21 00 006 Bleeding clutch hydraulic system
Necessary preliminary tasks
- Remove transmission underbody protection if necessary.
- Remove microfilter housing is necessary.
| IMPORTANT | From 08.06 a plastic clutch slave cylinder . See 2100006 BLEEDING CLUTCH HYDRAULICS (PLASTIC SLAVE CYLINDER) or 2152510 REMOVING AND INSTALLING/REPLACING CLUTCH SLAVE CYLINDER (PLASTIC) is installed in the E8X, E9X. Important notes on installation are described in this work step. |
Unfasten nuts and remove clutch slave cylinder (pressure line remains connected).
Scheme 72
Fit special tool 21 5 030 on clutch slave cylinder (1).
Press piston rod (2) with aid of spindle completely into clutch slave cylinder.
Scheme 73
Connect bleeder unit to brake fluid expansion tank.
| IMPORTANT | Check relevant Operating Instructions for each device. |
Charging pressure should not exceed 2 bar.
Connect bleeder hose to bleed valve (1).
Hold clutch slave cylinder in illustrated position (refer to figure) with special tool 21 5 030.
Open bleeder valve (1).
If bubble-free brake fluid emerges, retract piston rod (2) of clutch slave cylinder with aid of spindle a little and press in again.
If no air bubbles escape, close bleeder valve (1), otherwise repeat procedure.
| IMPORTANT | Do not under any circumstances remove special tool 21 5 030 from clutch slave cylinder when brake system is pressurized. Piston with push rod can jump out of clutch slave cylinder. |
Scheme 74
Switch off bleeder unit or remove from brake fluid expansion tank.
Slowly retract piston rod (2) of clutch slave cylinder (1) with special tool 21 5 030.
Remove special tool 21 5 030 from clutch slave cylinder (1).
Fit clutch slave cylinder to transmission.
Installation
Replace self-locking nuts.
Tightening torque 21 52 5AZ .
Correct brake fluid level in expansion tank.
21 00 006 Bleeding clutch hydraulics (plastic slave cylinder)
Necessary preliminary tasks
- Remove underbody protection from transmission.
Connect bleeder unit to brake fluid expansion tank.
| IMPORTANT | Check relevant Operating Instructions for each device. Charging pressure should not exceed 2 bar. |
Connect bleeder hose to bleed valve (1).
Open bleed valve (1) and flush until clear brake fluid emerges without air bubbles.
Close bleed valve.
Scheme 75
Switch off bleeder unit or remove from brake fluid expansion tank.
Correct brake fluid level in expansion tank.
21 21 500 Removing and installing/replacing clutch (GS6-53BZ) S65
Necessary preliminary tasks
Remove TRANSMISSION .
| IMPORTANT | When reinstalling the removed clutch, be sure when disassembling the clutch to use special tool 21 2 180 . Failure to comply with this instruction will result in total failure. |
Block flywheel with special tools 11 9 260 HOLDER and 11 9 265.
Scheme 76
Note. Locking hooks (1) of special tool 21 2 180 must engage in openings of pressure spring.
Scheme 77
Insert special tool 21 2 180 in clutch.
Press special tool 21 2 180 together at handles (1) as far as it will go and tighten down knurled screws (2).
Adjustment ring of clutch is now secured in its original position (wear position).
Release screws and remove clutch from flywheel.
Tightening torque 21 21 1AZ .
Scheme 78
| IMPORTANT | Observe the following procedure when reinstalling the removed clutch and clutch discs. Pressure plate and dual-mass flywheel with line markings: Pressure plate and dual-mass flywheel are balanced together. Line markings must be located one on top of the other during assembly Pressure plate and dual-mass flywheel with dot markings: Dot markings must be located one on top of the other during assembly |
Centre clutch disc (2) with special tool 21 2 280 MANDREL on flywheel.
| IMPORTANT | Install clutch disc in correct position. Note designation for "engine side"/"transmission side". Handle clutch disc with care. Do not touch surfaces of friction linings. |
Scheme 79
Note. Clutch (1) must be secured by way of dowel pins (2). Bolt clutch (1) to flywheel.
Remove special tool 21 2 180 .
Tightening torque 21 21 1AZ .
Scheme 80
Withdraw special tool from clutch disc with aid of accompanying screw (1).
