00 Brake Testing and Bleeding: 2008 BMW 328xi 2008 BMW 328xi

2008 BMW 328xi
BRAKES Brakes - Repair Instructions - 325i, 325xi, 330i, 330xi, 328i, 328xi, 335i and 335xi
BRAKES
Brakes - Repair Instructions - 325i, 325xi, 330i, 330xi, 328i, 328xi, 335i and 335xi
00 BRAKE TESTING AND BLEEDING

34 00 ... GENERAL INFORMATION
The brake system is one of the most important safety systems on any motor vehicle. It is therefore essential to
act with utmost care when working on the brake system and to follow the instructions below.
General:
 Ensure cleanliness and only use rags which do not lose lint.
 Wash away or vacuum up brake dust, do not clear it away using compressed air. This dust is a health
hazard.
 Do not under any circumstances allow any oil or grease to get into the brake system. This would result in
a complete malfunction of the brake system.
 When cleaning brake components with brake cleaner, do not allow brake cleaner to get into in the brake
system.
 Even the most minute traces of brake cleaner must be avoided.
Brake fluid:
 Replace brake fluid at least every two years.

 Never reuse drained brake fluid.
 Always use BMW-approved brake fluid, refer to BMW Service Operating Fluids .
 Dispose of brake fluid in approved appliances only.
 Do not allow brake fluid to drain into drain pipes, into the outside environment or into unsuitable
facilities. This would create the risk of groundwater contamination since brake fluid is classed as a fluid
that is hazardous to water.
 Do not allow brake fluid to come into contact with paintwork as this will destroy the paint.
 Brake fluid must not be allowed to remain on bare skin too long in order to avoid skin problems. Wash
skin coated with brake fluid with water and soap.
 If brake fluid makes contact with eyes, immediately flush with large quantity of clean water and visit eye
doctor.
Wheel brakes:
 Brake pads:
Brake pads must be replaced when the Warning Threshold Of The Brake Pad Wear Indicator is
reached.
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2008 BMW 328xi
Brake pads must always be replaced on both sides of any axle.
The friction surfaces of the brake pads must not come into contact with oil or grease. The brake pads must
be replaced if they are fouled by such substances.
In the case of rotation-dependent brake pads, make sure the arrow marking points in the direction of
rotation of the brake disk for when the vehicle is moving forward. Brake pads with left/right markings
must be fitted on the relevant side of the vehicle.
One-sided angled areas on the brake pads must be located on the disk contact side of the brake caliper for
when the vehicle is moving forward.
 Brake discs:
Brake disks must not be scored or cracked. Furthermore, Minimum Brake Disk Thickness , disk runout,
parallelism and surface roughness of the friction surfaces must not exceed or drop below the permitted
values.
Always strip preservative off new parts before installation. With the rear brake discs, also strip
preservative off brake drum on parking brake.
 Always strip preservative off new parts before installation.

 Brake calipers:
Only approved pastes on the basis of glycol must be used for repairs on brake calipers.
All moving parts on the brake caliper must move freely: note grease specifications.
Use only BMW-approved lubricants to grease caliper guides (refer to BMW Service Operating Fluids ).
Brake lines, brake hoses:
 Brake lines and brake hoses must be correctly routed and must not abut with body or components in a
way which would cause chafing.
 To prevent damage, release and tighten brake line couplings with a special brake line wrench only.
 The system must be bled each time any brake lines have been detached.
 All connection points must be checked for leaks.
 Only tighten down brake hoses on the front axle when wheels are in straight-ahead position.
 Close off open connections of brake lines and individual components to prevent dirt from getting into the
brake system.
 When tightening down brake line couplings, observe tightening torque refer to 34 32 1AZ in 34 32
BRAKE LINES .
Wheel-slip control system:
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2008 BMW 328xi
The wheel-slip control system is essentially maintenance-free; however the following must be observed:
 When carrying out welding work with electric welding equipment, be sure to disconnect the plug from
the electronic control unit (ignition turned off).
 During painting work, the control unit may be subjected for brief periods to loads of max. 95°C and for
long periods (approx. 2 hours) to loads of max. 85°C.
 Terminals must be completely tight on end poles of battery.
 Brake lines on hydraulic unit must not be swapped over: if applicable, mark them prior to disassembly.
On completion of repair work, carry out swap-over test with the DIS diagnosis system.
34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS / BRAKE PADS
IMPORTANT: After completing work:
 Carry out function check on brake analyzer (test stand) ensure that the
brakes complies with legal requirement
 Carry out test braking while driving at low speed; the effectiveness of the
brakes may be reduced during the initial braking operations.
 Exaggerated drastic and continuous braking operations faster braking in
are not permitted.
 Advise the customer not to perform any wilful drastic braking in the first
200 km after brake replacement.
 Attach mirror tag to interior rearview mirror.
34 00 ... TESTING AWD VEHICLES ON DYNAMIC BRAKE AND POWER ANALYZERS (E30, E34,
E46, E53, E83, E60, E61, E90, E91, E92)
NOTE: Running AWD vehicles on dynamic brake analyzers is governed by different

instructions, depending on the vehicle model.
IMPORTANT: Power measurements on single-axle roller dynamometers are generally not

permitted as total failure of the transfer case cannot be ruled out during such
measurements.
In order to test AWD vehicles on dynamic brake analyzers, it is essential to follow various measures in
accordance with the special instructions in Appendices 1 to 5 for the vehicles in question:
1. E30 AWD
2. E34 AWD
3. E46 AWD
4. E53 X5
5. E83 X3
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6. E60 / E61 AWD

7. E90/E91/E92 AWD
34 00 009 CHECKING BRAKES ON TEST STAND
Necessary preliminary tasks:
 Check tires for damage

 Check tyre treads
 Check tyre pressure
IMPORTANT: The corresponding system must be deactivated on vehicles equipped with

ASC+T or DSC.
The ASC+T or DSC telltale and warning light must light up in the instrument
cluster!
The brakes must be at normal operating temperature. To do so, gently warm up the brake disks and brake drums
while dry by braking the vehicle several times.
Fig. 1: Identifying Brakes Test Stand

Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Only brake test stands (analyzers) with test speeds of 2.5-6 km/h may be used.
You must follow without fail the guidelines contained in the operating instructions of the relevant test stand
manufacturer.
Failure to do so may result in damage to the vehicle and the system and also personal injury.
34 00 010 CHECKING THICKNESS OF BRAKE PAD
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Special tools required:
 34 1 260
NOTE: The thickness of the outer brake pads can be determined without removing the
wheels.
If necessary, move car until opening for brake pad wear indicator (brake pad)
can be seen through rim styling.
Insert special tool 34 1 260 through rim into opening for brake pad wear indicator.
Press special tool onto brake pad. Slide ring (1) in direction of arrow up to stop and read off measured value.
NOTE: A. Brake disk

B. Brake pad with backplate
Safe Limit For Lining Wear, Front Brake.
Safe Limit For Lining Wear, Rear Brake.
Fig. 2: Identifying Special Tool (34 1 260)

34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM
NOTE: Read And Comply With General Information.
IMPORTANT: When carrying out repairs to the brake system, follow the procedure set out in
Bleeding Brake System With Dsc.
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Unclip retaining tabs (1).
Pull cover (3) out of guide (2) and remove.
Fig. 3: Identifying Brake System Retaining Tabs, Cover And Guide

Connect brake fluid changer to expansion tank and switch on.
NOTE: Check relevant Operating Instructions for each device.
Charging pressure should not exceed 2 bar.
Fig. 4: Identifying Brake Fluid Changer

Flushing brake system completely
Connect bleeder hose with collecting tray to bleeder valve on rear right brake caliper.
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Open bleeder valve and purge until clear, bubble-free brake fluid emerges.
Close bleed valve.
Follow same procedure on rear left, front right and front left wheel brake.
Fig. 5: Identifying Rear Right Brake Caliper Bleeder Valve

NOTE: The clutch slave cylinder must also be scavenged in vehicles with manual
transmissions.
Switch off brake fluid changer and remove from expansion tank.
Check brake fluid level.
Close expansion tank.
NOTE: Pay attention to rubber seal (1) in sealing cap.
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Fig. 6: Identifying Expansion Tank, Brake Fluid Level And Sealing Cap Rubber Seal
34 00 050 BLEEDING BRAKE SYSTEM WITH DSC
NOTE: Read And Comply With General Information.
When replacing or repairing, observe the filling and bleeding instructions for
the following parts:
 Tandem brake master cylinder

 Hydraulic unit
 Components and connecting lines which are fitted between these
assemblies.
Connect bleeder unit with max. 2 bar filling pressure.
A second person is needed to help carry out this work.
Unclip retaining tabs (1).
Pull cover (3) out of guide (2) and remove.
Fig. 7: Identifying Brake System Retaining Tabs, Cover And Guide

Connect DIS.
Select path: Service functions - Chassis/Suspension - Slip control systems - Bleeding procedure.
Connect brake fluid changer to expansion tank and switch on.

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IMPORTANT: Check relevant Operating Instructions for each device.
Charging pressure should not exceed 2 bar.
Fig. 8: Identifying Brake Fluid Changer

Flushing brake system completely
Open bleeder valve and purge until clear, bubble-free brake fluid emerges.
Close bleed valve.
Follow same procedure on rear left, front right and front left wheel brake.

Bleeding rear-axle brake circuit

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Close bleeder valve.
Run bleeding routine with DIS with bleeder valve open.
After completing routine, press brake pedal 5 times to floor; clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at rear left.

Bleeding front-axle brake circuit
Connect bleeder hose with collecting tray to bleeder valve on front right brake caliper.
Close bleeder valve.
Run bleeding routine with DIS with bleeder valve open.
After completing routine, press brake pedal 5 times to floor, clear and bubble-free brake fluid must flow out.
Close bleed valve.
Repeat procedure at front left.
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Fig. 11: Identifying Front Right Brake Caliper Bleeder Valve

Switch off brake fluid changer and remove from expansion tank.
Check brake fluid level.
Close expansion tank.
NOTE: Pay attention to rubber seal (1) in sealing cap.
Fig. 12: Identifying Expansion Tank, Brake Fluid Level And Sealing Cap Rubber Seal
34 00 513 CHECKING PARKING BRAKE SETTING (VEHICLE CHECK FOR SERVICE)
IMPORTANT: Follow instructions for Brake testing on test stand.
NOTE: If deviations are identified during the following check, the parking brake must
be adjusted:
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Drive vehicle onto chassis dynamometer. Warm up brakes. Check handbrake. 0th tooth (handbrake released):
 Vehicles with manual transmission: Shift lever in neutral position.

 Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential =150 N.
 With locking differential = 200 N (possibly odd display).
1st tooth: No increase in braking force with regard to 0th tooth. Indicator lamp can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
5th tooth: The brake force display must have reached > or = 400 N.
Checking brake force differential at wheel:
Apply handbrake until a wheel circumferential force (measured on brake test stand) of min. 1000 N is reached.
Max. permitted brake force differential right/left =35 % (referred to greater brake value).
It must be possible to brake with locked wheels with the handbrake.
11 FRONT BRAKE
34 11 ... OVERVIEW OF FRONT BRAKES
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Fig. 13: Identifying Brake Disk, Brake Pad And Brake Caliper
34 11 000 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH FRONT DISC
BRAKES (TRW FLOATING CALIPER)
 34 1 050
 34 1 280
 Remove Wheels
 Remove Brake Pad Wear Sensor
Pull brake pad wear sensor (1) towards rear out of lining (left side only).
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Release guide screw (2).
If necessary, grip at hexagon head (3).
Tilt brake caliper upwards.
Installation:
Replace guide screws.
For tightening torque refer to 34 11 5AZ in 34 11 FRONT BRAKE .
Fig. 14: Identifying Brake Pad Wear Sensor, Guide Screw And Hexagon Head
Remove brake pads (1) in direction of arrow from brake console.
IMPORTANT: Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change brake pads round.
Observe Minimum Thickness Of Brake Pads.
Clean brake pads.
Do not apply grease to brake pad backplate.
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Fig. 15: Identifying Brake Pads Removal Direction

Check minimum brake disc thickness:
 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with Setpoint Value.
New brake pads may only be installed if the brake disc thickness is greater than or equal to the Minimum
Brake Disc Thickness (MIN TH).
Fig. 16: Identifying Special Tool (34 1 280) And Brake Disc Measuring Points
Press brake piston fully back with special tool 34 1 050.
IMPORTANT: When pressing piston back, note brake fluid level in expansion tank.
Overflowing brake fluid will damage the paintwork.

