34 11 552 Overhauling left or right front brake caliper (brake caliper removed)

WARNING: This page is about a different car, the 2005 BMW 645Ci and 2004 BMW 645Ci. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

34 1 133

NOTE: Use repair kit, refer to BMW Parts Service.

Bear in mind that guide sleeves and screws come in different lengths:

16" brake system: two short guide sleeves with two short screws.
17" brake system: one long guide sleeve and one short guide sleeve with one long screw and one short screw.
18" brake system: two long guide sleeves with two long screws.

Take off plastic caps (1).

Unscrew guide screws (2).

Fig 1: Removing Plastic Caps

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Installation:

Only clean guide screws; do not grease. Check guide bolts, replace if necessary.
E65 and E66:
Tightening torque, refer to 34 11 3AZ in BRAKES - TIGHTENING TORQUES - 645CI .

Dismantle brake caliper and remove brake linings.

Installation:

Press brake lining fully outwards and insert spring (4).

Fig 2: Removing Insert Spring

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WARNING: Danger of injury! In the following work step, large forces occur at the brake caliper piston up to more than 2800 N.

Carefully force piston out through connection bore with compressed air.

Fig 3: Forcing Piston Out Through Connection Bore With Compressed Air

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To protect piston, place a protective plate (e.g. hard wood or hard felt) in caliper recess.

Do not grip piston with fingers - risk of trapping!

Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.

IMPORTANT: Bear in mind that guide sleeves and screws come in different lengths. Long guide sleeve with long screw is seated on disk inlet at bottom, short sleeve with short screw is seated on disk outlet at top.

Fig 4: Checking Guide Sleeves

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Remove sealing ring carefully with a plastic needle.

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.

Fig 5: Removing Sealing Ring

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Installation:

Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and sealing sleeve,
Refer to OPERATING FLUIDS - BRAKES .

Install sealing cover in rear annular groove of cylinder bore. Press in piston with a hardwood board.

IMPORTANT: Do not tilt piston.

Fig 6: Installing Sealing Cover In Cylinder Bore Rear Annular Groove

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Press on dust protection sleeve evenly up to stop with special tool 34 1 133.

Fig 7: Pressing Dust Protection Sleeve With Special Tool

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Installation:

The area between dust protection sleeve and brake caliper housing must be kept dry so as to ensure correct seating for the dust protection sleeve.
Keep Ate brake cylinder paste or brake fluid away from this area.
Make sure dust protection sleeve is correctly seated on piston.