2001 BMW 540i AC line

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-- I
I: ... . -. Rear Suspension! -- .- -
Air compressor pump relay, removing and
installing
- Working in cargo compartment, remove spare wheel.
4 Remove air supply pump fasteners (arrows). Turn pump
over.
- Turn relay plug 45" and remove relay.
EHC control module, removing and
installing
The EHC control module is mounted on the right side of the
spare tire
well in the cargo compartment.
- Remove spare tire.
4 Remove electrical components cover (A).
- Release control module wiring harness plug loclting clip (B)
and remove module.
- Installation is reverse of removal.
- After assembly, reset ride height using BMW diagnostic scan
tool DIS.
Air supply unit, removing and installing
CAUTION-
Maintain high levels of cleanliness around air line connec-
tions when disassembling and assembling air suspension
components. Even small dirt particles can cause
leakage in
the pressurized system.
When the airsupply unit is removed for any reason, reset ride
height using BMW scan tools DIS or
MoDiC.
- Remove spare tire.
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Rear Suspension
4 Remove air line fittings (A) from bottom of air distribution con-
nectors.
Cut off wire ties.
WARNING-
Vehicle will lower when the air pipes are opened.
4 Rotate air line distribution connector (A) 45" in direction of
arrow to remove.
Rotate electrical connector
(B) 45" in direction of arrow to
remove.
Compress wiring connector locking clips
(arrows) and dis-
connect wiring harness.
< Remove air supply unit mounting fasteners (arrows) and re-
move unit.
- Installation is reverse of removal.
When installing air lines always match line colors.
a After assembly, reset ride height using BMW diagnostic
scan tool DIS.

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331-1 1
Final rive(
< Coat seal with differential oil and drive into place using BMW
special tools 00 5 500 and 33 4 250 or equivalent.
Replace snap ring (arrow) on final drive output flange shaft.
Coat output flange
shaft with differential oil where it con-
tacts shaft seal.
. Push output flange into final drive until flange splines en-
gage splines of differential gear and snap ring can be
heard to snap into place.
- Remainder of installation is reverse of removal.
Check and, if necessary, set differential oil level. See Dif-
ferential oil level, checking.
Tightening torques Drive axle to final drive flange
Torx bolts
(M10) 83 Nm (61 ft-lb)
Torx bolt with ribbed teeth (M10) 64 Nm (47 it-lb)
Torx bolt with ribbed teeth (Mi0 silver) 80 Nm (59 ft-lb)
Torx bolt with ribbed teeth (MI0 black) 100 Nm (74 ft-lb)
- Torx bolt with ribbed teeth (M12) 135 Nm (100 ft-lb)

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I Final Drive
4 Support inner hub with BMW special tools 26 1 110 and
press axle shaft out of joint using BMW special tool 21 2 120.
- Clean all old lubricant off shaft splines and inner joint splines.
If the CVjoint must be disassembled for cleaning and inspec-
tion, be sure to matchmark inner and outer race and interme-
diate ball cage. This allows reassembly
ofparfs in their
original positions.
NOTE-
To inspect a CVjoint, clean away the grease and loolc forgall-
ing, pitting, and other signs of wear orphysical damage. Pol-
ishedsurfaces or visible ball traclts alone are not necessarily
cause forreplacement. Discoloration due to overheating indi-
cates
laclt of lubrication.
- Slide CV joint boot onto axle shaft
- Apply LoctiteO270 or an equivalent heavy-duty loclting corn-
pound to drive axle splines. Position new CV joint on shaft so
that raised or taller side of hub is facing shaft.
WARNING-
Do not let the locking compound contact the balls in the joint.
Apply only a thin coat to cover the splines.
While supporting axle shaft with BMW special tool
33 2 130
press inner hub of CV joint onto shaft. Install a new circlip.
- Install new boot clamps.
- Use sealing gel to seal dust cover to CV joint prior to reinstal-
lation.
NOTE-
* Do not let the ball hub pivot too far in the outer ring of the
joint.
Tlie balls will fa1 out.
Before installing each small boot clamp be sure to
'burp"the
boot by flexing the CVjoint. A small screwdriver inserted be-
tween the boot and the axle shafl will help the process.
CV joint lubricant capacity
Wheel hub end
80 gram (2.8 oz)
Differential end
85 gram (3.0 oz)

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, Brake caliper bolt tool
4 ASC bleeder wrench
(Tool No. BMW 34
3 110)
4 Brake line flare wrench set (12 mm, 14 mm, 17 mm, 19 rnm)
(Tool No. BMW 34 3 150)
34 3 152
34 3 153
34 3 154
4 DSC Dressure sensor installation socltet
4 ABS IASC or ABSI DSC control unit 42-pin harness adapter
(break-out adapter)
(Tool No. BMW 34 5 240)
0
(Tool NO. BMW 34 5 160)

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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.

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Brakes
Warnings and cautions
WARNING-
. E39 cars require special BMWsen/ice equipment toprop-
erly bleed the brake hydraulic system. See Bleeding
Brakes for additional information.
Semi-metallic and metallic brake friction materials in
brake pads or shoes may produce dangerous dust.
Brake fluid is poisonous, corrosive and dangerous to
the environment. Wear safety glasses and rubber
gloves when worliing with
bralie fluid. Do not siphon
brake fluid with your mouth. Dispose of brake fluid
properly
Do not reuse self-locking nuts, bolts or fasteners. They
are designed to be used only once and may fail if re-
used. Always replace them with new self-locliing fas-
teners.
CAUTlOI\C
Immediately clean bralie fluid spilled on painted surfaces
and wash with water, as
bralie fluid will remove paint.
Always use new brake fluid from a fresh, unopened
container.
Brake fluid will absorb moisture from the air.
This can lead to corrosion problems in the
braking sys-
tem, and will also lower the fluid boiling point.
. Plug open lines and brake fluid ports to prevent con-
tamination.
Only tighten brake hoses on front wheels
with wheels
in straight ahead position.
If carrying out electric welding
worlc, be sure to discon-
nect electrical harness connector from electronic con-
trol module.
Do not expose electronic control modules to high sus-
tained heat, such as in a paint drying booth. Maximum
heat exposure:-95°C (203
OF) for short periods of time-
85'C (185°F) for Ions periods of time (approx. 2 hours)

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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