Recommended replacement interval for the part category Brake caliper : 100000 km

Important!

This replacement procedure can be used for:
BMW 5 Touring (E39) 520 i, BMW 5 Touring (E39) 530 i, BMW 5 Touring (E39) 525 i, BMW 5 Touring (E39) 520 i, BMW 5 Touring (E39) 530 d, BMW 5 Touring (E39) 525 d, BMW 5 Touring (E39) 520 d, BMW 5 Touring (E39) 540 i … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Calipers for 5 Touring (E39) and other BMW models

Brake caliper

        Brake caliper for 5 Touring (E39) Petrol (286 hp)
      
        Brake caliper for 5 Touring (E39) Diesel (136 hp)
      
        Brake caliper for 5 Touring (E39) Diesel (163 hp)
      
        Brake caliper for 5 Touring (E39) Diesel (193 hp)
      
        Brake caliper for 5 Touring (E39) Petrol (170 hp)
      
        Brake caliper for 5 Touring (E39) Petrol (192 hp)
      
        Brake caliper for 5 Touring (E39) Petrol (231 hp)
      
        Brake caliper for 5 Touring (E39) Petrol (163 hp)

Replacement: brake caliper – BMW 5 Touring (E39). Tools you'll need:

                        Wire brush
                      
                        WD-40 spray
                      
                        Brake cleaner
                      
                        Copper grease
                      
                        Brake caliper guide pins grease
                      
                        HEX bit no.H7.
                      
                        Flare nut spanner №11
                      
                        Flare nut spanner №14
                      
                        Wheel impact socket #17
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Crow bar
                      
                        Flat Screwdriver
                      
                        Brake hose clip
                      
                        Brake bleeder kit
                      
                        Wheel chock

Buy tools

Replacement: brake caliper – BMW 5 Touring (E39). AUTODOC recommends:

The replacement procedure is identical for the left and right brake calipers on the same axle.
All work should be done with the engine stopped.

Replacement: brake caliper – BMW 5 Touring (E39). Recommended sequence of steps:

Step 1

Open the bonnet. Unscrew the brake fluid reservoir cap.

Step 2

Secure the wheels with chocks.
Step 3

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 4

Raise the front of the car and secure on supports.

Step 5

Unscrew the wheel bolts.

Replacement: brake caliper – BMW 5 Touring (E39). Tip:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6

Remove the wheel.
Step 7

Detach the brake caliper retaining spring. Use a flat screwdriver.
Step 8

Remove the dust boot caps of the brake caliper guide pins. Use a flat screwdriver.
Step 9

Spread the brake pads. Use a crowbar.
Step 10

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.

Step 11

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 12

Remove the guide pins from the brake caliper.
Step 13

Clamp the brake hose off using a brake hose clamp.
Step 14

Clean the area where the brake hose is connected to the caliper, and the guide pins area. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – BMW 5 Touring (E39). After applying the spray, wait a few minutes.
Step 15

Loosen the brake hose fastening. Use a flare nut spanner #14.
Step 16

Remove the brake caliper.

Replacement: brake caliper – BMW 5 Touring (E39). Tip from AUTODOC experts:
When replacing the brake caliper, it is recommended to check the brake hose for damages and, if necessary, to replace it with a new one.When replacing a brake caliper it is recommended to replace brake pads, check the state of the brake discs and replace them with new ones if necessary.Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur.
Step 17

Remove the brake pads.
Step 18

Unscrew the brake hose from the brake caliper.
Step 19

Disconnect the brake hose.
Step 20

Treat the brake hose. Use a brake cleaner.

Replacement: brake caliper – BMW 5 Touring (E39). AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 21

Install and fix the brake hose into a new caliper.
Step 22

Install the brake pads.

Replacement: brake caliper – BMW 5 Touring (E39). AUTODOC experts recommend:
If going to use the old brake pads, clean them.
Step 23

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – BMW 5 Touring (E39). After applying the spray, wait a few minutes.
Step 24

Install the brake caliper and fix it.
Step 25

Tighten the fastener connecting the brake pipe to the brake caliper. Use a flare nut spanner #14. Use a torque wrench. Tighten it to 22 Nm torque.
Step 26

Remove the brake hose clamp.
Step 27

Clean the brake caliper guide pins.

Step 28

Treat the brake caliper guide pins. Use the brake caliper guide pin grease.

Replacement: brake caliper – BMW 5 Touring (E39). Professionals recommend:
If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
Step 29

Screw in the guide pins.
Step 30

Tighten the brake caliper fasteners. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 31

Install the dust boot caps of the brake caliper guide pins.
Step 32

Install the brake caliper retaining spring. Use a flat screwdriver.
Step 33

Connect the brake bleeder kit to the brake bleeder screw.

Step 34

Undo the brake bleeder screw. Use a flare nut spanner #11.
Step 35.1

Bleed the brake caliper system.

Step 35.2

Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 36

Tighten the brake caliper bleed screw. Use a flare nut spanner #11. Use a torque wrench. Tighten it to 13 Nm torque.
Step 37

Disconnect the brake bleeder kit.

Step 38

Clean dirt from the brake hose bolt. Use a brake cleaner.

Replacement: brake caliper – BMW 5 Touring (E39). Tip from AUTODOC:
After applying the spray, wait a few minutes.
Step 39

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 40

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – BMW 5 Touring (E39). After applying the spray, wait a few minutes.
Step 41

Install the wheel.

Replacement: brake caliper – BMW 5 Touring (E39). Tip from AUTODOC:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 42

Screw in the wheel bolts. Use wheel impact socket #17.
Step 43

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 nm torque.
Step 44

Remove the jacks and chocks.

AUTODOC recommends:
Important! Replacement: brake caliper – BMW 5 Touring (E39). Check the brake fluid level in the reservoir and top up if necessary.
Step 45

Tighten the brake fluid reservoir cap. Close the hood.

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