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Check dust sleeve (1) for damage and replace if necessary.
Clean contact face (2) of brake piston and apply a thin coating of anti-squeak compound.
IMPORTANT: Dust sleeve must not come into contact with antisqueak compound as this may
cause the dust sleeve to swell.
Fig. 18: Identifying Brake Caliper Dust Sleeve And Contact Face
Clean contact face (1) of brake caliper and apply a thin coating of anti-squeak compound.
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Fig. 19: Identifying Brake Caliper Contact Face

Clean hammerhead guides and apply a thin coating of anti-squeak compound.
IMPORTANT: Brake pad with indentation (1) is intended for accommodating the brake pad
wear sensor and must be fitted on the piston side.
Fig. 20: Identifying Brake Pad With Indentation

Replacement:
Remove lining retaining springs (1).
Installation:
Clean contact face of brake carrier and apply a thin coating of anti-squeak compound.
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Fig. 21: Identifying Brake Lining Retaining Springs

NOTE: After completing work:
 Fully depress brake pedal several times so that brake pads contact brake
discs.
 When installing new brake pads at front and rear axles, brake fluid level
must be brought up to "MAX" marking.
 Read and comply with Notes On Braking In New Brake Disc Brake Pads.
 When replacing linings, reset CBS display in accordance with factory
specification.
34 11 000 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH FRONT DISC
BRAKES (TEVES FLOATING CALIPER)
 34 1 050
 34 1 280
IMPORTANT: The brake pad wear sensor must be replaced once it has been removed (brake
pad wear sensor loses its retention capability in the brake pad).
 Remove Wheels
 Remove Brake Pad Wear Sensor
Lift out retaining spring (1).
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Fig. 22: Identifying Brake Caliper Retaining Spring

Remove plastic plugs (1).
Fig. 23: Identifying Brake Caliper Plastic Plugs

Unfasten guide screws (1) and lift out brake caliper towards rear of vehicle.
Installation:
Clean guide screws only; do not grease.
Check threads.
Replace all guide screws which are not in perfect condition.
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IMPORTANT: Tie brake caliper back and do not allow to hang from brake hose.
Fig. 24: Identifying Brake Caliper Guide Screws

Remove outer brake pad.
Inner brake pad is located with its spring in the piston.
Clean brake pads.
Do not grease backs of brake pads sleeve.
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Fig. 25: Removing Outer Brake Pads

Fig. 26: Identifying Special Tool (34 1 280) And Brake Pad Measuring Points
Turn piston fully back with special tool 34 1 050.
IMPORTANT: When pressing down piston, note brake fluid level in expansion tank.
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Clean contact faces (1 ... 2) of brake pad hammer heads/brake caliper housing and coat with anti-squeak
compound.
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Fig. 29: Identifying Brake Caliper Contact Faces


Clean brake console at hammerhead guides and apply a thin coating of anti-squeak compound.
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Fig. 31: Identifying Brake Console

discs.
 Read and comply with notes on Braking In New Brake Discs / Brake Pads.
specification.
34 11 000 REMOVING AND INSTALLING/RENEWING BRAKE PADS ON BOTH FRONT DISC

BRAKES (BREMBO)
IMPORTANT:  Brake pad wear sensor: after removal it must be replaced (brake pad wear
sensor loses its retention capability in the break pad).
 Retaining spring: bei for vehicles older than 48 months it is recommended
to replace the retaining spring!
 Remove Wheels .
 Remove brake pad wear sensor.
Release bolts (1) and pull off brake caliper with brake anchor plate towards rear.
Installation: Tightening torque 34 11 2AZ.

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Fig. 32: Release Bolts (1) And Pull Off Brake Caliper With Brake Anchor Plate Towards Rear
Turn piston back fully with special tool 34 1 050.
Fig. 33: Turn Piston Back Fully With Special Tool 34 1 050
Pull brake pads (1) off guide pins (2) and remove.
IMPORTANT: Mark any worn brake pads. In the event of one-sided brake pad wear, do not
change brake pads round.
Observe minimum thickness of brake pads.
Installation: Clean brake pads, brake caliper and guide pins. Do not grease backs of brake pads sleeve. Brake
pads must be correctly seated on guide pins.
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Fig. 34: Pull Brake Pads (1) Off Guide Pins (2) And Remove
 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with setpoint value.
Fig. 35: Position Special Tool 34 1 280 At Three Measuring Points In Area (1) And Measure
IMPORTANT: New brake pads may only be fitted if the brake disc thickness is greater than
the minimum brake disc thickness (MIN TH).
IMPORTANT: Do not grease brake pads and guides with brake pad paste.
Clean contact surface (1) of brake pistons with brake cleaner.
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Fig. 36: Clean Contact Surface (1) Of Brake Pistons With Brake Cleaner
Replace expanding spring (1).
Fig. 37: Replace Expanding Spring (1)

 When installing new brake pads at front and rear axles, brake fluid level
 Fully depress brake pedal several times so that brake pads contact brake
discs.
 Read and comply with notes on braking in new brake discs / brake pads.
 When replacing linings, reset CBS display in accordance with factory
specification.
34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE

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CALIPER (TRW)
 Remove Wheels .
 Read and comply with General Information.
After completing work:
Bleeding Braking System
Press clutch pedal down to floor and secure with pedal support.
NOTE: The pedal support may only be released when the brake lines are reconnected.
This prevents brake fluid from emerging from the expansion tank and air from entering the system when the
brake lines are opened.
Fig. 38: Identifying Secured Pedal Support

If necessary, pull brake hose out of holder (1).
Disconnect brake hose from brake line (2).
IMPORTANT: Grip brake hose at square head (3) to prevent connecting piece from turning in
retaining bracket.
Installation:
For tightening torque refer to 34 32 1AZ in 34 32 BRAKE LINES .
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Detach brake hose from brake caliper (4).
Installation:
For tightening torque refer to 34 32 2AZ in 34 32 BRAKE LINES .
Fig. 39: Identifying Brake Hose Holder, Brake Line, Caliper And Square Head
IMPORTANT: Never twist brake hose when installing it and avoid all contact with parts
attached rigidly to the body.
NOTE: First tighten brake hose on brake caliper.
Move wheels into straight-ahead position.
Insert brake hose in bracket and screw onto brake pipe.
If necessary, replace brake pad wear sensor.
Unscrew guide bolts (3).
Remove brake caliper by pulling upwards.
Installation:
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Fig. 40: Identifying Brake Pad Wear Sensor, Hexagon Head And Guide Bolts
34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT OR RIGHT BRAKE

CALIPER (TEVES)
 Remove Wheels .
 Bleed Braking System
This prevents brake fluid from emerging from the expansion tank and air from
entering the system when the brake lines are opened.
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Fig. 41: Identifying Secured Pedal Support

retaining bracket.
Installation:
For tightening torque refer to 34 32 1AZ in34 32 BRAKE LINES .
Installation:
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Fig. 42: Identifying Brake Hose Holder, Caliper, Line And Square Head
Remove brake caliper by pulling upwards.
Installation:
Fig. 43: Identifying Brake Pad Wear Sensor, Guide Bolts And Hexagon Head
34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH FRONT BRAKE DISCS
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 34 1 280
 Remove Wheels
 Remove and clean Brake Pads
After completing work, read and comply with Notes On Braking In New Brake Discs / Brake Pads.
 Compare measurement result and lowest value with setpoint value.
If the brake discs are replaced, you must also fit new brake pads.
Brake discs may only be replaced in pairs (on each axle).
Release screws (1), remove brake caliper (2) with brake console (3) and tie back.
Installation:
Brake hose remains connected.

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Check that brake hose is correctly seated in holder.
Fig. 45: Identifying Brake Caliper, Screws And Brake Console

Release screw (1) and remove brake disc (2).
Installation:
Replace screw.
IMPORTANT: To release brake disc: Do not under any circumstances strike friction ring with
a hammer or similar!
If necessary, carefully tap on base of brake disc chamber with a rubber mallet.
Clean contact surface of brake disc at wheel hub thoroughly and remove traces
of corrosion.
Unevenness on contact surface may result in distortion of brake disc!
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Fig. 46: Identifying Brake Disc And Screw

34 11 220 REMOVING AND INSTALLING/REPLACING BOTH FRONT BRAKE DISCS (BREMBO)
 Remove wheels.
 Remove and clean brake pads.
After completing work, read and comply with notes on braking in new brake discs / brake pads .
 Position special tool 34 1 280 at three measuring points in area (1) and measure.
 Compare measurement result and lowest value with setpoint value. See BRAKES - TECHNICAL
DATA - SEDAN/WAGON .
If the brake discs are replaced, you must also fit new brake pads. Brake discs may only be replaced in pairs (on
each axle).
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Fig. 47: Identifying Measuring Points
IMPORTANT: New brake pads may only be fitted if the brake disc thickness is greater than
the minimum brake disc thickness (MIN TH). See 34 11 FRONT BRAKE E90 .
of corrosion.
Unevenness on contact surface may result in distortion of brake disc.
Release screw (1) and remove brake disc (2). Installation: Replace screw. Tightening torque 34 11 1AZ. See
FRONT BRAKES .
Fig. 48: Identifying Brake Disc With Mounting Screw
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34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD

PLATE AT FRONT
 Remove Front Brake Disks
Release screws (1) and remove brake guard plate (2).
Installation:
Fig. 49: Identifying Mounting Screws And Brake Guard Plate

34 11 520 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT BRAKE

CALIPER (BREMBO)
 Remove Wheels .
 Remove front brake pad sensor.
NOTE: Read and comply with General Information.
After completing work: Bleed braking system.
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Fig. 50: Locating Pedal Support
Fig. 51: Pull Brake Hose Out Of Holder (1)

retaining bracket.
Disconnect brake hose from brake line (2). Installation: Tightening torque 34 32 1AZ, see 34 32 BRAKE
LINES .
Detach brake hose from brake caliper (4). Installation: Tightening torque 34 32 2AZ, see 34 32 BRAKE
LINES .
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NOTE: First tighten brake hose on brake caliper. Move wheels into straight-ahead
position. Insert brake hose in bracket and screw onto brake pipe.
Release bolts (1) and pull off brake caliper with brake anchor plate towards rear. Installation: Tightening torque
34 11 2AZ, see 34 11 FRONT BRAKE .
Fig. 52: Release Bolts (1) And Pull Off Brake Caliper With Brake Anchor Plate Towards Rear
Pull brake pads (1) off guide pins (2) and remove.
Fig. 53: Pull Brake Pads (1) Off Guide Pins

IMPORTANT: Mark any worn brake pads. In the event of one-sided brake pad wear, do not
change brake pads round. Observe minimum thickness of brake pads. See 34
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11 FRONT BRAKE E90 .
Installation: Clean brake pads, brake caliper and guide pins. Do not grease backs of brake pads sleeve. Brake
pads must be correctly seated on guide pins.
IMPORTANT: Do not grease brake pads and guides with anti-squeak paste.
Clean contact surface (1) of brake pistons.
Fig. 54: Clean Contact Surface (1) Of Brake Pistons

34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (TRW) (BRAKE CALIPER
REMOVED)
 00 9 316
WARNING: In the following work step, large forces occur at the brake caliper piston
(up to more than 2800 N).
Danger of injury!
NOTE: Use repair kit.
Carefully force piston out through connection bore with compressed air.
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!
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Fig. 55: Removing Piston Out Of Connection Bore With Compressed Air
Press off dust sleeve (1).
Fig. 56: Identifying Brake Caliper Housing Dust Sleeve

Carefully remove seal (1) with special tool 00 9 316.
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.
Install new seal.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal, refer to BMW Service
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Operating Fluids .
Fig. 57: Identifying Special Tool (00 9 316) And Brake Caliper Housing Seal
Fit dust sleeve (1) in groove (2) of brake caliper housing and press into the annular groove.
Installation:
The area between the dust sleeve and the brake caliper housing must be kept dry. It must not come into contact
with Ate brake cylinder paste or brake fluid so as to ensure that the dust sleeve is perfectly seated.
Fig. 58: Identifying Brake Caliper Housing Dust Sleeve And Groove
Lightly press brake piston against dust sleeve (1).
Inflate dust sleeve with compressed air (max. 2 bar) via the connection hole. Dust sleeve snaps over brake
piston.
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Installation:
Coat dust sleeve and brake piston with brake fluid to facilitate installation of dust sleeve.
Press piston into cylinder bore until dust sleeve (1) snaps into annular groove (2) of brake piston.
IMPORTANT: Do not twist brake piston.
Fig. 59: Identifying Brake Caliper Housing Dust Sleeve And Annular Groove
34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (TEVES) (BRAKE

CALIPER REMOVED)
 00 9 316
Danger of injury!
NOTE: Use repair kit.
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.
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Fig. 60: Identifying Brake Caliper Housing Guide Sleeves

Carefully force piston out through connection bore with compressed air.
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!
Fig. 61: Removing Piston From Connection Bore Using Compressed Air
CARMANUALSUSA
2008 BMW 328xi
Fig. 62: Identifying Brake Caliper Housing Dust Sleeve

Carefully remove seal (1) with special tool 00 9 316.
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.
Install new seal.
Installation:
Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal,
Refer to BMW Service Operating Fluids .
Fig. 63: Identifying Special Tool (00 9 316) And Brake Caliper Housing Seal
CARMANUALSUSA
2008 BMW 328xi
Fit dust sleeve (1) in annular groove of piston (2).
Press piston into cylinder bore.
Evenly press dust sleeve (1) onto brake caliper housing as far as it will go.
Installation:
Fig. 64: Identifying Brake Caliper Housing Dust Sleeve And Annular Groove
34 11 552 OVERHAULING LEFT OR RIGHT FRONT BRAKE CALIPER (BREMBO) (BRAKE

CALIPER REMOVED)
Danger of injury!
IMPORTANT: To protect the pistons, place a protective plate (1) (e.g. hard wood or hard felt)
in caliper recess. Do not grip piston with fingers - risk of trapping!
CARMANUALSUSA
2008 BMW 328xi
Fig. 65: Place A Protective Plate In Caliper Recess

Carefully force piston out through brake hose connection bore with compressed air.
Installation: Do not jam piston when pressing in.
Fig. 66: Press Off Dust Sleeve (1)