Scheme 81
Installing new clutch
| IMPORTANT | Locking element may only be removed clutch is screwed down! |
Note. From 09/08 pressure plate and dual-mass flywheel are no longer balanced together!
| IMPORTANT | On vehicles which had pressure plate and dual-mass flywheel with line markings installed: When installing a new clutch, also replace the dual-mass flywheel and install a reinforced overcenter helper spring. On vehicles which had pressure plate and dual-mass flywheel with dot markings installed: Clutch and dual-mass flywheel can be replaced individually. |
Centre clutch disc (2) with special tool 21 2 280 MANDREL on flywheel.
| IMPORTANT | Install clutch disc in correct position. Note designation for "engine side"/"transmission side". Handle clutch disc with care. Do not touch surfaces of friction linings. |
Fit clutch to flywheel.
Tightening torque 21 21 1AZ .
| IMPORTANT | Clutch must be secured by way of dowel pins (1). |
Scheme 82
Carefully unscrew locking element (1) clockwise or counterclockwise with WAF 14 Allen key (2).
Note. A slight snapping of the plate spring while unscrewing the lock is possible.
Scheme 83
Withdraw special tool from clutch disc with aid of accompanying screw (1).
11 22 513 Replacing roller bearing for dual-mass flywheel
Note. Flywheel removed!
Position special tool 11 2 010 in roller bearing.
Twist out roller bearing with special tool 11 2 343.
Scheme 84
Assemble special tools 11 2 350 and 00 5 500 MANDREL .
Drive in roller bearing with special tools 11 2 350 and 00 5 500 MANDREL in direction of arrow as far as it will go.
Scheme 85
Assemble engine.
Note. Flywheel removed!
Using hydraulic press (1) and special tool 21 2 051, press out dual-mass flywheel downwards on engine side.
| IMPORTANT | Risk of damage: Roller bearing must not be driven out. |
Scheme 86
Push roller bearing (2) onto special tool 21 2 052.
Using hydraulic press (1), press roller bearing into dual-mass flywheel as far as it will go on clutch side.
| IMPORTANT | Risk of damage: Observe press-in instruction: Roller bearing must not be driven in. Roller bearing mounting force/travel monitored: Min. 2000N 1 mm before end of pressing in. Max. 15000N during entire press-in procedure. |
Scheme 87
21 51 500 Removing and installing or replacing clutch release bearing/lever
Note. (transmission removed)
New version (except M models)
Release bearing and release lever have been combined to form a single release module.
If possible, do not disassemble the release module. Otherwise, there is a risk of the release module being incorrectly reassembled.
Installation
Make sure that the correct cam (1) of the release bearing is on the sliding surface (2) of the release lever.
Note. Do not grease sliding surfaces (2).
Scheme 88
(Scheme 89): Cam (1) of release bearing (A=12 mm) is on sliding surface of release lever.
This version is for 4-cylinder gasoline engines.
(Scheme 89): Cam (1) of release bearing (A=7 mm) is on sliding surface of release lever.
This version is for 6-cylinder gasoline and diesel engines.
Scheme 89
Remove release module (1) from spring wire clip.
Remove release module.
Note. Illustration similar.
Scheme 90
Installation
Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.
Note. Illustration similar.
Scheme 91
Previous version
Detach release bearing (1).
Installation
Clean all sliding surfaces on clutch release bearing, check for damage and replace if necessary.
Do not grease clutch release bearing.
Sliding surfaces (2) of clutch release bearing must rest on sliding surfaces (3) of release lever.
Apply a thin coating of grease to sliding surfaces (2) of release bearing.
Note. Graphic similar
Scheme 92
| IMPORTANT | Only on E60/E61M5 M5 and E63/E64 M6 (7-speed SMG transmission) - lightly grease guide sleeve. |
Previous clutch release bearing
Clutch release bearing with moving thrust plate (1).
Swivel motion of thrust plate (1) possible.
Scheme 93
Withdraw release lever (4) from spring wire clip (5) and remove.
Installation
Clean release lever.
Note. Illustration similar.
Scheme 94
Previous release lever
Installation
Apply a thin coating of grease to release lever at sliding surfaces (1 and 2) only.
Scheme 95
Installation
Check spring wire clip (5) and ball pin (6) for damage and replace if necessary.
Apply a thin coating of grease to ball pin (6).
Note. The spring wire clip and ball pin must always be replaced on the S6S 420G transmission. Illustration similar.
Clean guide sleeve (7).
Installation
Except for E60/61 M5 and E63/64 M6 (7-speed SMG transmission) - do not grease guide sleeve.
If guide sleeve is greased, the release lever can stick on the guide sleeve.
Note. Illustration similar.
