How to change front brake discs on BMW 5 Touring (E39) – replacement guide
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Recommended replacement interval for the part category Brake disc : 50000km
Important!
This replacement procedure can be used for:
BMW 5 Touring (E39) 520 i,
BMW 5 Touring (E39) 523 i,
BMW 5 Touring (E39) 528 i,
BMW 5 Touring (E39) 530 d,
BMW 5 Touring (E39) 525 tds,
BMW 5 Touring (E39) 520 i,
BMW 5 Touring (E39) 520 d,
BMW 5 Touring (E39) 525 d,
BMW 5 Touring (E39) 530 d,
BMW 5 Touring (E39) 520 i,
BMW 5 Touring (E39) 525 i,
BMW 5 Touring (E39) 520 i,
BMW 5 Touring (E39) 523 i
…
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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 Discs for 5 Touring (E39) and other BMW models
Replace the brake disks on the car BMW 5 Touring (E39) in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
All work should be done with the engine stopped.
Replacement: brake discs – BMW 5 Touring (E39). Take the following steps:
Step 1
Open the hood.
Step 2
Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3
Detach the air duct from the cabin filter housing.
Step 4
Release the cabin filter cover clips.
Step 5
Remove the cabin filter housing cover.
Step 6
Remove the cabin filter housing seal.
Step 7
Remove the cabin air filter housing.
Step 8
Unscrew the brake fluid reservoir cap.
Step 9
Secure the wheels with chocks.
Step 10
Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 11
Raise the front of the car and secure on supports.
Step 12
Unscrew the wheel bolts.
Replacement: brake discs – BMW 5 Touring (E39). Tip from AUTODOC:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 13
Remove the wheel.
Step 14
Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 15
Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 16
Spread the brake pads. Use a crowbar.
Step 17
Detach the brake caliper retaining spring. Use a crowbar.
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.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. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 19
Remove the brake pads.
Step 20
Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 21
Unscrew the caliper bracket fastening. Use a drive socket #18. Use a tap wrench.
Step 22
Remove the caliper bracket.
Step 23
Clean the brake disc fasteners. Use a wire brush. Use WD-40 spray.
Step 24
Unscrew the brake disc fastening. Use HEX No.H6. Use an impact screwdriver.
Step 25
Remove the brake disc.
Step 26
Clean the hub. Use a wire brush.
Step 27
Treat the contacting surface. Use copper grease.
Step 28
Install the brake disc.
Step 29
Tighten the brake disc fastening. Use HEX No.H6. Use a torque wrench. Tighten it to 16 Nm torque.
Step 30
Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – BMW 5 Touring (E39). After applying the spray, wait a few minutes.
Step 31
Install the brake caliper bracket.
Step 32
Tighten the brake caliper bracket. Use a drive socket #18. Use a torque wrench. Tighten it to 110 Nm torque.
Step 33
Treat the brake caliper piston. Use a brake cleaner.
Replacement: brake discs – BMW 5 Touring (E39). Tip:
After applying the spray, wait a few minutes.
Step 34
Press in the brake caliper piston. Use brake caliper wind back tool.
Step 35
Install the brake pads.
Step 36
Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 37
Install the dust boot caps of the brake caliper guide pins.
Step 38
Install the brake caliper retaining spring.
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.
Replacement: brake discs – BMW 5 Touring (E39). Tip from AUTODOC experts:
After applying the spray, wait a few minutes.
Step 41
Install the wheel.
AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. BMW 5 Touring (E39)
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.
Replacement: brake discs – BMW 5 Touring (E39). AUTODOC recommends:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 44
Tighten the brake fluid reservoir cap.
AUTODOC recommends:
BMW 5 Touring (E39) – Without starting the engine, press the brake pedal several times until it feels firm.
Step 45
Install the cabin air filter housing.
Step 46
Reinstall the cabin filter housing seal.
Step 47
Reinstall the cabin filter housing cover. Make sure you hear a click indicating that it is locked in place.
Step 48
Attach the cabin filter cover clips.
Step 49
Install the air duct housing.
Step 50
Remove the fender protection cover.
Step 51
Close the hood.
Step 52
Remove the jacks and chocks.
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