IMPORTANT: Machining of cylinders and pistons is not permitted.
Installation: Dust sleeve must be correctly seated in groove (1) of piston and groove (2) of brake caliper.
CARMANUALSUSA
2008 BMW 328xi
Fig. 67: Dust Sleeve Must Be Correctly Seated In Groove (1) Of Piston And Groove (2) Of Brake Caliper
34 11 667 PRECISION-TURNING BOTH FRONT BRAKE DISCS ON BOTH SIDES
IMPORTANT: Always precision-turn both sides of both brake discs on one axle.
Observe Max. Machining Dimension Per Friction Ring Side
Minimum Brake Disc Thickness (MIN TH)
Brake discs of M models (Compound brake discs) must not be machined!
Only one brake pad set may be used up on brake discs which have been lathe-
turned to Minimum Thickness (MIN TH).
Stationary brake disc lathe:
In the case of stationary brake disc lathes, the Brake Disc Must Be Removed.
Please refer to the lathe manufacturer's instruction manual for the exact procedure.
IMPORTANT: Only BMW-approved brake disc lathes may be used!
CARMANUALSUSA
2008 BMW 328xi
Fig. 68: Identifying Stationary Brake Disc Lathe

Mobile brake disc lathe:
In the case of mobile brake disc lathes, only the Brake Caliper Has Must Be Removed.
The brake discs remain on the car.
Fig. 69: Identifying Mobile Brake Disc Lathe:

After fine-grinding the brake discs, measure the Thickness Difference inside the braking surfaces at 8 points
with an external micrometer.
CARMANUALSUSA
2008 BMW 328xi
Fig. 70: Measuring Brake Discs Thickness

21 REAR BRAKES
34 21 ... OVERVIEW OF REAR BRAKE
CARMANUALSUSA
2008 BMW 328xi
Fig. 71: Identifying Rear Brakes Components Location

34 21 171 REMOVING AND INSTALLING / REPLACING A BRAKE CARRIER / BRAKE GUARD

AT REAR
 Remove expander lock

 Remove wheel hub
Release screws (1).
Installation:
For tightening torque refer to 34 21 3AZ in 34 21 REAR BRAKE .
CARMANUALSUSA
2008 BMW 328xi
Release screws (2) and remove brake carrier (3).
Installation:
Fig. 72: Identifying Mounting Screws And Brake Carrier

34 21 173 REPLACING REAR LEFT (OR RIGHT) BRAKE CARRIER
 Remove expander lock.

 Remove wheel hub. See 33 41 153 REPLACING WHEEL BEARING (75 MM) ON REAR AXLE
SHAFT ON LEFT or 33 41 153 REPLACING WHEEL BEARING (85 MM) ON REAR AXLE
SHAFT ON LEFT .
Release screws (1). Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR BRAKE .
Release screws (2) and remove brake carrier (3). Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR
BRAKE . Release screws (1). Installation: Tightening torque, see 34 21 3AZ in 34 21 REAR BRAKE .
CARMANUALSUSA
2008 BMW 328xi
Fig. 73: Removing Brake Carrier

34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH REAR DISC
BRAKES (TRW FLOATING CALIPER)
 34 1 050
 34 1 280
 Remove Wheels
 Remove Rear Brake Pad Wear Sensor
Release guide screw (1).
If necessary, grip at hexagon head.
Tilt brake caliper upwards.
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 74: Identifying Rear Brake Pad Guide Screws

Remove brake pads (1) in direction of arrow from brake console.
Clean brake pads.
Do not apply grease to brake pad backplate.
Fig. 75: Identifying Brake Pads And Removal Direction


CARMANUALSUSA
2008 BMW 328xi
Press brake piston fully back with special tool 34 1 050.
IMPORTANT: When pressing piston back, note brake fluid level in expansion tank.


CARMANUALSUSA
2008 BMW 328xi
Fig. 78: Identifying Brake Caliper Dust Sleeve And Face


Clean hammerhead guides and apply a thin coating of anti-squeak compound.
IMPORTANT: Brake pad with indentation (1) is intended for accommodating the brake pad
wear sensor and must be fitted on the piston side.
CARMANUALSUSA
2008 BMW 328xi
Fig. 80: Identifying Brake Pad With Indentation

discs.
 Read and comply with Notes On Braking In New Brake Discs / Brake Pads.
specification.
Replacement:
Remove lining retaining springs (1).
Installation:
Clean contact face of brake carrier and apply a thin coating of anti-squeak compound.
CARMANUALSUSA
2008 BMW 328xi
Fig. 81: Identifying Brake Pad Retaining Springs

34 21 200 REMOVING AND INSTALLING OR REPLACING BRAKE PADS ON BOTH REAR DISC
BRAKES (TEVES FLOATING CALIPER)
 34 1 050
 34 1 280
 Remove Wheels
 Remove Rear Brake Pad Wear Sensor
CARMANUALSUSA
2008 BMW 328xi
Fig. 82: Identifying Brake Pad Retaining Spring

Remove cover plug (1).
Pull brake pad wear sensor out of brake pad (right side only).
Fig. 83: Identifying Brake Pad Cover Plug

Remove brake caliper (2) by pulling forward.
Installation:
CARMANUALSUSA
2008 BMW 328xi
Check threads.
Fig. 84: Identifying Guide Bolts And Brake Caliper

Clean brake pads.
CARMANUALSUSA
2008 BMW 328xi
Fig. 85: Removing Outer Brake Pad

Turn piston fully back with special tool 34 1 050.

Brake Disc Thickness (MIN TH)..
CARMANUALSUSA
2008 BMW 328xi
Fig. 87: Identifying Special Tool (34 1 280) And Measuring Points
Clean contact faces (1...2) of brake pad hammer heads/brake caliper housing and coat with anti-squeak
compound.
CARMANUALSUSA
2008 BMW 328xi
Fig. 89: Identifying Brake Caliper Contact Faces


Clean brake caliper mounting bracket at hammer head guides and apply a thin coating of anti-squeak
compound.
CARMANUALSUSA
2008 BMW 328xi
Fig. 91: Identifying Brake Caliper Mounting Bracket


specification.
discs.
 Read and comply with Notes On Braking In New Brake Discs / Brake Pads.
34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH REAR BRAKE DISCS
 34 1 280
 Remove Wheels
 Remove and clean Brake Pads
 Adjusting Handbrake
 Read and comply with Notes On Braking In New Brake Discs / Brake Pads.
CARMANUALSUSA
2008 BMW 328xi
If the brake discs are replaced, you must also fit new brake pads.
Always replace brake discs in pairs.
Fig. 92: Identifying Special Tool (34 1 280) And Measuring Points
Release screws (1). Remove and suspend brake caliper from vehicle.
Installation:
Fig. 93: Identifying Brake Caliper Mounting Screws

CARMANUALSUSA
2008 BMW 328xi
Release screw (1) and remove brake disc (2).
Installation:
Replace screw.
of corrosion.
Unevenness on contact surface may result in distortion of brake disc!
Fig. 94: Identifying Screw And Brake Disc

34 21 745 REMOVING AND INSTALLING OR REPLACING REAR LEFT OR RIGHT BRAKE

CALIPER (TRW)
 Remove Wheels
CARMANUALSUSA
2008 BMW 328xi
Bleed Braking System
Fig. 95: Identifying Pedal Support

IMPORTANT: Grip brake hose at square head (2) so that connecting piece cannot rotate in
retaining bracket.
Installation:
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 96: Identifying Brake Caliper, Brake Line And Square Head
Pull brake pad wear sensor towards rear out of lining (right side only).
Remove brake caliper by pulling forward.
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 97: Identifying Brake Caliper Guide Bolts And Hexagon Head
34 21 745 REMOVING AND INSTALLING OR REPLACING REAR LEFT OR RIGHT BRAKE

CALIPER (TEVES)
 Remove Wheels
After completing tasks, bleed Braking System.
CARMANUALSUSA
2008 BMW 328xi

retaining bracket.
Installation:
Installation:
Fig. 99: Identifying Brake Caliper, Square Head And Brake Line
CARMANUALSUSA
2008 BMW 328xi
Fig. 100: Identifying Brake Caliper Retaining Spring

Remove cover plug (1).
Pull brake pad wear sensor out of brake pad (right side only).
Fig. 101: Identifying Cover Plug

CARMANUALSUSA
2008 BMW 328xi
Remove brake caliper (2) by pulling forward.
Installation:
Check threads.
Fig. 102: Identifying Brake Caliper And Guide Bolts

Clean brake pads.
CARMANUALSUSA
2008 BMW 328xi
Fig. 103: Removing Brake Pad

34 21 812 OVERHAULING LEFT OR RIGHT REAR BRAKE CALIPER (BRAKE CALIPER

REMOVED)
(up to more than 2800 N). Risk of injury!
Check guide sleeves (5), fitting repair-kit guide sleeve if necessary.
Fig. 104: Check Guide Sleeves (5), Fitting Repair-Kit Guide Sleeve If Necessary
Carefully force piston out through connection bore with compressed air. 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!
CARMANUALSUSA
2008 BMW 328xi
Fig. 105: Carefully Force Piston Out Through Connection Bore

Press off dust sleeve.
Carefully remove sealing ring special tool 00 9 316. 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. Install new seal.
Fig. 106: Carefully Remove Sealing Ring Special Tool 00 9 316

Installation: Apply a light coat of Ate brake cylinder paste to cylinder bore, piston and seal.
Fit dust sleeve (1) in annular groove of piston (2). Press piston into cylinder bore.
Evenly press dust sleeve (1) onto brake caliper housing as far as it will go.
CARMANUALSUSA
2008 BMW 328xi
Fig. 107: Fit Dust Sleeve (1) In Annular Groove Of Piston

Installation: The area between the dust sleeve and the brake caliper housing must be kept dry. It must not come
into contact with Ate brake cylinder paste or brake fluid so as to ensure that the dust sleeve is perfectly seated.
34 21 947 PRECISION-TURNING BOTH REAR BRAKE DISCS ON BOTH SIDES
IMPORTANT: Always precision-turn both sides of both brake discs on one axle.
Observe Max. Machining Dimension Per Friction Ring Side
Minimum Brake Disc Thickness (MIN TH)
Brake discs of M models (Compound brake discs) must not be machined!
Only one brake pad set may be used up on brake discs which have been lathe-
turned to Minimum Thickness (MIN TH) .
Stationary brake disc lathe:
In the case of stationary brake disc lathes, the Brake Disc Must Be Removed.
CARMANUALSUSA
2008 BMW 328xi
Fig. 108: Identifying Stationary Brake Disc Lathe:

Mobile brake disc lathe:
In the case of mobile brake disc lathes, only the Brake Caliper Has Must Be Removed.
The brake discs remain on the car.
Fig. 109: Identifying Mobile Brake Disc Lathe:

After fine-grinding the brake discs, measure the Thickness Difference inside the braking surfaces at 8 points
with an external micrometer.
CARMANUALSUSA
2008 BMW 328xi
Fig. 110: Measuring Brake Discs Thickness

31 MASTER BRAKE CYLINDER

34 31 ... OVERVIEW OF BRAKE MASTER CYLINDER / BRAKE BOOSTER
CARMANUALSUSA
2008 BMW 328xi
Fig. 111: Identifying Master Brake Cylinder Components Location

34 31 181 REMOVING AND INSTALLING / REPLACING EXPANSION TANK FOR HYDRAULIC

BRAKE ACTUATION

 Remove Lower Section Of Microfilter Housing
NOTE: Suck the brake fluid out of the expansion tank. Use a suction bottle used
exclusively for drawing off brake fluid.
Do not reuse drawn out brake fluid.

CARMANUALSUSA
2008 BMW 328xi
 Bleeding Braking System
Pull off supply hose (1) of clutch hydraulic system if necessary.
Unfasten plug connection (2) and disconnect.
Unlock quick-release fastener (3) and disconnect vacuum line.
Feed brake line out of rubber grommet and remove cover (4).
Fig. 112: Identifying Expansion Tank Cover, Supply Hose, Plug Connection And Quick-Release Fastener
Unclip locking pin (1) from retaining lugs (2) and pull out locking pin.
Pull expansion tank in direction of arrow vertically out of brake master cylinder.
Fig. 113: Identifying Expansion Tank Locking Pin And Retaining Lugs
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: Check rubber plug in brake master cylinder for damage and replace if
necessary.
Push the expansion tank vertically onto the master brake cylinder.
Fig. 114: Pushing Expansion Tank Vertically Onto Master Brake Cylinder
34 31 505 REMOVING AND INSTALLING / REPLACING MASTER BRAKE CYLINDER FOR DSC
 32 1 270
 Remove Expansion Tank.

