Recommended replacement interval for the part category Brake Disc : 50000 km

Important!

This replacement procedure can be used for:
BMW 5 Saloon (E39) 520 i, BMW 5 Touring (E39) 520 i

The steps may slightly vary depending on the car design.

How to change front brake discs / front brake rotors on BMW 520i (E39) [TUTORIAL AUTODOC]

Replacement: brake discs – BMW E39. List of the tools you'll need:

                        Wire brush
                      
                        WD-40 spray
                      
                        Brake cleaner 
                      
                        Copper grease 
                      
                        HEX bit no.H6.
                      
                        HEX bit no.H7.
                      
                        Drive socket # 18 
                      
                        Wheel impact socket #17
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Brake caliper wind back tool
                      
                        Impact screwdriver
                      
                        Crow bar
                      
                        Fender cover
                      
                        Wheel chock

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

BMW 5 Saloon (E39) 520 i

BMW 5 Touring (E39) 520 i

Replacement: brake discs – BMW E39. AUTODOC experts recommend:

Replace the brake disks on the car BMW 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 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 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.
Step 18

Remove the brake caliper.

Replacement: brake discs – BMW E39. AUTODOC experts recommend:

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 9 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 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 75 Nm torque.
Step 33

Treat the brake caliper piston.Use a brake cleaner.

Replacement: brake discs – BMW 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 35 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 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 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 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 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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