Scheme 96
21 52 510 Removing and installing or replacing clutch slave cylinder
Note. After completing work bleed CLUTCH HYDRAULIC SYSTEM .
| IMPORTANT | From 08.06 a plastic CLUTCH SLAVE CYLINDER is installed in the E81, E87 and E9X. Important notes on installation are described in this work step. |
Seal supply hose to clutch master cylinder with special tool 13 3 010 TERMINAL .
Note. Illustration shows E46.
Scheme 97
Remove transmission underbody protection if necessary.
Release union screw (1) on hydraulic line.
Release nut (2) and remove hydraulic line (3) with bracket.
Installation
Tightening torque 21 52 1AZ .
Note. Illustration similar.
Version with throttle valve, tightening torque 21 52 12AZ .
Scheme 98
Release nut and remove clutch slave cylinder.
Installation
Tightening torque 21 52 5AZ .
| IMPORTANT | N47 with H-transmission only Clutch slave cylinder must not rest at the side on the transmission. Failure to comply with this instruction may result in leaks at the clutch slave cylinder. |
Scheme 99
Installation
Clean thrust member (1) and contact face on release lever (2).
Lightly grease thrust member (1) on contact face (3).
Scheme 100
| IMPORTANT | Spacer between fuel line and pressure hose of clutch slave cylinder must be correctly fitted. |
Scheme 101
21 52 500 Removing and installing/replacing clutch master cylinder
Note. After completing work, bleed clutch hydraulic system See 2100006 BLEEDING CLUTCH HYDRAULIC SYSTEM or 2100006 BLEEDING CLUTCH HYDRAULICS (PLASTIC SLAVE CYLINDER) .
Necessary preliminary tasks
- Remove «TRIM PANEL»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-45-185-removing-and-installingreplacing) for pedal assembly.
Unclip retaining tabs (1).
Pull cover (3) out of guide (2) and remove.
Scheme 102
Draw off brake fluid up to supply hose of clutch hydraulic system (1). For this purpose, use only a vacuum pipe that is exclusively used for removing brake fluid.
Detach supply hose (1) from expansion tank.
Scheme 103
Release screws (1) on cylinder (2).
Tightening torque: 21 52 4AZ
Scheme 104
Disconnect return spring (1).
Detach locking clip (3) and pull clutch pedal with clutch master cylinder off bearing block.
Press pin ends (2) together and remove pin.
Installation
Replace locking clip.
The locking clip must be seated with both legs in the pin groove.
Scheme 105
Detach retainer (1) with a screwdriver (2).
Note. Do not foul carpet with brake fluid.
Detach hydraulic line from clutch master cylinder.
Scheme 106
Detach supply hose (1) from clutch master cylinder.
| IMPORTANT | Do not pull supply hose completely into interior. |
Scheme 107
Lever out shift element (1) from clutch master cylinder (2) with screwdriver.
Release plug connection (3) and disconnect plug (4) from shift element (1).
Scheme 108
Installation
Shift element is secured against incorrect installation.
Shift element must snap audibly into place.
Scheme 109
21 52 510 Removing and installing/replacing clutch slave cylinder (plastic)
Note. After completing work bleed CLUTCH HYDRAULIC SYSTEM .
Seal hydraulic line to clutch slave cylinder with special tool 13 3 010 TERMINAL .
Scheme 110
Release nuts and remove clutch slave cylinder (1) with holder (2).
Installation
Replace self-locking nuts.
Tightening torque 21 52 5AZ .
| IMPORTANT | N47 with H-transmission only Clutch slave cylinder must not rest at the side on the transmission. Failure to comply with this instruction may result in leaks at the clutch slave cylinder. |
Scheme 111
Unlock spring retainer (1).
Disconnect hydraulic line (2).
Scheme 112
Press cylinder together by hand.
Connect hydraulic line with cylinder pressed.
Scheme 113
Remove special tool 13 3 010 TERMINAL .
Hold cylinder piston vertically downwards.
Press piston 5 times into cylinder.
Scheme 114
| IMPORTANT | All-wheel drive vehicles only |
Installation
Check pressure hose for traces of abrasion.
If no traces of abrasion by the propeller shaft can be detected on the pressure hose
The pressure hose must be bent approx. 30 mm away from the propeller shaft.
If traces of abrasion by the propeller shaft can be detected on the pressure hose
The pressure hose must be replaced.
After replacement, the clutch hydraulics must be BLED .
Press in piston until it engages.
Install clutch slave cylinder.
Bleed CLUTCH HYDRAULICS .
Installation
Clean thrust member (1) and contact face on release lever.
Lightly grease thrust member (1) on contact face (2).