 Remove Footwell Trim.
 Bleeding brake system with DSC
IMPORTANT: The brake booster must be slackened so that the brake master cylinder can be
removed and installed without tilting!
Remove locking clip (1) and disengage and pull out locking pin.
Slacken nuts (2).
Installation:
CARMANUALSUSA
2008 BMW 328xi
Replace self-locking nuts.
For tightening torque refer to 35 11 1AZ in 35 11 PEDAL ASSEMBLY CONSOLE .
Fig. 115: Identifying Brake Cylinder Locking Clip And Nut

Unfasten brake lines (1).
Installation:
Close off brake lines and brake master cylinder with plugs 32 1 270.
If necessary, detach line (3) from hydraulic unit and press downwards slightly.
Installation:
IMPORTANT: Do not bend brake lines.
Release nuts (2) and feed brake master cylinder out of brake booster.
Installation:
For tightening torque refer to 34 31 1AZ in 34 31 BRAKE MASTER CYLINDER .
CARMANUALSUSA
2008 BMW 328xi
Fig. 116: Identifying Brake Lines, Retaining Nuts And Hydraulic Unit Line
Installation:
Replace sealing ring.
Fig. 117: Identifying Brake Cylinder Sealing Ring

Installation:
When inserting the brake master cylinder (2) into the brake booster (1), make sure the pressure rod of the brake
booster and that of the brake master cylinder meet each other on one level.
CARMANUALSUSA
2008 BMW 328xi
Fig. 118: Inserting Brake Master Cylinder And Brake Booster

32 BRAKE LINES
34 32 ... OVERVIEW OF BRAKE LINES
CARMANUALSUSA
2008 BMW 328xi
Fig. 119: Identifying Brake Lines Components Location

34 32 861 REPLACING ALL BRAKE PIPES
 34 5 100
NOTE: The brake lines are only supplied in the straight version and correct length with
connecting nipple.
Read and comply with General Information.
After completing work, bleed Braking System.
Observe Safety Instructions On Raising The Vehicle.
CARMANUALSUSA
2008 BMW 328xi
New brake lines are bent into shape with bending tool 34 5 100.
Removed brake pipes can be used as templates for bending.
IMPORTANT:  Protective coating of brake line must not be damaged during bending.
 Do not kink or bend back brake lines.
 Watch distances to rigid and movable vehicle parts. Brake lines may not
make contact or rub.
 Tighten down brake line couplings with torque wrench.
Installation:
Fig. 120: Identifying Bending Tool (34 5 100)

34 32 881 REPLACING FRONT LEFT OR RIGHT BRAKE HOSES
NOTE:  Read and comply with General Information.
After completing work: Bleed Braking System
CARMANUALSUSA
2008 BMW 328xi

Cars up to model year approx. 07/05:
Pull brake hose out of holder (1).
Detach brake hose from brake line (2).
retaining bracket.
Installation:
Fig. 122: Identifying Brake Hose Holder, Brake Line, Caliper And Square Head
CARMANUALSUSA
2008 BMW 328xi
Installation:
Cars from model year approx. 07/05:
Pull brake hose out of both holders (1).
retaining bracket.
Detach brake hose from brake line (3).
Installation:
Installation:
Fig. 123: Identifying Brake Caliper, Square Head, Brake Line And Holders
IMPORTANT: First tighten brake hose on brake caliper.
CARMANUALSUSA
2008 BMW 328xi
Never twist brake hose when installing it and avoid all contact with parts
34 32 951 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN REAR AXLE
CARRIER AND BODY)
 34 3 170

 Remove Rear Left Wheel

IMPORTANT: Grip brake hose at square drive to prevent connecting piece from turning in
retaining bracket.
CARMANUALSUSA
2008 BMW 328xi
Never twist brake hose (3) when installing it and avoid all contact with parts
Detach brake hose from brake line (2) and remove brake hose (3).
Installation:
Fig. 125: Identifying Brake Line And Brake Hoses

Installation:
Tighten brake line using torque wrench (Hazet 6282-1CT with reversible ratchet head) and special tool 34 3
170.
CARMANUALSUSA
2008 BMW 328xi

34 32 980 REPLACING REAR LEFT OR RIGHT BRAKE HOSE (BETWEEN BRAKE CALIPER AND
PIPE)
NOTE:  Read and comply with General Information.

retaining bracket.
Never twist brake hose when installing it and avoid all contact with parts
Installation:
CARMANUALSUSA
2008 BMW 328xi
Installation:
Fig. 128: Identifying Brake Caliper, Brake Line And Square Head
Installation:
First tighten brake hose on brake caliper.
33 BRAKE BOOSTER
34 33 051 REMOVING AND INSTALLING OR REPLACING NON-RETURN VALVE FOR BRAKE
BOOSTER

 Remove Hydraulic Unit
IMPORTANT:  If a rubber vacuum hose is fitted, it can be replaced individually.

 If a plastic vacuum line is fitted, it can only be replaced single unit
together with the non-return valve.
CARMANUALSUSA
2008 BMW 328xi
NOTE: Before beginning work, fully press the brake pedal several times to reduce the
vacuum pressure in the brake booster. This makes it easier to remove the
nonreturn valve.
Remove non-return valve (1) from brake booster.
Unlock quick-connect coupling (2) and detach vacuum line.
Disconnect plug connection (3) and remove differential pressure sensor.
Feed out vacuum line.
Installation:
Check sealing ring in brake booster and replace if necessary.
Fig. 129: Identifying Brake Booster Non-Return Valve, Quick-Connect Coupling And Plug Connection
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (N52 ON BRAKE BOOSTER)

IMPORTANT: Before beginning work, fully press the brake pedal several times to reduce the
vacuum pressure in the brake booster.
Unlock quick-release fastener (1) and pull out vacuum line (2).
CARMANUALSUSA
2008 BMW 328xi
Fig. 130: Identifying Vacuum Line And Quick-Release Fastener

Unfasten hose clip (1).
Installation:
Replace hose clip.
Pull off vacuum hose (2).
Unclip vacuum line (4) from fixture (3) and feed out.
Fig. 131: Identifying Brake Booster Hose Clip, Vacuum Hose, Fixture And Vacuum Line
34 33 071 REPLACING VACUUM HOSE FOR BRAKE BOOSTER (N52 ON VACUUM PUMP)
CARMANUALSUSA
2008 BMW 328xi

 Removing Intake Air Manifold
IMPORTANT: Before starting work, press the brake pedal to the floor several times to reduce
the vacuum pressure in the brake booster.
This makes it easier to detach the vacuum hose.
Unclip vacuum line from fixture (2).
Release hose clamp (3) and disconnect vacuum line.
Installation:
Replace hose clamps.
Fig. 132: Identifying Vacuum Pump Vacuum Line, Hose Clamp And Hose Clip
34 33 505 REMOVING AND INSTALLING OR REPLACING BRAKE BOOSTER

 Remove Brake Master Cylinder
 Remove left Footwell Trim.
Detach locking clip (1) from brake pedal, disengage and pull out locking pin.
CARMANUALSUSA
2008 BMW 328xi
Unscrew nuts (2).
Installation:
For tightening torque refer to 35 11 1AZ.
Fig. 133: Identifying Brake Booster Locking Clip And Nut

Carefully pull brake booster (1) out of bulkhead and tilt out.
If necessary, disengage brake line from holder on bulkhead and press slightly to one side.
IMPORTANT: Do not use any force when removing and installing the brake unit; the brake
unit can be damaged under certain circumstances.
Brake lines must not be bent.
The Non-Return Valve must be modified when the brake booster is replaced.
CARMANUALSUSA
2008 BMW 328xi
Fig. 134: Identifying Brake Booster

35 ELECTRICAL COMPONENTS/WEAR INDICATOR

34 35 001 REPLACING A BRAKE LINING SENSOR
If a brake pad sensor that has already been ground has to be replaced even
though the minimum brake pad thickness has not yet been reached, you must
observe the following: The new sliding contact must be filed down with a file to
the same length as the ground sliding contact.
 Remove Wheels
Open plug housing (1).
Unclip lead of brake lining sensor (2) from plug housing (1).
Disconnect associated plug connection of lead from brake lining sensor (2).
Feed lead from brake lining sensor (2) out of fixtures.
CARMANUALSUSA
2008 BMW 328xi
Fig. 135: Identifying Brake Plug Housing And Sensor (Version 1)

Fig. 136: Identifying Brake Plug Housing And Sensor (Version 2)

Press clip (1) together and detach brake pad sensor (2) in direction of arrow from brake caliper (3).
Installation:
Make sure clip (1) and brake lining sensor (2) are correctly seated in brake caliper (3).
CARMANUALSUSA
2008 BMW 328xi
Fig. 137: Identifying Clip, Pad Sensor And Brake Caliper

34 35 003 REPLACING A BRAKE PAD SENSOR (REAR)
If a brake pad wear sensor that has already been ground has to be replaced
even though the minimum brake pad thickness has not yet been reached, you
must observe the following: The new sliding contact must be filed down with a
file to the same length as the ground sliding contact.
 Remove Wheel
Slacken nut (1). Pull wheel arch trim (2) gently to one side. Disengage cable from holders (3).
CARMANUALSUSA
2008 BMW 328xi
Fig. 138: Disengaging Cable From Holders

Disconnect plug connection (1). Installation: Ensure proper locking of the plug connector and proper seating of
the cable in the brackets.
Fig. 139: Removing/Installing Cable In Brackets

Disengage cable from holders (1). Detach brake pad wear sensor (2) in direction of arrow from brake caliper
(3). Installation: Make sure holders (1) and brake pad wear sensor (2) are correctly seated in brake caliper.
Fig. 140: Removing/Installing Brake Pad Wear Sensor

41 PARKING BRAKE
34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS / BRAKE PADS
IMPORTANT: After completing work:

CARMANUALSUSA
2008 BMW 328xi
 Carry out function check on brake analyzer (test stand) ensure that the
brakes complies with legal requirement
 Carry out test braking while driving at low speed; the effectiveness of the
brakes may be reduced during the initial braking operations.
 Exaggerated drastic and continuous braking operations faster braking in
are not permitted.
 Advise the customer not to perform any wilful drastic braking in the first
200 km after brake replacement.
 Attach mirror tag to interior rearview mirror.
34 10 014 ADJUSTING HANDBRAKE
 32 1 030
Perform inspection in the following manner:
When 1st ratchet is engaged, no braking force should be exerted.
The difference in wheel circumferential forces between the left and right wheels may deviate by max. 30 %
from the greater value (measured on brake analyzer).
In event of larger deviations of wheel circumferential force: carry out readjustment.
It must be possible to brake with locked wheels with the handbrake.
The handbrake must be readjusted whenever the actuation stroke is greater than 10 teeth.
NOTE: The handbrake can only be adjusted correctly when the parking brake Bowden
cables and all moving handbrake parts are free to move and fully operational.
Basic handbrake adjustment is necessary:
 When replacing parking brake shoes.

 When replacing brake disks.
 In event of excessive actuation stroke (10 teeth).
 When replacing handbrake cables.
1. Setting instruction for brake shoes (basic setting)
Unclip boot for handbrake lever.
CARMANUALSUSA
2008 BMW 328xi
Release handbrake lever.
Lock adjuster unit (ASZE).
Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook
(2) engages in stop (1).
Installation:
Unlock adjuster unit (ASZE).
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from stop (1) of adjusting spring.
Fig. 141: Identifying Special Tool (32 1 030), Retaining Hook And Stop
Completely unscrew one wheel stud on each rear wheel.
Installation:
For tightening torque refer to 36 10 1AZ in 36 10 WHEELS .
Turn wheel until adjustment screw is visible in tapped hole.
CARMANUALSUSA
2008 BMW 328xi
Fig. 142: Identifying Wheel Stud

Turn adjusting screw with a screwdriver until the wheel is no longer able to turn.
Then unfasten the adjusting screw 8 notches.
Fig. 143: Turning Wheel Adjusting Screw

CARMANUALSUSA
2008 BMW 328xi
Fig. 144: Identifying Special Tool (32 1 030), Restraining Hook And Stop
IMPORTANT: Follow instructions for Brake Testing On Test Stand.
2. Setting instruction for parking brake Bowden cables
The handbrake lever must be applied 5 times to approx. 400N actuating force.
1. On brake analyzer
0th tooth (handbrake released): Vehicles with manual transmission: Shift lever in neutral
position.
Vehicles with automatic transmission: Selector lever in "N" position.
 Without locking differential < or =150 N.

 With locking differential < or = 200 N (possibly odd display).
1st tooth: No increase in braking force with regard to 0th tooth. Indicator lamp can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
5th tooth: The brake force display must have reached > or = 400 N.
Checking brake force differential at wheel:
Apply handbrake until a wheel circumferential force (brake force display) of min. 1000 N is
reached.
CARMANUALSUSA
2008 BMW 328xi
Max. permitted brake force differential right/left < or =35 % (referred to greater brake value).
3. Braking in the duo-servo parking brake
The following braking-in procedures are applicable in case of insufficient braking effect or after replacing
brake disks and/or brake shoes.
1. On brake analyzer
Apply handbrake lever until wheel circumferential force on first wheel is 800 N.
Lock lever in next lower tooth.
Release handbrake lever after approx. 2 minutes.
2. When driving on road
(If possible inside the company grounds or on an unused road)
At approx. 40 km/h, apply handbrake lever until braking action can be felt.
Pull up handbrake lever into next notch and drive on for approx. 400 m.
A basic requirement is that handbrake is adjusted uniformly.
NOTE: If necessary, repeat braking-in procedure.

Allow brake to cool down sufficiently.
34 41 ... OVERVIEW OF PARKING BRAKE
CARMANUALSUSA
2008 BMW 328xi
Fig. 145: Identifying Parking Brake Components Location

34 41 000 REMOVING AND INSTALLING / REPLACING HANDBRAKE LEVER
 32 1 030
 Remove Airbag Control Unit
 Adjust Handbrake

CARMANUALSUSA
2008 BMW 328xi
Using special tool 32 1 030, press stop (1) of adjusting spring back to such an extent that retaining hook (2)
engages in stop (1).
Installation:
Release screws (1).
For tightening torque refer to 34 41 5AZ in 34 41 PARKING BRAKE .
Remove bracket for centre console (2).
CARMANUALSUSA
2008 BMW 328xi
Fig. 147: Identifying Centre Console And Screws

Disconnect cable (1) from handbrake check switch.
Unclip cable bracket (2) at point (3).
Remove cable bracket and place forward.
Fig. 148: Identifying Cable Bracket And Point

Press retainer (1) in balance arm (2) forward in direction of arrow.
Detach handbrake Bowden cables (3) from balance arm (2).
CARMANUALSUSA
2008 BMW 328xi
Fig. 149: Identifying Retainer, Balance Arm And Bowden Cables

Release nuts (1) and remove handbrake lever (2).
Installation:
Handbrake lever and adjustment unit (ASZE) are only exchanged completely as a single unit.
Fig. 150: Identifying Handbrake Lever And Nuts

34 41 120 REMOVING AND INSTALLING OR REPLACING BOTH HANDBRAKE BOWDEN

CABLES

CARMANUALSUSA
2008 BMW 328xi
 32 1 030
NOTE: After completing tasks, Adjust Handbrake.
CARMANUALSUSA
2008 BMW 328xi
Fig. 152: Identifying Handbrake Bowden Cables, Retainer And Balance Arm
Release screw (1) and remove holder (2).
Installation:
Fig. 153: Identifying Holder And Screw

NOTE: To release the parking brake Bowden cable from the expander lock, it is
necessary to Remove The Brake Disk on the following vehicles:
 E90 330i 330d

 All E91
Release one wheel stud.

