Brake pads wet
Brake pads
heat-glazedorfluid-soalted
Vacuum booster or vacuum hose
connections to booster faulty
--- Warped brake rotors
Brake pads worn
Brake pads heat-glazed or oil-soaked Remove
brake pads and clean calipers. Use original
equipment pads for proper fit and use BMW anti-squeal
compound during installation,
Replace brake pads. Ciean rotors. Replace leaking caliper:
as required.
Replace worn bearings. See 310 Front Suspension
or33C
Rear Suspension.
Check component installation. Checldreplace anti-rattle
springs.
Checlt fluid level and inspect for signs of leakage.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Replace master cylinder.
Bleed system using factory or compatible diagnostic tool.
Replace master cylinder. Diagnose traction control system
using factory or compatible diagnostic tool.
Use light pedal pressure to dry pads while driving.
Replace
bralte pads and rotors. Replace leaking calipers.
lnspect vacuum lines. Test vacuum booster and replace as
required. Test vacuum non-return valve for one-way flow.
Resurface or replace rotors.
Replace brake pads.
Clean rotors. Replace leaiting calipers.
Incorrect tire pressures or worn tires
Brake pads on one side of car heat-
glazed or fluid-soaked
Caliper or brake pads binding
Worn suspension components
Brake caliper or brake pads binding
Master cylinder or traction control
system faulty lnspect
tire condition. Checlt and correct tire pressures.
Replace brake pads. Clean rotors. Replace leaking
calipers.
Clean and recondition brakes.
Inspect for worn or damaged suspension components. See
310 Front Suspension or 330 Rear Suspension.
Ciean or replace caliper.
Replace master cylinder. Diagnose traction control system
using faclory or compatible diagnostic tool.

Downloaded from www.Manualslib.com manuals search engine
340-8
1 Brakes
Brake bleeding is usually done for one of two reasons: either
to replace old brake fluid as part of routine maintenance or to
expel trapped air in the system that resulted
from opening the
brake hydraulic system during repairs.
Read the
Warnings listed below before beginning the bleed-
ing procedure an on any
E39 car. If air enters the ACS or DSC
hydraulic unit, the factory BMW Service Tester MUST be
used in conjunction with a bralte pressure bleeder before the
vehicle is driven.
The BMW
ServiceTester (DISpluslGT1iMoDiC) must be
used to bleed the braltes if:
Any hydraulic brake system components are replaced, in-
cluding bralte lines.
Air has enter the
ABSIASC or ABSlDSC hydraulic unit.
WARNING -
* The ASC and DSC systems use electronic controls and a
sophisticated hydraulic unit Once air enters the hydraulic
unit, it is very difficult to remove using traditional methods.
For this reason, pressure
brake bleeding should be done
in conjunction with the BMW
Sewice Tester (DIS-
plus/GTl/MoDiC). The tester electrically cycles the hy-
draulic unit solenoids in the hydraulic unit while
pressurized brake fluid is forced through the system.
When flushing the brake fluid from the system, use ex-
treme care to not let the
brale fluid reservoir run dry If
air enters the hydraulic unit, the BMW Service Tester
MUST be used to bleed the brale system before the
vehicle is driven.
Always use new brake fluid from an unopened container. It is
important to bleed the entire system when any part of the hy-
draulic system has been opened. Be sure to have the special
equipment needed before beginning the job.
When bleeding the
braltes, start atthe wheel farthest from the
master cylinder and progress in the following order:
right rear brake
left rear brake
* right front brake
left front brake

Downloaded from www.Manualslib.com manuals search engine
340-1 2
Brakes Brake pads, checking and replacing
Brake pads can be replaced without disconnecting the brake
fluid hose from the caliper or having to bleed the brakes. The
rotors can be replaced without disassembling wheel hub and
bearing. Always machine or replace rotors in pairs. Replace
pads in sets.
Front and rear brake pad replacement procedures are identical.
WARNING -
* Altllough semi-metallic andmetallic brale friction materials
in brake pads or shoes no longer contain asbestos, they
produce dangerous dust.
Treat all
brale dust as a hazardous material.
Do not create dust by grinding, sanding, or cleaning
brake friction surfaces with compressed air.
CAUTION--
Pressing caliper piston in may cause brake fluid reservoir to
overflow To prevent this, use a clean syringe to first remove
some fluid
from reservoir.
Raise car and remove wheels,
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
/ 4 To measure brake pad lining thickness, insert BMW special
n 1 tool 34 1 260 at either frontilght wheel or left rear wheel -
Move wheel until notch for brake wear indicator can be
seen through wheel opening.
Insert tip of tool into notch so that the body of tool rests on
brake pad backing plate
(A), and tip touches bralte disc
(B).
Replace pads if thickness is 3.0 mm (0.12 in) or less.
Pry off
bralte calipe~ , anti-rattle spring (arrow).

