< 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 (1998 models)
1998V-8 cars with Bosch DSC Ill v. 5.3 are equipped with a DSC prechargepump 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 requirespecialBMWserviceequipmenttoproperly bleedthe brakes. Removalof hydrauliccomponents is not recommendedunless this equipmentis available. Forsafety reasons, the brakesystem on cars with ABSmustbebledusing the proceduresdescribedin this repairgroup.
-Using a clean syringe, empty brake fluid reservoir.
CAUTIOI\C
Brake fluidis highly corrosiveanddangerous to the environment. Disoose of it orooerlv.
Working at precharge pump, disconnect hydraulic lines (A) and electrical harness connector (6)Clean. up dripping fluid.
hydraulic unit. Labelallcon-
1Brakes
-
-
Remove precharge pump mounting bracket fasteners and remove 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 pressuresensor is screwed into the DSC hydraulic unit (right rear of engine compartment).
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-
-
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WARNING-
*€39 cars require specialBMWservice equipment to properlybleedthebrakes. Removalof the DSCpressuresensor isnotrecommendedunlessthis equipmentisavailable. For safety reasons, the brakesystemon cars withABS mustbe bledusing the proceduresdescribedin this repairgroup.
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.
Tighteningtorque
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 1traction electronic control module (1997 -1 998 models)
4 The traction control electronic control module in 19971998 models is located to the left of the glove compartment.
NOTE-
In both ASC and early DSC systems this location is usedfor the electronic control unit.
-Before removing the traction control electronic module, read any fault codes in memory.
ABS I DSC control module (1999 - 2002 models)
The DSC electronic control unit in 1999and later models (from 911998) is boltedto the DSC hydraulic unit in the right rear of the engine compartment.
-Before removingthe 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 function in DIS or MoDiC.
ABS I traction control hydraulic unit, removing and installing
WARNING-
E39cars requirespecialBMWsewice equipmentto properly bleedthe brakes. Removalof the hydraulic unit is not recommendedunless this equipment is available. Forsafety reasons, the brake system on cars with ABS mustbebledusing the proceduresdescribedin this repairgroup.
NOTE-
Before starting this procedure, readcontrol module memory andprint out diagnostic record.
DSC system: Adjust steering angle sensor using either DISplus, GTI, or MoDiC. After completing work, function test control module.
Tightening torques Brake lines to hydraulic unit
DSC electronic control unit to hydraulic unit (use new screws)
Hydraulic unit to body
Mounting bracket to hydraulic unit
Check rubber mount for hydraulic unit/control module. Replace if damaged.
Make sure all nuts, fluid couplings, thread bores and mating 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 ServiceTesteras describedearlier.
340-32
Brakes
The procedure for removing the ABS I ASC or ABS I DSC hydraulic 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 environment. Dispose of it properiw
4 Disconnect electrical harness connector (A) at hydraulic unit (1998 DSC hydraulic unit in V-8model 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 mountingscrews. Remove hydraulic unit.
-If necessary, separate hydraulic unit from control module.
-Installation is reverse of removal, noting the following:
This chapter covers system descriptions and general information for the repair groups found in sections4 Body and 5 Body Equipment.
Body dimensions (in inches)
E39 Sport Wagon
Crash behavlor
-frontal impact
-side impact
Structural body components
Body
-rear impact
-rigidity
-rollover
-strength
-vibrations
-acoustics
Bumpers
Seets,.steerlng system
compartment lid
-bendable
.dents
-vibrations
-vibration patterns
bars
Fenders
-aerodvnamic
Body shell
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 constructed 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.
Exterior and aerodynamics
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.
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-8sedan
0.31
6-cylinder
Sport Wagon
0.31
V-8Sport Wagon
0.33
Fenders
The exterior panels are corrosion-resistant zinc coated (galvanized) steel. The front fenders are bolted on. For front fender replacement information, see 410 Fenders, Engine Hood.
400-4
IBodv-General
Bumpers
The front and rear bumpers are clad in high quality deformable 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 greaterthanthat forwhich bumpers and hydraulic dampeners are designed. This helps avoid expensive damage to the body at impact speeds up to 14 kph (9
mph).
The E39 Sport Wagon was introduced to the US market in 911998 (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 variants:
6-cylinder (5251, 528i) powered by the 2.8 liter M52 TU engine (1999) 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 eliminates 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 models and optional on 6-cylinder models.
Sport Wagon cargo capacities are shown below.
Sport Wagon load capacities
Cargo capacity
Rear seat up
909 liters (32.1cu ft)
Rear seat folded down
I809 liters (63.9cu ft)
Load limit
Cargo compartment
460 Kg (1014lb)
Roof
I00 Kg (220lb)
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"measured from the rear roof pillar (D-pillar) and to a height of 2029 mm (79.8in) 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 located 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.
.
IBody-General
-
Wiperlwasher stalk switch
1
Rear wiper system
The rear wiper assembly on the E39 Sport Wagon is a selfcontained unit. The control electronicsare integrated into the gear drive that is part of the motor assembly. The control electronics contain two hall sensors, one forthe park position and one forthe end stop or to signal reverse direction of the wiper motor.
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
-4
3The wiper system automatically controls the following safety and convenience features:
502400100
* 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 mountedon a hinge. It can be swung out to access the batteryand fuse panel by unscrewingthe knob.