CARMANUALSUSA
2008 BMW 328xi
Bring wheel into position (tapped hole turned down approx. 20° from horizontal).
F = direction of travel
Installation:
Reinstall wheel stud only after handbrake has been adjusted.
For tightening torque refer to 36 10 1AZ in 36 10 WHEELS .
Fig. 154: Identifying Wheel Position

Nipple (1) and expander lock (2) are visible through tapped hole.
Push in core of handbrake cable in direction of expander lock as far as it will go and grip firmly.
Press nipple (1) downwards through tapped hole with a screwdriver.
Pull handbrake cables out of wheel carrier.
CARMANUALSUSA
2008 BMW 328xi
Fig. 155: Pressing Nipple Downwards Through Tapped Hole With Screwdriver
Installation:
Insert handbrake cable into brake carrier/brake guard plate. Sleeve must be inserted up to stop.
Nipple of handbrake cable must audibly snap into place in expander lock.
Disconnect handbrake cables from holders (1).
Pull handbrake cables towards rear out of guide tube.
Fig. 156: Identifying Handbrake Cables

34 41 140 REMOVING AND INSTALLING OR REPLACING GUIDE TUBE FOR HANDBRAKE

CABLES

CARMANUALSUSA
2008 BMW 328xi
 32 1 030

 Remove Propeller Shaft
Installation:

CARMANUALSUSA
2008 BMW 328xi
Fig. 158: Identifying Handbrake Bowden Cables, Retainer And Balance Arm
Pull handbrake cables out of guide tube.
Release screws (1).
Release screws (2) and feed out guide tube (3) towards bottom.
Installation:
Replace seal.
Fig. 159: Identifying Handbrake Guide Tube And Mounting Screws

34 41 220 REMOVING AND INSTALLING/REPLACING ALL HANDBRAKE SHOES
CARMANUALSUSA
2008 BMW 328xi
 32 1 030
 34 4 000
 Remove Rear Brake Disk
Disconnect return spring (1) with brake spring pliers.
Installation:
Check and if necessary replace return spring (1).
Pay attention to installation position of adjustment screw (2).
Apply a thin coat of Grease to bush and screw threads.
CARMANUALSUSA
2008 BMW 328xi
Fig. 161: Identifying Handbrake Return Spring And Adjustment Screw

Disconnect return spring (1) with brake spring pliers.
Installation:
Check and if necessary replace return spring (1).
Fig. 162: Identifying Handbrake Return Spring

Turn clamping pins (1) with special tool 34 4 000 through 90° and disconnect.
Remove brake shoes (2).
CARMANUALSUSA
2008 BMW 328xi
Fig. 163: Identifying Special Tool (34 4 000), Clamping Pins And Brake Shoes
34 41 250 REMOVING AND INSTALLING/REPLACING EXPANDER LOCK FOR HANDBRAKE

SHOES
 32 1 030
 Remove Handbrake Shoes
CARMANUALSUSA
2008 BMW 328xi
Pull expander lock (1) forwards, disconnect handbrake Bowden cable (2) and remove expander lock.
Fig. 165: Identifying Handbrake Bowden Cable And Expander Lock

51 MECHANICAL-HYDRAULIC COMPONENTS
34 51 527 REMOVING AND INSTALLING OR REPLACING DSC HYDRAULIC UNIT

 Extract Brake Fluid
CARMANUALSUSA
2008 BMW 328xi
NOTE: Extract brake fluid out of expansion tank. Use a suction bottle used exclusively
for drawing off brake fluid.
Do not reuse drawn out brake fluid.
IMPORTANT: Do not mix up brake lines.
If necessary, mark before removal.
Close off connection bores with plugs.
Disconnect plug connection (1).
Press cover (2) gently to one side.
Unfasten brake lines (3).
Installation:
Fig. 166: Identifying Plug Connection, Cover And Brake Lines

Unscrew nuts (1).
Installation:
CARMANUALSUSA
2008 BMW 328xi
For tightening torque refer to 34 51 6AZ in 34 51 SLIP CONTROL SYSTEM (DSC) .
Fig. 167: Identifying Hydraulic Unit Mounting Nuts

Tilt out hydraulic unit (1) in direction of side panel.
IMPORTANT: If necessary, release brake lines from holder on bulkhead.
Brake lines must not be bent!
Fig. 168: Identifying Hydraulic Unit

When replacing hydraulic unit:
Release screws (1) and convert holder (2).
Installation:
CARMANUALSUSA
2008 BMW 328xi
Modify DSC Control Unit.
Fig. 169: Identifying Hydraulic Unit Convert Holder And Screws

When replacing control unit:
 Carry out programming/coding

 Adjustment Of Steering Angle Sensor
 Mix-up check of brake lines
 Function check, hydraulic unit
52 ELECTRONIC COMPONENTS
34 52 ... OVERVIEW OF ELECTRONIC COMPONENTS
CARMANUALSUSA
2008 BMW 328xi
Fig. 170: Identifying Electronic Components Location

34 52 516 REMOVING AND INSTALLING/REPLACING DSC CONTROL UNIT (N52 / N52K / N53 /
N54)
IMPORTANT: Read and comply withNotes On Protection Against Electrostatic Damage (ESD
Protection).
Replacement:
 Carry out programming/coding

 Steering Angle Sensor Adjustment
CARMANUALSUSA
2008 BMW 328xi
or
Carry out Adjustment For Active Front Steering
 Mix-up check of brake lines

 Function check, hydraulic unit
Release screws (1) and carefully detach control unit (2) towards front.
IMPORTANT: Risk of damage to the contacts when removing and installing the hydraulic
unit.
Fig. 171: Identifying Control Unit And Retaining Screws

IMPORTANT: Replace all seals in area (1).
Fig. 172: Identifying DSC Control Unit Seals

CARMANUALSUSA
2008 BMW 328xi
Installation:
Keep sealing faces clean.
Replace screws.
Observe tightening sequence (1-4).
Fig. 173: Identifying Tightening Sequence For DSC Control Unit Mounting Screws
34 52 525 REPLACING ONE FRONT PULSE GENERATOR
NOTE: Read and comply with General Information.
Open connector housing (1), pull plug connector (2) out of bracket and disconnect.
Pull cable with rubber grommet out of holders (3).
Installation:
Ensure proper locking of plug connector and proper seating of rubber grommets.
CARMANUALSUSA
2008 BMW 328xi
Fig. 174: Identifying Connector Housing, Holders And Rubber Grommet

Release hexagon socket head cap screw (1) and pull wheel speed sensor (2) out of bore.
Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to BMW
Service Operating Fluids ).
Fig. 175: Identifying Wheel Speed Sensor And Cap Screw

34 52 535 REPLACING A REAR PULSE GENERATOR
 Remove Wheels .
CARMANUALSUSA
2008 BMW 328xi
Unscrew nut (1).
Pull wheel arch trim (2) gently to one side.
Disengage cable from holders (3).
Fig. 176: Identifying Rear Wheel Arch Trim, And Mounting Nuts
Installation:
Ensure proper locking of the plug connector and proper seating of the cable in the brackets.
Fig. 177: Identifying Rear Pulse Generator Plug Connection

CARMANUALSUSA
2008 BMW 328xi
Disengage cable from holders (1).
Unfasten socket head cap screw (2).
Withdraw wheel speed sensor (3) from bore hole.
Installation:
Clean bore hole for pulse generator and grease with Staburags NBU 12/K lubricating grease (refer to BMW
Service Operating Fluids ).
Fig. 178: Identifying Wheel Speed Sensor, Cable Holder And Cap Screw
34 52 550 REMOVING AND INSTALLING / REPLACING DSC SENSOR
IMPORTANT: Read and comply with Notes On Protection Against Electrostatic Damage (ESD
Protection).
 Remove Left Front Seat

 Remove Front Left Entrance Cover Strip
Lift carpet (1) and fold back to side.
Remove underlay (2).
Disconnect plug connection.
CARMANUALSUSA
2008 BMW 328xi
Installation:
Ensure proper locking of plug connector.
Slacken screws (3)
Release screws (4) and remove bracket with yaw sensor.
Installation:
Fig. 179: Identifying Carpet, Underlay And Screws

When replacing DSC sensor:
Release screws (1) and modify DSC sensor (2).
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 180: Identifying DSC Sensor And Screws

90 TROUBLESHOOTING
34 90 ... TROUBLESHOOTING BRAKE SYSTEM
TROUBLESHOOTING CHART
Fault Cause Remedy
Brakes pull to one side a) Tyre inflation pressure a) Correct tyre inflation
not in keeping with pressure
regulations b) Change or Replace Tyres
b) Unevenly worn tyre c) Replace Brake Pads,
treads Check for causes
c) Oil on pads/liners d) Replace Brake Pads,
d) Wrong type of Check for causes
pads/liners f) Replace Guide Bolts
f) Guide bolts dirty or g) Check Wheel Alignment
damaged
h) Remove and install, repair
g) Axle geometry not or replace Floating Calipers
correct
i) Check shock absorber,
h) Corrosion in floating Replacing If Necessary
calipers
k) Replace Brake Pads,
i) No shock absorber action check floating caliper
k) Pad of one caliper worn
Brakes excessively hot while a) Compensating port in a) ReplaceMaster Brake
driving brake master cylinder Cylinder
blocked c) Replace Master Brake
c) Swollen rubber parts due Cylinder
to use of wrong brake fluid
CARMANUALSUSA
2008 BMW 328xi
d) Bleeder hole on d) Clean Expansion Tank

expansion tank blocked e) Remove and install, repair
e) Corroded floating or replace Floating Calipers
calipers f) Check handbrake and
f) Handbrake lever not handbrake Bowden cables,
released fully Repair If Necessary
Fault Cause Remedy
Poor braking effect in spite of Brake pads oil-splattered or burnt; Replace Brake Pads
great force on pedal wrong type of brake pads
Travel at brake pedal normal
Poor braking effect in spite of Brake booster malfunctions - Check brake booster
great force on pedal engine vacuum
Travel at brake pedal too short
Poor braking effect in spite of One brake circuit failed due to Leakage test of brake system
great force on pedal leaks or damage
Travel at brake pedal too long
Brake pedal can be pressed down a. Air in brake system a. Bleed brakes
softly and springily
b. Not enough brake fluid in b. Top up or change brake
expansion tank fluid Bleed brakes
c. Overheated brake fluid - c. Change brake fluid, Bleed
vapour lock due to brakes
excessive water content in
brake fluid or excessive
brake loads
Brake is bled and readjusted, but a. Primary cup seal in brake a. Replace Master Brake
brake pedal can be pressed down master cylinder damaged Cylinder
too far
b. Leaking separating cup b. Replace Master Brake
seals on floating piston of Cylinder
brake master cylinder c. Leakage test of brake
c. Leak in brake system system
Fault Cause Remedy
Uneven pad wear a. Wrong type of pads/liners a. Replace Brake Pads
b. Dirty fist caliper recesses, b. Remove and install, repair
damaged caps or replace Floating
c. Corrosion in floating Calipers
calipers c. Remove and install, repair
d. Swollen rubber ring for or replace Floating
piston control Calipers
CARMANUALSUSA
2008 BMW 328xi
d. Remove and install, repair

or replace Floating
Calipers
Brake pads worn at angle a. Wheel-bearing play a. Replace Wheel Bearings
excessive b. Check floating caliper
b. Brake disk not aligned with installation
fist caliper c. Remove and install, repair
c. Corrosion in floating or replace Floating
calipers Calipers
d. Angular brake-disk wear d. Grind or replace Brake
e. Minimum lining thickness Disks
undershot e. Replace Brake Pads
f. Spring force insufficient f. Replace Spring
g. Guide bolts damaged g. Replace Guide Bolts
Seized brake pads, pad does not a. Dirty fist caliper recesses, a. Remove and install, repair
move off brake disk damaged caps or replace Floating
b. Corrosion in floating Calipers
calipers b. Remove and install, repair
c. Compensating port in brake or replace Floating
master cylinder blocked Calipers
c. Replace Master Brake
Cylinder
Fault Cause Remedy
Brakes squeal or rattle a. Wrong type of pads/liners a. Replace Brake Pads
b. Dirty floating caliper b. Remove and install/clean
recesses Floating Calipers
c. Spring force insufficient c. Replace Spring
d. Brake disk not aligned with d. Check floating Caliper
fist caliper Installation
e. Brake-disk runout e. Replace brake Disks
f. Excessive thickness f. Measure brake disk
deviation within braking thickness Grind or replace
surface Disks
g. Liner wear excessive or g. Replace Brake Shoes
one-sided h. Grind or replace brake
h. Rust edges on brake disks Disks
i. Pad loose i. Replace Brake Pads
j. Wheel-bearing play j. Replace Wheel Bearings
excessive
CARMANUALSUSA
2008 BMW 328xi
Brake-pedal dead travel excessive a. Wheel-bearing play a. Replace Wheel Bearings

