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Home >> BMW >> 2009 >> 650i 2D Convertible, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 131 (DISC - 525i, 530i & 545i) >> Overhaul >> Brake Caliper

Brake Caliper

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Danger of injury. large forces occur at brake caliper piston of up to 629 pound-force (2800 N).
NOTE: Use original BMW repair kit.
NOTE: Front guide sleeves and screws come in different lengths. On 16" brake system, there are 2 short guide sleeves with 2 short screws. On 17" brake system, there is one long guide sleeve and one short guide sleeve with one long screw and one short screw. On 18" brake system, there are 2 long guide sleeves with 2 long guide screws.
  1. Remove brake caliper. For front caliper, see BRAKE CALIPER (FRONT) . For rear caliper, see BRAKE CALIPER (REAR) .
  2. Take off plastic caps (1). See Fig 1. Unscrew guide screws (2).
  3. Dismantle brake caliper and remove brake linings.
  4. Place a protective plate of wood or hard felt in caliper recess. Do NOT grip piston with fingers. Carefully force piston out through connection bore with compressed air. See Fig 2.
  5. Check guide sleeves (5). See Fig 3. Note that front guide sleeves and screws come in different lengths. Long guide sleeve with long screw is seated on disc inlet at bottom. Short sleeve with short screw is seated on disc outlet at top. If necessary, fit repair kit guide sleeve.
  6. Remove sealing ring carefully with a plastic needle. See Fig 4. Clean cylinder bores and parts with alcohol and dry with compressed air. Thoroughly inspect cylinder bore, piston and flange surfaces. Machining of cylinders and pistons is not permitted.
  7. Apply a light coat of brake cylinder paste to cylinder bore, piston and sealing sleeve. Install sealing cover in rear annular groove of cylinder bore. Press in piston with a hardwood board. Do NOT tilt piston.
  8. The area between dust protection sleeve and brake caliper housing must be kept dry to ensure correct seating of dust protection sleeve. Keep brake cylinder paste or brake fluid away from this area. On rear caliper, press on dust protection sleeve evenly up to stop with Special Tool (34 1 132). See Fig 5. On front caliper, press on dust protection sleeve evenly up to stop with Special Tool (34 1 133). Make sure dust protection sleeve is correctly seated on piston.
  9. To assemble caliper, reverse disassembly procedure. Tighten guide bolts to specification. See TORQUE SPECIFICATIONS . Press brake lining fully outwards and insert spring (4). See Fig 6.
  10. Install brake caliper. For front caliper, see BRAKE CALIPER (FRONT) . For rear caliper, see BRAKE CALIPER (REAR) .
Fig 1: Locating Plastic Caps & Guide Screws
G00302303Courtesy of BMW OF NORTH AMERICA, INC.
Fig 2: Pressing Out Piston
G00103296Courtesy of BMW OF NORTH AMERICA, INC.
Fig 3: Locating Guide Sleeves
G00103297Courtesy of BMW OF NORTH AMERICA, INC.
Fig 4: Removing Sealing Ring
G00103298Courtesy of BMW OF NORTH AMERICA, INC.
Fig 5: Pressing On Dust Cover Rear
G00103360Courtesy of BMW OF NORTH AMERICA, INC.
Fig 6: Identifying Retaining Spring
G00103299Courtesy of BMW OF NORTH AMERICA, INC.
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