Honda Bmw 5 Service Manual

							
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-   
						

							
1 Brakes 
- Remove precharge  pump mounting  bracket fasteners  and re- 
move pump. 
- Installation  is reverse  of removal, noting  the following: 
Be  sure  to replace rubber  pump mounts  if damaged 
01 
worn. 
Bleed  brakes as  described  earlier. 
Tightening torque  Brake  line 
to precharge  pump 18 Nrn (13 ft-lb) 
DSC pressure  sensor (1 999 - 2002 models) 
On 1999 and later DSC systems, the  DSC pressure sensor is 
screwed into the  DSC hydraulic unit (right rear of engine com- 
partment). 
WARNING- 
* €39 cars  require  special  BMW service  equipment  to prop- 
erly bleed  the brakes.  Removal  of the 
DSCpressure sensor 
is  not  recommended unless  this equipment is available.  For 
safety  reasons, the  brake system  on cars  with ABS  must  be 
bled  using  the procedures described  in this  repair  group. 
Switch  off ignition  and remove 
key to male  sure brake 
system cannot  be activated. 
- Disconnect electrical harness connector at switch. 
- Use BMW special tool 34 5 160 to remove  and install  sensor. 
Inspect threads and sealing surfaces  for damage. 
* Work quicltly to avoid excessive  brake fluid leakage. 
Tightening  torque 
Pressure  sensor 
to hydraulic  19  Nrn (14ft-lb) 
unit 
- Reconnect harness connector 
- Bleed front  brakes as  described earlier. 
- Press on brakes  and check  for leaks at sensor. 
- Turn  on ignition and firmly depress brake  pedal. Check that 
DSC warning light does not  come on.   
						

							
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.   
						

							
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)   
						

							
400 Body-General 
........................ General ........................... .40 0.2  Roof paddin~ 400-7 
Body Assembly ................... .40 0.2 
Body dimensions (in inches) 
............ .40  0.2 
Bodyshell 
........................... 400-3 
Exterior  and aerodynamics 
............. .40 0.3 
Sport Wagon ...................... .40 0.4 
Tailgate 
............................ .40  0.5 
Tailgate lock  system 
.................. .40 0.5 
Rear wiper  system ................... .40 0.6 
Antenna  and sound system ............ .40 0.6 
Safety  and Security  Features ....... .40 0.7 
Safety cage 
......................... .40  0.7 
Door  locks  and door  handles 
........... .40 0.7 
. 
........................... Seat belts  400-7 
Airbags ............................ 400-8 
Battery safety terminal (BST) 
........... 400-9 
Security 
............................ 400-9 
Interior  Features ................... 400-9 
............................. Seats 400-10 
Instruments and controls .............. 400-10 
Central body  electronics 
.............. 400-1 1 
Heating and Air 
Conditioning (IHKA) 
............... 400-12   
						

							
400-2 
Body-General 
This chapter covers system descriptions and  general infor- 
mation for  the repair groups  found in sections 
4 Body and 
5 Body Equipment. 
Body dimensions  (in inches) 
E39 sedan  E39 
Sport  Wagon   
						

							
Body shell 
Exterior and aerodynamics 
Crash behavlor -frontal impact 
-side  impact 
Body 
-rear  impact  Structural body components  -rigidity 
-rollover -strength -vibrations -acoustics 
Bumpers  compartment lid -bendable Seets,.steerlng system .dents -vibrations bars -vibration patterns 
Fenders -aerodvnamic 
With its traditional styling features,  such as the ltidney grille. 
circular headlights  behind a glass cover (for reasons  of 
streamlining),  and the 
kiclt in the  rear most  roof pillar (C-pil- 
lar), the E39 can be immediately recognized as a BMW. 
The BMW 5 Series chassis is a unibody design constructed  of 
high strength  steel. Attaching parts,  such as the  front fenders, 
rear quarter  panels, doors, 
trunk lid and hood are also  con- 
structed  of 
steel. 
Computer  aided design (CAD) techniques have been used  in 
refining  the 
E39 body to reduce vehicle weight while retaining 
strength  and increasing torsional  rigidity. For  good handling 
purposes, the  more rigid the structure  the more precisely  the 
suspension  can operate. 
Wind  resistance 
Windows  bonded flush to the body and  the guided  flow of 
cooling  air into  the engine compartment provide the 
carwith a 
good  coefficient  of drag  (Cd). 
E39 cars have  been designed 
for balanced aerodynamics but not necessarily  an extremely 
low  Cd.  See table  below. 
Windshield wipers are designed for effectiveness  at speeds 
up  to and  beyond  200 
ltph (124 mph). 
Coefficient of aerodynamic drag (Cd) 
6-cylinder  sedan  0.30 
V-8 sedan 0.31 
6-cylinder  Sport Wagon  0.31 
V-8 Sport Wagon  0.33 
Fenders 
The  exterior panels are corrosion-resistant zinc coated (gal- 
vanized) steel.  The front fenders are bolted on. For front  fend- 
er  replacement information, see 
410 Fenders,  Engine 
Hood.   
						