Downloaded from www.Manualslib.com manuals search engine
340-1 4
Brakes
4 Apply a thin coating of BMW anti-squeal compound to caliper
contact face
(arrow).
Do not apply grease to brake pad backing plate.
Right Left
CAUTION-
Do not let calliper rubber dust sleeve come in contact with
anti-squeal compound. The rubber will swell and deteriorate.
4 Apply a thin coating of BMW anti-squeal compound to bralte
pad rests (arrows) on pad carrier.
4 When installing directional brake pads, install the marked
pads as shown.
NOTE-
BMW-supplied (OEM) front brake pads may be marked as di-
rectionalpads. Aftermarket brands are generally not labeled
as directional. When installing directional pads, be sure to in-
stall them as indicated in the illustration.
- Where applicable, insert brake pad wear sensor into cutout
in new pad. Push sensor into pad cutout until it locks into
place.
- -
- NOTE-
If brake lining indicator light illuminatedprior to brake pad re-
placement, replace wear sensor.
- Route pad wear sensor wiring through caliper opening and
under bleeder dust cap.

Downloaded from www.Manualslib.com manuals search engine
340-1 5
Brakes
- Remainder of installation is reverse of removal.
- Clean brake caliper mounting bolts (7 mm Allen). Replace
ones which are not in perfect condition. Do not grease.
Top up brake fluid to MAX marking.
- Before driving car, pump bralte pedal several times so that
brake pads contact brake rotors.
Check that brake fluid level is correct. Top up if necessary.
Hold ignition key for at least
30 seconds in accessory po-
sition without starting engine. This clears any fault codes in
memory and turns off brake pad warning light.
Tightening torques Brake caliper to pad carrier
(7 mm Allen)
Front caliper
30 Nm (22 It-lb)
- Rear caliper 28 Nm (21 It-lb)
Road wheel to hub
120i 10 Nm (89i7 ft-lb)
Brake rotors, removing and installing
- Raise car and remove wheels
WARNING-
Male sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
Remove brake caliper carrier bolts (arrows). Suspend brake
caliper from chassis using stiff wire.
NOTE-
Hydraulic brake line remains connected.
4 Remove bralte rotor mounting screw (arrow) and remove ro-
tor.
- Inspect rotor for cracks, signs of overheating and scoring.
- Minimum allowable thickness (MIN TH) is stamped on rotor
hub. Measure rotor braking surface with a micrometer at
eight to ten different points and use the smallest measure-
ment. Compare to specifications in table below.
- If rotor does not pass minimum thickness requirements or is
damaged, replace rotor.

Downloaded from www.Manualslib.com manuals search engine
340-23
Brakes
- Using flat-bladed screwdriver, reach into brake drum through
lug bolt hole. Turn brake adjuster until wheel no longer turns.
Back adjuster off
12 notches.
Parking brake adjusting (initial)
Back
off adjuster through wheel
lug bolt hole 12 notches
- Working inside car, set parking brake several times to seat
cable. Then pull parking brake
lever up two notches. Tighten
cable adjusting nuts until it is just possible to turn rear wheels
with slight resistance.
- Release lever and make sure rear wheels turn freely
- Turn on ignition. Pull up parlting brake lever 1 notch and
make sure that parking bralte warning light comes on. if not,
adjust parking bralte warning light contact switch.
- Install parking brake lever boot. Install road wheel lug bolts.
Tightening torque Road
wheel to hub 120 i. 10 Nrn (89 i- 7 ft-lb)
Parking brake shoes, removing and
installing
- Raise rear of car and remove road wheels.
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for
the purpose. Place jack stands beneath structural
chassis points. Do not place
jaclc stands under suspension
parts.
- Without disconnecting brake fluid hose, remove rear bralte
calipers from trailing arms. Remove rear brake rotors as de-
scribed earlier.
CAUTION-
Do not let the brake caliper assembly hang from the brake
hose. Support caliper from chassis with strong wire.
4 Unhook return sprlngs (arrows) from brake shoes

Downloaded from www.Manualslib.com manuals search engine
340-24
Brakes
4 Remove brake shoe retaining pins using BMW special tool
34 4 000 or equivalent.
Rotate retainer
114 turn to release.
Spread shoes apart and lift out.
4 Note position of bralte shoe adjuster (arrow).
Right side is illustrated. Left is mirror image of this.
- Apply thin coat of grease to sliding parts and pins before re-
assembly.
- Installation is reverse of removal. Be sure to adjust parlting
bralte cables as described earlier.
Tightening torque
Road wheel to
hub 120 i lo Nm (89 i 7 ft-lb)
Parking brake cable, replacing
The parking brake is actuated by two separate Bowden ca-
bles. Each cable can be replaced separately.
- Working inside car, gain access to base of parking brake -
handle by removing center console storage tray and center
armrest, as necessary.
4 Use BMW special tool 34 1 030 or equivalent deep 10 mm
socket to remove parlting brake cable
loclc nuts (A) at base of
parking brake handle.
- Raise rear of car.
WARNING -
Male sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jaclc stands under suspension
Darfs.