2000 BMW 528i installing AC

Downloaded from www.Manualslib.com manuals search engine
.- -
Brakes
Disconnect master cylinder brake lines (A)
Plug open brake lines to prevent contamination.
Remove master cylinder mounting nuts
(6) and remove
cylinder.
NOTE-
It may be necessary to remove the brake booster with master
cylinder attached due to limited access.
Bralce master cylin-
dercan then be removed from booster. See Brake booster,
removing and installing later
in this repair group.
- During reinstallation, make sure all nuts, fluid couplings,
thread bores, and mating surfaces are clean.
- Mount master cylinder to bralte booster using new sealing O-
ring and new self-locking nuts.
CAUTIOI\C
* Be sure to align master cylinderpushrod and booster
pushrod.
* Do not over-torque master cylinder mounting nuts. This
could damage the brake booster and prevent proper
vacuum build-up.
Tightening torque Brake master cylinder to brake booster
26 Nm (19 ft-lb)
- Connect bralte fluid lines to master cylinder.
Tightening torque Brake fluid line to master cylinder
18 Nm (13 ft-lb)
- Carefully reinstall fluid reservoir using new sealing grommets.
- Reconnect precharge pump fluid supply hose, if applicable. -
- Reconnect hydraulic clutch fluid supply hose, if applicable.
- Remainder of installation is reverse of removal.
Top up with fresh brake fluid.
Bleed entire brake system as described earlier

Downloaded from www.Manualslib.com manuals search engine
Brakes
- Pump brake pedal a few times to reduce vacuum in brake
booster. This makes removal of
check valve easier.
- Remove or loosen hose clamp(s) at check valve.
- Disconnect hoses. Remove valve to test or replace.
NOTE-
If valve is pressed into grommet in vacuum booster, pry it out
carefully.
- Reinstall valve using new hose clamps
NOTE-
Install the valve so that the molded arrow is pointing toward
the intake manifold.
Brake booster, removing and installing
CAUTIO&
All E39 vehicles sold in the USA are equipped with Antiloclc
Braking System (ABS) and either Automatic Stability Control
(ASC) or Dynamic Stability Control (DSC). In order for the
bralchg and stability controls to work properk if brake fluid
lines are disconnected and reconnected,
male sure that the
brake system is bled by an authorized BMW dealer or other
qualified repair facility using the BMW Service Tester: See
Brake Bleeding earlier in this group.
- Disconnect negative (-) cable from battery.
I CAUTION- I
Prior to disconnecting the battery read the battery discon-
nection cautions given in
001 General Cautions and
I Warnings. I
- Remove bralte master cylinder as described earlier.
- Disconnect engine vacuum hose from bralte booster.

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
340-28
Brakes
- Remove sensor mounting screws. Lift sensor away from
bracket.
- Installation is reverse of removal.
CAUTION-
Be sure to tighten the DSC acceleration sensor(s) and
mounting bracket, if applicable, to specified torques. The
sensor
is vibration sensitive and subject to cause DSC
malfunctions if installed improperly.
a After replacing the sensor, perform sensor adjustment
using either DIS or
MoDiC under Service Functions
menu.
Tightening
torques
Lateral acceleration I rotational rate sensor 8 Nm (6 R-ib)
to bracket
Sensor bracket to body
8 Nm (6 ft-lb)
DSC steering angle sensor, removing and
installing
4 Remove lower dash panel mounting fasteners (A) and (5).
- Remove steering column lower trim panel. See 320 Steering
and Wheel Alignment.
Remove steering shaft clamping bolt (arrow).
Disconnect sensor wiring harness connector.

Downloaded from www.Manualslib.com manuals search engine
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-

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
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)

Downloaded from www.Manualslib.com manuals search engine
1 410 Fenders. Engine Hood
General ........................... .41 0.2 Engine Hood ...................... 410-6
Special tools ........................ .41 0.2 Hood, raising to service position ......... 410-6
........... Hood. removing and installing 41 0-7 Front Fenders ..................... .41 0.2 Hood. aligning ....................... 41 0-8 Front fender. removing and installing ..... .41 0.2 Hood latch components ............... 41 0-10
Hood release cable and
spring pins, adjusting
................. 410-1 1