							
400-4 
I Bodv-General 
Bumpers 
The front  and rear bumpers are clad  in high  quality 
deform- 
able plastic  and, at  solid barrier impact speeds  of 4 kph  (2.5 
mph), provide  protection  with virtually  no damage  to the 
bumper 
orthe vehicle.  In addition  to hydraulic dampeners. 
which absorb  the initial impact energy, these bumpers  are 
backed  by compressible  tubes. These deform in  a controlled 
manner  at impact  speeds greaterthan  that 
forwhich bumpers 
and hydraulic dampeners are designed.  This helps avoid ex- 
pensive damage  to the body  at impact  speeds  up to 14  kph (9 
mph). 
The E39  Sport Wagon was  introduced to  the US market in 
911 998 (model  year 1999).  It shares many components with 
the  E39  sedan  and is identical to  it from  the B-pillar  forward. 
US 
marltet 5  Series  Sport Wagons  are available  in two vari- 
ants: 
6-cylinder 
(5251, 528i) powered  by the  2.8 liter M52 TU en- 
gine  (1 999) or the  2.5 liter M54 engine (2000  and later) 
* V-8 (540i) powered  by the 4.4 liter  M62  TU engine 
The  wheelbase  of the  Sport Wagon is the same as  the sedan. 
Howeverthe  body is 30 
mm (1.2 in) longer  and 10 mm (0.4 in) 
higher. 
The  Sport  Wagon  rear suspension was redesigned to  elimi- 
nates  the upper  rear spring strut  mounting on the  E39 sedan. 
The  use of separate coil  springs and 
shoclc absorbers results 
in  a flat,  wide floor  in the  cargo  area. See 
300 Suspension, 
Steering  and Brakes-General. 
The  self-leveling air  spring suspension system (electronic 
height control  or EHC) is standard  on Sport Wagon V-8  mod- 
els  and  optional  on 6-cylinder models. 
Sport  Wagon cargo  capacities are shown below. 
Sport  Wagon  load capacities 
Cargo  capacity 
Rear seat up 909 liters (32.1 cu ft) 
Rear seat  folded down I809 liters (63.9 cu ft) 
Load  limit 
Cargo  compartment 
460 Kg (1014 lb) 
Roof 
I00 Kg (220 lb)   
						

							
400-5 
Body-General 
Tailgate 
The E39 Sporl Wagon tailgate is large with a low sill  for easy 
cargo loading.  The tailgate opens to  an angle  of 
88 mea- 
sured from the  rear roof pillar (D-pillar)  and to a height  of 
2029 
mm (79.8 in) measured  from the ground  to the upper edge  of 
the  raised tailgate. 
The  rear window is  bonded to a load  bearing  frame and can 
be  opened separately  from the main  tailgate.  Tailgatesupport 
gas springs  are recessed into cavities  in the roof. 
Tailgate  lock system 
A mechanical tailgate lock cylinder is not  used; the tailgate is 
opened  by the unlock  pad above the license plate,  the remote 
tailgate  switch located  in the drivers kick panel, or via 
FZV 
(Iteyless entry) control. 
4 An emergency  release mechanism is incorporated  into the 
latch assembly  to open  the hatch from  the vehicle interior  if a 
malfunction occurs. 
The  tailgate lock assembly includes  an automatic soft close 
(SCA) feature.  The electrical operation  of SCA  is a function  of 
central  body electronics 
(ZKE Ill). The SCA actuator  is locat- 
ed  in the  rear cowl  panel below  the tailgate.  The actuator is 
controlled by  a load relay in the  General Module.  A locking 
cam  is mounted  on an eccentric that is driven by  the actuator. 
4 The  SCA cam always turns  in the same  direction to open  or 
close the  tailgate. The cam  turns 
180 to open  or to close. 
When the cam turns  in the up direction the notch  in the  cam 
SCA actuator pushes  on a lever  on the  back of the  latch in the tailgate.  This 
mechanically unlocks the latch.  The tailgate is raised  up and 
can be  opened.   
						

							
. 
I Body-General 1 
Rear wiper system 
The rear wiper assembly on the E39 Sport Wagon  is a self- 
contained  unit. The control electronics are integrated into the 
gear  drive that  is part  of the motor  assembly.  The control elec- 
tronics contain two hall sensors,  one 
forthe park position and 
one 
forthe end  stop or  to signal  reverse direction  of the wiper 
motor. 
- 
Wiperlwasher 
stalk  switch 
/ 4 - 3 
502400100 
4 The rear wiper is controlled through the  stalk switch on the 
steering column. The switch includes the following  functions: 
Intermittent  rear window  wiping 
Programmed rear  window wiping interval 
Operation  of rear  window washer 
The  wiper  system automatically controls the following safety 
and  convenience features: 
* Wiper interrupted when  rear glass is opened 
Wiper interrupted if wiper arm  is blocked 
Continuous wiping  when vehicle is shifled into  reverse 
Antenna and sound system 
4 There  are two  diversity  FM antenna  amplifiers: 
FMI  amplifier located  in the  rear  window  frame 
FM2 / FZV amplifier located in  the lefl D-pillar 
The radio amplifier  and CD changer are behind the side 
ac- 
cess panels  in the cargo  compartment: 
CD  changer on  lefl side 
Sound system subwoofer on right  side 
The subwoofer has a  hold down  knob and is mounted  on a 
hinge.  It can be swung  out to access 
the batteryand fuse  pan- 
el  by  unscrewing the  knob.