excessive b. Check Floating Calipers
fist caliper c. Replace brake Disks
c. Brake-disk runout d. Measure brake disk
d. Excessive thickness thickness Grind or replace
deviation within braking Disks
surface e. Leakage test of brake
e. Brake system leaking system
f. Air in brake system f. Bleed Brakes
g. Wrong type of pads/liners g. Replace Brake Pads
Fault Cause Remedy
Jammed piston in brake caliper a. Dirty fist caliper recesses, a. Remove and install, repair
damaged caps or replace Floating
b. Brake disk not aligned with Calipers
fist caliper b. Check Floating Calipers
c. Pistons corroded in floating installation
calipers c. Remove and install, repair
or replace Floating
Calipers
Pulsating effect on brake pedal a. Wheel-bearing play a. Replace Wheel Bearings
excessive b. Check Floating Calipers
fist caliper c. Replace brake Disks
c. Brake-disk runout d. Measure brake disk
d. Excessive thickness thickness Grind or replace
deviation within braking Disks
surface
Handbrake effect insufficient a. Brake shoes oil-splattered a. Replace Brake Shoes,
b. Excessive dead travel determine cause
between brake shoes and b. Adjust Handbrake
brake drums c. Remove and install
c. Corroded transmitting handbrake and expander
elements locks Check Bowden
cables, replacing if
necessary
CARMANUALSUSA
2008 BMW 328xi
2006 SUSPENSION Front axle - Repair Instructions - AWD
2006 SUSPENSION
Front axle - Repair Instructions - AWD
00 GENERAL
00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
Possible symptoms are:
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness
Protective measures/rules of conduct:
 Pour oil only into appropriately marked containers

 Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
 Observe country-specific safety regulations
First aid measures:
 Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of
water and consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the
recovery position and seek immediate medical attention.
00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
Danger of injury!
Contact with eyes or skin may result in injury!
CARMANUALSUSA
Sunday, August 30, 2015 5:35:56
2008 BMW 328xi
 Impaired sight
 Irritation of the eyes
 Reddening of the skin
 Rough and cracked skin
 Wear protective goggles

 Wear oil-resistant protective gloves
First aid measures:
 Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-
rinsing bottle. If irritation of the eyes persists, consult a doctor.
 Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.
NOTE: Do not use solvents/thinners.
00 SAFETY INSTRUCTIONS FOR HANDLING OIL
WARNING: DANGER OF POISONING if oil is ingested/absorbed through the skin! See
RISK OF INJURY if oil comes into contact with eyes and skin! See
Recycling:
Observe country-specific waste-disposal regulations.
Measures if oil is unintentionally released:
 Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work
area. Wear personal protective clothing/equipment.
 Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems,
pits, cellars, water and the ground.
 Limiting spread: Use oil blocks to prevent the surface spread of oil.
 Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
NOTE: Do not flush oil away with water or aqueous cleaning agents.
00 ... ... RAISING VEHICLE WITH TROLLEY JACK

CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: Observe the following trolley-jack-related instructions:
1. Use only BMW-distributed/approved trolley jacks which have rubber plate

contact points.
2. Trolley jacks must be regularly serviced and always checked for
functional reliability before they are used!
3. Check the rubber plate on the trolley jack prior to each replacing if
necessary.
Fig. 1: Identifying Trolley Jacks

WARNING: The vehicle may be raised with a trolley jack only at the following jacking
points!
1. Car jacking point on reinforcement strut (rear-wheel drive)

2. Side car jacking points
3. Rear differential
Risk of damage: It is not permitted to raise the vehicle at the rear

differential cover!
CARMANUALSUSA
2008 BMW 328xi
Fig. 2: Identifying Car Jacking Point On Reinforcement Strut

1. Car jacking point on front axle carrier (all-wheel drive)
Fig. 3: Identifying Car Jacking Point On Front Axle Carrier

31 ... . OVERVIEW OF FRONT AXLE (AWD)
CARMANUALSUSA
2008 BMW 328xi
Fig. 4: Identifying Front Axle (AWD) Components

1. REINFORCEMENT PLATE.
2. FRONT AXLE SUPPORT
3. STABILISER
4. STABILISER LINK
5. SWIVEL BEARING
6. SPRING STRUT SHOCK ABSORBER
7. TRACTION STRUT
8. FRONT DIFFERENTIAL / OUTPUT SHAFTS
9. WHEEL BEARING
10. CONTROL ARM
31 .. .. LAYOUT OF SPRING STRUT SHOCK ABSORBER
CARMANUALSUSA
2008 BMW 328xi
Fig. 5: Identifying Layout Of Spring Strut Shock Absorber Components

1. SPRING STRUT SHOCK ABSORBER

2. LOWER SPRING PAD
3. COIL SPRING
4. AUXILIARY DAMPER
5. Wheel arch
6. UPPER SPRING PLATE
7. Centering pin
8. Grease cap
9. Nut
10. UPPER SPRING PAD
11. THRUST BEARING
12. DUST SLEEVE
13. Thrust washer/shim
14. RUBBER GAITER
31.. ... OVERVIEW OF FRONT DIFFERENTIAL/OUTPUT SHAFTS

CARMANUALSUSA
2008 BMW 328xi
Fig. 6: Identifying Front Differential/Output Shafts Components

1. OUTPUT SHAFT / GAITERS

2. BEARING BLOCK
3. FRONT DIFFERENTIAL
4. SHAFT SEAL (OUTPUT SHAFT)
5. SHAFT SEAL (DRIVE FLANGE)
6. O-RING (FRONT DIFFERENTIAL)
7. O-RING (BEARING BLOCK)
31 00 ... FRONT AXLE + STEERING (AWD): WHEEL/CHASSIS ALIGNMENT CHECK MUST BE

CARRIED OUT AFTER THE FOLLOWING WORK
CARMANUALSUSA
2008 BMW 328xi
Fig. 7: Identifying Front Axle Carrier, Steering Gear, Control Arm And Support Bearing
A wheel/chassis alignment check must be carried out after the following work:. See 32 00 ...
CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE
 Release of following screw/bolt connections:

 Steering gear to front axle carrier
 Control arm to front axle carrier
 Compression strut to front axle carrier
 Support bearing to body (if centering pin is missing)
 Tie rod end to tie rod
 Replacement of following parts:

1. Front axle carrier
2. Steering gear
3. Gaiter (if the tie rod end has to be screwed off)
4. Control arm
5. Support bearing (if centering pin is missing)
6. Swivel bearing
CARMANUALSUSA
2008 BMW 328xi
7. Compression strut or compression strut rubber mount

8. Tie rod end
9. Tie rod
31 00 ... INFORMATION ON REPLACING SHOCK ABSORBERS
Facts:
When a shock absorber is faulty on one side (leaking, noises, limit values exceeded on the shock tester), often
both shock absorbers on the axle in question are replaced.
Consequence:
This is not necessary for technical reasons and causes the manufacturer not to recognize the unnecessarily
removed shock absorbers as damaged parts. Unnecessarily high costs for the customer can be avoided by
replacing the shock absorber on one side only.
Procedure:
Shock absorbers may be replaced on one side only until they have completed 50 000 km service.
Exception: On all M-GmbH models, when a limit value is exceeded on one side, it is still necessary always to
replace both shock absorbers on the relevant axle.
31 00 ... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)
Due to the chemical and corrosion characteristics of aluminum, always comply with the following points when
handling aluminum components:
 Do not bring into contact with battery acid!

 Do not clean with wire brushes made of brass or iron! Always use wire brushes with stainless steel
bristles!
 Do not expose to flying sparks when grinding/separating! Cover components!
 Do not strike with steel welding splashes! Cover components!
 Do not expose to temperatures > 80 °C, even for brief periods! Temperatures in paint facilities do not
have the same impact
31 00 ... NOTES ON REPAIRING THREADS
IMPORTANT: Install Helicoil thread inserts so that they are flush with the original thread.
NOTE: Damaged threads in engine carrier may be repaired with Helicoil thread inserts.
Comply with the procedure described in the example.
CARMANUALSUSA
2008 BMW 328xi
Fig. 8: Identifying Damaged Threads

Procedure:
1. Create a clean core hole; if necessary, drill out screw remnants
Fig. 9: Drilling Out Screw Remnants

2. Create locating thread for Helicoil thread insert
CARMANUALSUSA
2008 BMW 328xi
Fig. 10: Creating Locating Thread For Helicoil Thread Insert

3. Pick out Helicoil thread insert in accordance with the TABLE and screw into the locating thread until
flush with the original thread. See
Fig. 11: Screwing Helicoil Thread Insert Into Locating Thread

4. Break drive pin and remove
CARMANUALSUSA
2008 BMW 328xi
Fig. 12: Identifying Drive Pin

10 FRONT AXLE SUSPENSION

31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE (AWD)
IMPORTANT: Observe SAFETY INSTRUCTIONS for raising the vehicle.
Driving without reinforcement plate is not permitted!
Release screws (1).
Remove reinforcement plate (2).
Installation:
Replace screws.
Tightening torque 31 10 3AZ. See 31 10 FRONT AXLE SUSPENSION
CARMANUALSUSA
2008 BMW 328xi
Fig. 13: Identifying Reinforcement Plate Screws

51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION

(AWD)
NOTE: Illustration created using 330xi as an example. There may be differences in

detail in the case of other vehicle models.
Remove screws (1 to 4).
Pull underbody protection (5) forward under bumper trim (6).
Installation:
Centre underbody protection (5) and tighten down screws (1 to 4).
Fig. 14: Identifying Underbody Protection, Forward Under Bumper Trim And Screws
CARMANUALSUSA
2008 BMW 328xi
51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
Single-part underbody protection (without E90/E91/E92 AWD):
Release screws (1).
Pull underbody protection (2) in direction of arrow out of bracket (3).
Installation:
Ensure correct seating.
Centre underbody protection (2) and tighten down screws (1).
Fig. 15: Identifying Centre Underbody Protection Screws

Two-part underbody protection
Release screws (1).
Detach underbody protection (2) from bracket (3) and remove.
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 16: Identifying Underbody Protection And Bracket

Single-part underbody protection (E90/E91/E92 AWD):
Release screws (1).
Remove underbody protection (2) downwards.
Installation:
Fig. 17: Identifying Centre Underbody Protection And Screws

11 FRONT SUB-FRAME
CARMANUALSUSA
2008 BMW 328xi
31 11 001 REPLACING FRONT AXLE CARRIER (AWD)
WARNING: Danger to life!
SECURE ENGINE IN INSTALLATION POSITION to prevent it from falling

down.
 Secure ENGINE IN INSTALLATION POSITION

 Remove FRONT WHEELS .
 Remove STABILIZER.
 Only on right side: Remove front ride-height sensor with bracket from front axle carrier
 Remove BOTH COMPRESSION STRUTS FROM FRONT AXLE CARRIER.
 Remove BOTH CONTROL ARMS ON BOTH SIDES FROM FRONT AXLE CARRIER.
 Lower FRONT AXLE CARRIER.
Release nuts and remove screws (1) towards bottom.
Tie up power steering gear (2).
Installation:
Replace screws and nuts.
Tightening torque 32 00 1AZ. See 32 00 STEERING
Fig. 18: Identifying Power Steering Gear And Screws

Lower front axle carrier and take down from special tool.
CARMANUALSUSA
2008 BMW 328xi
Remove heat shield(s).
Remove both ENGINE MOUNTS and if necessary remove with vacuum lines from front axle carrier.
Take front axle carrier down and set down on a suitable surface.
Installation:
Use previous front axle carrier as a template for modifying or replacing small parts.
Fig. 19: Identifying Lower Front Axle Carrier

After installation:
 Perform CHASSIS ALIGNMENT CHECK .

 Carry out STEERING ANGLE SENSOR ADJUSTMENT.
31 11 506 LOWERING / RAISING FRONT AXLE CARRIER (AWD)
 00 2 040
 31 4 081
 31 4 082
 33 3 274
SECURE ENGINE IN INSTALLATION POSITION to prevent it from falling

down.
CARMANUALSUSA
2008 BMW 328xi
 SECURE ENGINE IN INSTALLATION POSITION

 Remove UNDERBODY PROTECTIVE PLATE .
 Remove REINFORCEMENT COVER ON LEFT AND RIGHT .
 Remove REINFORCEMENT PLATE.
 Remove DOUBLE JOINT FROM POWER STEERING GEAR
 N52: Remove coolant pipe from front axle carrier
 If necessary, disconnect plug connection on ride-height sensor and expose line up to engine carrier
 M57T2: Disconnect vacuum line from electrically operated valve to engine mounts at T-piece
WARNING: Danger of injury!
Failure to comply with the following instructions may result in the vehicle
slipping off the lifting platform and critically injuring other persons.
When supporting components, make sure that
 the vehicle can no longer be raised or lowered

 the vehicle does not lift off the locating plates on the lift platform
If necessary, position special tool 00 2 040 with a 2nd person helping on workshop jack. See 00 2 040 BASIC
TAKE-UP FIXTURE
Insert special tools 31 4 081 and 31 4 082 into corresponding mountings of special tool 00 2 040.. See 00 2 040
BASIC TAKE-UP FIXTURE
Align special tool 00 2 040 to front axle carrier. See 00 2 040 BASIC TAKE-UP FIXTURE
NOTE: Make sure when raising that the special tools 31 4 081 are correctly inserted
into the corresponding recesses on the front axle carrier.
If necessary, lower special tool 33 3 274. See 33 3 270 SET OF SUPPORTS
Support front axle carrier by raising special tool 00 2 040. See 00 2 040 BASIC TAKE-UP FIXTURE
CARMANUALSUSA
2008 BMW 328xi
Fig. 20: Identifying Special Tool

IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release screws (1, 2).
M57T2: Remove cooler return line from front axle carrier.
Lower front axle carrier.
Installation:
Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS.
Tighten down first screws (1) and then screws (2).
Tightening torque 31 10 1AZ. See 31 10 FRONT AXLE SUSPENSION
CARMANUALSUSA
2008 BMW 328xi
Fig. 21: Identifying Screws

After installation:
 Carry out STEERING ANGLE SENSOR ADJUSTMENT .
12 STRUTS WITH RUBBER MOUNTS

31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM (AWD)
 31 2 240
 31 2 241
 31 2 242
 31 2 243
 31 2 244
 31 2 245
 31 2 246
NOTE: If the control arm is detached from the front axle carrier, it is necessary after
reinstallation to carry out a wheel/chassis alignment check.
 Remove FRONT WHEEL .
Version with xenon lights:
Release nut (1) and remove jointed rod (2) from control arm (3).
Installation:
Replace self-locking nut.
Tightening torque 37 14 3AZ. See 37 14 ELECTRIC COMPONENTS
CARMANUALSUSA
2008 BMW 328xi
Fig. 22: Identifying Jointed Rod From Control Arm Nut

Release nut (1) and remove bolt (2) towards front.
Press swivel bearing in area of compression strut outwards and remove control arm from front axle carrier.
Installation:
Make sure that diesel enclosure is correctly positioned to side of control arm.
Tightening torque 31 12 3AZ. See 31 12 CONTROL ARMS AND STRUTS
Fig. 23: Identifying Bolt And Nut

Release nut (1) approx. 3-4 thread turns; if necessary, grip hexagon.
CARMANUALSUSA
2008 BMW 328xi
If necessary, replace lower section 31 2 242 with lower section 31 2 246. See 31 2 240 PULLER
Press control arm off swivel bearing with special tool 31 2 240 (comprising 31 2 241, 31 2 243, 31 2 244, 31 2
245 and 31 2 246). See 31 2 240 PULLER
Unscrew nut (1) and remove control arm.
Installation:
Keep journal on ball head and bushing in swivel bearing clean and free from oil and grease.
Fig. 24: Identifying Unscrew Nut

After installation:
 Perform chassis alignment check. See 32 00... CHASSIS/WHEEL ALIGNMENT CHECK

PROCEDURE
 Carry out steering angle sensor adjustment. See 61 31 996 CARRY OUT STEERING ANGLE
SENSOR ADJUSTMENT
31 12 026 REMOVING AND INSTALLING/REPLACING GUIDE JOINT IN SWIVEL BEARING

(AWD)
 31 2 240
 31 2 242
 31 2 246
CARMANUALSUSA
2008 BMW 328xi
 33 4 200
 33 4 205
 Remove front wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
Slacken nut (1), grip with Allen key if necessary.
Installation:
Unfasten screws (2).
Remove guide joint with compression strut from opening in swivel bearing.
Installation:
Recondition thread in swivel bearing.
Keep guide joint and opening in swivel bearing clean and free from oil and grease.
Replace micro-encapsulated screws.
Guide joint tightly seated in swivel bearing:
Fig. 25: Identifying Slacken Nut

CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: The guide joint must be replaced once it has been driven out with the special
tool.
Unscrew nut and screw special tool 33 4 205 onto guide joint. See 33 4 200 TOOL KIT / STRIKER
FIXTURE
Drive guide joint out of swivel bearing with special tool 33 4 200. See 33 4 200 TOOL KIT / STRIKER
FIXTURE

If necessary, screw nut (1) onto guide joint by a few turns.
If necessary, replace lower section 31 2 242 with lower section 31 2 246. See 31 2 240 PULLER
Press guide joint with special tool 31 2 240 out of compression strut. See 31 2 240 PULLER
Unscrew nut (1) and remove guide joint.
Installation:
Keep journal on guide joint and bushing in compression strut clean and free from oil and grease.
CARMANUALSUSA
2008 BMW 328xi

31 12 090 REMOVING AND INSTALLING/REPLACING BOTH COMPRESSION STRUTS (AWD)
 31 2 240
 31 2 242
 31 2 246
NOTE: If the compression strut is detached from the front axle carrier, it is necessary
after reinstallation to carry out a wheel/chassis alignment check.
Replace both compression struts in event of hydro-mount damage.
 Remove guide joint on both sides from swivel bearing. See 31 12 026 Removing and
installing/replacing guide joint in swivel bearing (AWD)
 Remove reinforcement cover. See 51 71... REMOVING AND INSTALLING/REPLACING
LEFT/RIGHT REINFORCEMENT COVER
Unscrew nut (1).
Remove screw (2) to one side and remove compression strut (3) with guide joint.
Installation:
Tighten bolt connection in normal position. See 32 00 ... MOVING VEHICLE INTO NORMAL POSITION
CARMANUALSUSA
2008 BMW 328xi
Fig. 28: Identifying Screw And Compression Strut

If necessary, replace lower section 31 2 242 with lower section 31 2 246.. See 31 2 240 PULLER
Press guide joint with special tool 31 2 240 out of compression strut. See 31 2 240 PULLER
Installation:

CARMANUALSUSA
2008 BMW 328xi
After installation:
 Perform chassis alignment check. See 32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK

PROCEDURE
SENSOR ADJUSTMENT
31 12 148 REPLACING RUBBER MOUNTS ON BOTH COMPRESSION STRUTS (AWD)
 31 3 031
 31 3 032
IMPORTANT: The rubber mounts on both compression struts must always be replaced!
Carry out check:
There must always be a minimum amount of play in the guide joint.
1. Check guide joint play
NOTE: For this purpose, apply light pressure to the compression strut (in the area
of the guide joint) in the horizontal and vertical directions.
 Play is OK: Check bolt connection. ( See Point 2)

 Play is not OK: Replace rubber mount and guide joint. See 31 12 026 Removing and
installing/replacing guide joint in swivel bearing (AWD)
Fig. 30: Identifying Compression Strut

CARMANUALSUSA
2008 BMW 328xi
2. Check bolt connection (compression strut to guide joint) by tightening to 60 % of tightening torque 31 12
6AZ and listening for cracking sound31 12 CONTROL ARMS AND STRUTS
 Torque wrench cracking sound: Replace rubber mount
 Bolt connection turns: Replace compression strut and guide joint. See 31 12 090 Removing and
installing/replacing both compression struts (AWD)
Replacing rubber mount:
Remove both compression struts. See 31 12 090 Removing and installing/replacing both compression struts
(AWD)
Using a press and special tools 31 3 031 and 31 3 032, press rubber mount out of compression strut. See 31 3
030 PRESS-IN AND PRESS-OUT TOOL
NOTE: Special tool 31 3 031 must be exactly flush with rubber mount bushing. See 31 3
030 PRESS-IN AND PRESS-OUT TOOL
Fig. 31: Pressing Rubber Mount Using Special Tool

Installation:
Keep rubber mount and bushing in compression strut clean and free from grease.
Align rubber mount by way of opening (1) in bushing to marking (2) on compression strut and press in. The
deviation (A) must not exceed ± 5°.
CARMANUALSUSA
2008 BMW 328xi
Fig. 32: Identifying Rubber Mount And Deviation

Installation:
Protrusion (A) equally large.
Fig. 33: Identifying Protrusion

After installation:

PROCEDURE
SENSOR ADJUSTMENT
21 WHEEL BEARINGS AND STUB AXLE

31 21 090 REPLACING (REMOVING AND INSTALLING) LEFT OR RIGHT SWIVEL BEARING
(AWD)
CARMANUALSUSA
2008 BMW 328xi
 31 2 230
Remove front wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
IMPORTANT: Expand turning lock sufficiently to avoid damaging thread when releasing
collar nut.
Release collar nut; to do so, press brake pedal to floor.
Installation:
Replace collar nut, oil collar nut/wheel bearing contact surface only and tighten down.
No oil permitted on thread of shaft journal or collar nut.
Tightening torque 31 21 2AZ. See 31 21 WHEEL BEARINGS AND STEERING KNUCKLE
Secure collar nut by positive peening on flat areas of output shaft.
Fig. 34: Locating Turning Lock

Remove brake disc. See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH FRONT
BRAKE DISCS
Replacement only: Drive out wheel hub. See 31 21 180 Replacing bearing for front wheel (AWD)
Remove pulse generator from swivel bearing. See 34 52 525 REPLACING ONE FRONT PULSE
GENERATOR
Remove tie rod end from swivel bearing. See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD
CARMANUALSUSA
2008 BMW 328xi
Remove guide joint from swivel bearing. See 31 12 026 Removing and installing/replacing guide joint in
swivel bearing (AWD)
Remove control arm from swivel bearing. See 31 12 000 Removing and installing/replacing left or right
control arm (AWD)
Remove stabilizer link from spring strut. See 31 35 005 Removing and installing/replacing push rod
(stabilizer link) for left or right stabilizer (AWD)
Turn swivel bearing to one side.
Press output shaft out of wheel hub and tie up. See 31 60 ... Pressing output shaft out of drive flange (wheel
hub) and drawing in
Support swivel bearing with workshop jack and a suitable mounting.
Release nut (1) and remove holder (2).
Pull out bolt (3) towards front.
Spread swivel bearing with special tool 31 2 230. See 31 2 230 SOCKET
Lower workshop jack and remove swivel bearing.
Installation:
Keep press fit of swivel gearing and spring strut in lower area clean and free from oil and grease.
Spread swivel bearing with special tool 31 2 230, align by means of gap to positioning pins on back of spring
strut and raise as far as it will go. See 31 2 230 SOCKET
Tightening torque 31 31 3AZ. See 31 31 SPRING STRUTS
CARMANUALSUSA
2008 BMW 328xi
Fig. 35: Identifying Nut And Bolt

Replacement:
Modify dust sleeve (1).
Modify brake guard plate (2).. See 34 11 250 REMOVING AND INSTALLING / REPLACING A BRAKE
CARRIER / BRAKE GUARD PLATE AT FRONT
Installation:
Install new wheel bearing. See 31 21 180 Replacing bearing for front wheel (AWD)
Draw in wheel hub. See 31 21 180 Replacing bearing for front wheel (AWD)
Fig. 36: Identifying Dust Sleeve

After installation:
CARMANUALSUSA
2008 BMW 328xi
 Replacement only: Perform chassis alignment check. See 32 00 ... CHASSIS/WHEEL ALIGNMENT
CHECK PROCEDURE
31 21 121 REPLACING LEFT OR RIGHT WHEEL HUB
NOTE: Procedure is described in the document "Replacing front wheel bearing". See
31 21 180 Replacing bearing for front wheel (AWD)
31 21 180 REPLACING BEARING FOR FRONT WHEEL (AWD)
 22 1 018
 31 2 113
 33 2 116
 33 2 160
 33 2 201
 33 3 261
 33 3 266
 33 3 268
 33 4 200
 33 4 261
 33 4 262
IMPORTANT: Bearing cannot be dismantled.

Do not wash out bearing.
Remove front wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
collar nut.
CARMANUALSUSA
2008 BMW 328xi

Remove front brake disk34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH FRONT
BRAKE DISCS
Force drive flange with special tools 33 2 116 / 33 2 201, 33 2 160, 33 4 200 and 5 wheel bolts out of wheel
bearing. See 33 2 110 REMOVAL AND INSTALLATION TOOL , 33 2 200 FIXTURE , 33 2 160
SPACER RING , 33 4 200 TOOL KIT / STRIKER FIXTURE
NOTE: Rounded inside edge of special tool 33 2 160 must point to drive flange. See 33
2 160 SPACER RING
Detach INNER WHEEL BEARING RACE FROM DRIVE FLANGE .
Fig. 38: Identifying Inner Wheel Bearing Race From Drive Flange
Remove swivel bearing and clamp with aluminum clamping jaws in vice. See 31 21 090 Replacing (removing
and installing) left or right swivel bearing (AWD)
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: The bearing was destroyed when the wheel hub was removed and must not be
reused!
Lift out retaining ring (1).
Fig. 39: Lifting Out Retaining Ring

Pull out bearing with special tools 31 2 113, 33 4 261, 33 3 266 and 33 3 261.. See 31 2 110 FIXTURE , 33 4
260 SET OF TOOLS , 33 3 260 SET OF TOOLS
NOTE: The bearing can be forced out of the swivel bearing on a press.
Check dust sleeve, replace if necessary.
Fig. 40: Identifying Special Tools

IMPORTANT: Keep press-fit areas clean and free of oil and grease.
Wider chamfer (1) of bearing must point to swivel bearing!
CARMANUALSUSA
2008 BMW 328xi
Clean new bearing on press-fit area and bearing seat in swivel bearing.
Fig. 41: Identifying Wider Chamfer

Align bearing by way of wider chamfer to swivel bearing and draw in up to stop with special tools 31 2 113, 22
1 018, 33 4 262 and 33 3 261. See 31 2 110 FIXTURE , 22 1 010 SET OF TOOLS , 33 4 260 SET OF
TOOLS , 33 3 260 SET OF TOOLS
Fig. 42: Identifying Special Tools

Install new circlip (1).
NOTE: Make sure circlip (1) is correctly seated.
CARMANUALSUSA
2008 BMW 328xi
Fig. 43: Lifting Out Retaining Ring

Draw in wheel hub (1) up to stop with special tools 31 2 113, 33 3 268, 33 3 266 and 33 3 261. See 31 2 110
FIXTURE , 33 3 260 SET OF TOOLS ,
Fig. 44: Identifying Wheel Hub And Using Special Tools

Install swivel bearing. See 31 21 090 Replacing (removing and installing) left or right swivel bearing
(AWD)
Draw output shaft into wheel hub. See 31 60... Pressing output shaft out of drive flange (wheel hub) and
drawing in
Install front brake disk. See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH
FRONT BRAKE DISCS
Install front brake calliper. See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH
FRONT BRAKE DISCS
CARMANUALSUSA
2008 BMW 328xi
Tightening torque 31 21 2AZ. See 31 21 WHEEL BEARINGS AND STEERING KNUCKLE
Install front wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL

31 SPRING STRUT
31 .. .. LAYOUT OF SPRING STRUT SHOCK ABSORBER
CARMANUALSUSA
2008 BMW 328xi
Fig. 46: Identifying Layout Of Spring Strut Shock Absorber Components

1. Spring strut shock absorber. See 31 31 041 Replacing front left or right spring strut (AWD)
2. Lower spring pad. See 31 31 041 Replacing front left or right spring strut (AWD)
3. Coil spring. See 31 33 100 Removing and Installing/Replacing Coil Spring for Left or Right Front
Spring Strut
4. Auxiliary damper. See 31 31 041 Replacing front left or right spring strut (AWD)
5. Wheel arch
6. Upper spring plate. See 31 31 041 Replacing front left or right spring strut (AWD)
7. Centering pin
8. Grease cap
9. Nut
10. Upper spring pad. See 31 31 041 Replacing front left or right spring strut (AWD)
11. THRUST BEARING
12. Dust sleeve. See 31 31 041 Replacing front left or right spring strut (AWD)
13. Thrust washer/shim
14. Rubber gaiter. See 31 31 041 Replacing front left or right spring strut (AWD)
CARMANUALSUSA
2008 BMW 328xi
Facts:
Consequence:
Procedure:
31 31 003 REMOVING AND INSTALLING COMPLETE FRONT LEFT OR RIGHT SPRING STRUT
(AWD)
 31 2 230. See 31 2 230 SOCKET

 31 5 220. See 31 5 220 SUPPORT
IMPORTANT: If the centering pin is missing from the support bearing, the position of the
studs to the wheel arch must be marked so that the original camber is
approximately maintained.
Only one nut may ever be released for marking.
 Remove brake disc. See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH
FRONT BRAKE DISCS
 Remove stabilizer link from spring strut. See 31 35 005 Removing and installing/replacing push rod
(stabilizer link) for left or right stabilizer (AWD)
 Remove tie rod end from swivel bearing. See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD
 Remove guide joint from swivel bearing. See 31 12 026 Removing and installing/replacing guide joint
in swivel bearing (AWD)
 Remove control arm from swivel bearing. See 31 12 000 Removing and installing/replacing left or
right control arm (AWD)
CARMANUALSUSA
2008 BMW 328xi


Secure special tool 31 5 220 with wheel bolts to drive flange and support swivel bearing with workshop jack.
See 31 5 220 SUPPORT

Unclip line for lining wear sensor from swivel bearing.
Release screw (1) and remove bracket (2).
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 48: Identifying Bracket And Screw

IMPORTANT: Risk of damage!

When the swivel bearing is lowered, the tripod (2) can be pulled out of the tulip
(1) and fall into the rubber gaiter (3). In this event, it will be necessary to install
a new output shaft because the tripod (2) can jam or a roller of the tripod (2)
can slip off the moulding. The roller would then be located in the gaiter (3) or
bellows and result in rapid failure.
Fig. 49: Identifying Tulip, Rubber Gaiter And Tripod

Spread swivel bearing with special tool 31 2 230.. See 31 2 230 SOCKET
Carefully lower swivel bearing.
Installation:
CARMANUALSUSA
2008 BMW 328xi
Spread swivel bearing with special tool 31 2 230, align by means of gap to positioning pins (1) and raise with
workshop jack as far as it will go. See 31 2 230 SOCKET
Fig. 50: Identifying Pins And Using Special Tool

Centering pin missing: Make position of studs in relation to wheel arch.
Secure spring strut against falling out.
Unscrew nuts (1).
Remove spring strut downwards out of wheel arch.
Installation:
Clean contact surface in spring strut dome.
Align spring strut using centering pin to bore in wheel arch or studs to wheel arch and push upwards.
Tightening torque, 31 31 1AZ. See 31 31 SPRING STRUTS
CARMANUALSUSA
2008 BMW 328xi
Fig. 51: Identifying Unscrew Nuts

IMPORTANT: Replace faulty sealing washer (1).

Reinstall sealing washer (2) and plate insert (2).
Fig. 52: Identifying Sealing Washer And Plate

After installation:
 Carry out chassis/wheel alignment check if a spring strut with support bearing was or has been installed
without centering pin. See 32 00... CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE
31 31 041 REPLACING FRONT LEFT OR RIGHT SPRING STRUT (AWD)
 31 2 210. See 31 2 210 SOCKET WRENCH SOCKET WAF 21
CARMANUALSUSA
2008 BMW 328xi
 31 3 341. See 31 3 340 SPRING TENSIONER

 31 3 354. See 31 3 350 SPRING HOLDER
 31 3 355. See 31 3 350 SPRING HOLDER
 31 3 358. See 31 3 358 INSERT RING
WARNING: Prior to each use of the special tool 31 3 340. See 31 3 340 SPRING
TENSIONER , it is essential to read the associated Owner's Handbook
fully! All the safety precautions and instructions contained in the Owner's
Handbook must be strictly observed! Failure to observe these safety
precautions and instructions increases the risk of serious physical injury,
damage to your health and damage to property and equipment!
IMPORTANT: 1. Prior to each use, check the special tools for defects, modifications and
operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the spec tools!
4. These special tools are intended solely for the purpose tightening and
relieving cylindrical and tapered suspend springs.
5. Keep special tools dry, clean and free of grease.
6. Impact screwdrivers may not be used!
7. Do not compress coil spring to full extent.
NOTE: Read and comply with Information on replacing shock absorbers.
 Remove front spring strut. See 31 31 003 Removing and Installing Complete Front Left or Right
Spring Strut (AWD)
Removing:
Clamp special tool 31 3 341 in vice.31 3 340 SPRING TENSIONER
Install insert 31 3 358 in special tool 31 3 354. See 31 3 358 INSERT RING , 31 3 350 SPRING HOLDER
Position special tools 31 3 355. See 31 3 350 SPRING HOLDER and 31 3 354 with insert 31 3 358 . See 31 3
350 SPRING HOLDER from above on special tool 31 3 34131 3 340 SPRING TENSIONER until locking
pins (1) can be felt and heard to snap into place.
Check seating of special tools 31 3 355. See 31 3 350 SPRING HOLDER and 31 3 35431 3 350 SPRING
HOLDER with insert 31 3 35831 3 358 INSERT RING , correct if necessary.
CARMANUALSUSA
2008 BMW 328xi
Fig. 53: Identifying Locking Pins

Clean coil spring to remove coarse dirt and take up with special tools 31 3 355. See 31 3 350 SPRING
HOLDER and 31 3 354 31 3 350 SPRING HOLDER with insert 31 3 35831 3 358 INSERT RING .
Twist spring strut until end of coil spring (1) is flush with end of special tool 31 3 355.
WARNING: Special tool 31 3 354. See 31 3 350 SPRING HOLDER and centering ring 31
3 358 31 3 358 INSERT RING must rest correctly on upper spring plate!
Lower coil of coil spring must rest completely in recess of special tool 31
3 355. See 31 3 350 SPRING HOLDER !
Compress coil spring until stress on piston rod is relieved.
Fig. 54: Identifying Coil Spring

CARMANUALSUSA
2008 BMW 328xi
Take off cap.
Release nut with special tool 31 2 210. See 31 2 210 SOCKET WRENCH SOCKET WAF 21 (grip piston rod
in the process).

Remove support bearing (1), dust sleeve and supporting ring (2).
Remove spring strut with auxiliary damper, gaiter and lower spring pad sideways from tensioned coil spring.
Fig. 56: Identifying Dust Sleeve And Supporting Ring

Remove auxiliary damper (1) with gaiter (2) and lower spring pad (3).
Assembly:
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: Always replace auxiliary dampers in pairs.
Check auxiliary damper (1), gaiter (2) and lower spring pad (3) for damage, replace if necessary.
Attach lower spring pad (3) to spring plate.
Attach auxiliary damper (1) and gaiter (2) to piston rod.
Fig. 57: Identifying Auxiliary Damper And Lower Spring Pad

Insert spring strut in tensioned coil spring and align to end of coil spring (2) using lower spring pad (1).
Fig. 58: Identifying Coil Spring And Lower Spring Pad

Attach thrust washer (2) to piston rod.
Check support bearing (1) for damage, replace if necessary.

CARMANUALSUSA
2008 BMW 328xi
Attach dust sleeve and support bearing (1) to piston rod.
Fig. 59: Identifying Dust Sleeve And Supporting Ring

Replace self-locking nut and screw on as far as possible to avoid damaging the piston rod when relieving
tension on the coil spring.
Relieve tension on coil spring slightly.
NOTE: Make sure that lower and upper coils of coil spring rest completely in recess of
spring plate.
Tighten down nut with special tool 31 2 210. See 31 2 210 SOCKET WRENCH SOCKET WAF 21 (grip
piston rod in the process).
Fully relieve tension on coil spring.
Check installation position of gaiter, correct fold if necessary.
Fit cover cap.
IMPORTANT: Spring pad (1) must rest positively on spring plate (2)! Upper end of coil spring
must rest on stop of spring pad (1)!
IMPORTANT: Lower end of coil spring (2) must rest on stop of spring pad (1)!
CARMANUALSUSA
2008 BMW 328xi

After installation:
 Carry out wheel alignment check . See 32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK
PROCEDURE if a spring strut with support bearing was or has been installed without centering pin.
51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT

SPRING STRUT DOME
 00 9 120. See 00 9 120 TORQUE ANGLE MEASURING DIAL
IMPORTANT: Driving without the tension strut is not permitted. (Risk of damage to the body).
Tension strut screws must be tightened to torque and then tightened down
with special tool 00 9 120.. See 00 9 120 TORQUE ANGLE MEASURING DIAL
IMPORTANT: Catch (2) and seal (3) of cover (1) must not be damaged.
Even a minimally damaged cover (1) may result in water leaking in; if
necessary, replace cover (1).
NOTE: Two possible versions of cover (1):
A. Turn cover (with notch) approx. 45° counterclockwise

B. Snap out cover (without notch) in upward direction
CARMANUALSUSA
2008 BMW 328xi
Fig. 61: Identifying Catch, Seal And Cover

Remove cover (1) and release screw underneath.
Release screw (1).
Grip grommet (3) and pull out tension strut (2) in direction of arrow.
NOTE: Grommet (3) must not be pulled out of bulkhead because this eliminates the
possibility of correct feeding in when installed.
Fig. 62: Identifying Grip Grommet And Cover

Installation:
Replace screws.
CARMANUALSUSA
2008 BMW 328xi
Carefully feed tension strut (1) into grommet (2).
Tighten down screws to specified torque and then retighten to angle of rotation using special tool 00 9 120. See
00 9 120 TORQUE ANGLE MEASURING DIAL
Tightening torque 51 71 2AZ. See 51 71 SEALS AND LOOSE BODY PARTS
Fig. 63: Identifying Tension Strut

33 SPRING WITH SUSPENSION

31 33 001 (REMOVING AND INSTALLING) REPLACING FRONT LEFT OR RIGHT SPRING
STRUT SUPPORT BEARING
NOTE: Procedure is described in the document "Replacing front left or right spring
strut". See 31 31 041 Replacing Front Left or Right Spring Strut (AWD).
Replacement:
Vehicle with spacer ring:
NOTE: Spacer ring (A) is fitted in vehicles with "rough road package" version.
Unscrew nuts.
Remove spacer ring (A) from support bearing.
Installation:
Align spacer ring (A) using centering pin (1) to support bearing and place in position.
CARMANUALSUSA
2008 BMW 328xi
Tightening torque 31 31 1AZ. See 31 31 SPRING STRUTS .
If necessary, twist/drive out centering pin (1).
NOTE: If a support bearing (2) was fitted without centering pin (1), the centering pin (1)
of the new support bearing (2) must be driven or twisted out.
31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
 Move vehicle into normal position. See 32 00 ... MOVING VEHICLE INTO NORMAL POSITION
Determine actual ride height (A) - to do so, attach tape measure to rim flange (2) at bottom middle and measure
to lower edge of wheel arch (1).
Fig. 64: Identifying Ride-Level Height Of Vehicle

31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR LEFT OR RIGHT

FRONT SPRING STRUT
IMPORTANT: Both coil springs on the relevant axle must be replaced only in the event of
corrosion breakage!
NOTE: The coil spring is allocated in the Electronic Parts Catalogue (ETK) under the
menu item "Spring table" after the vehicle identification number has been
entered and the relevant optional extra of the car has been selected.
NOTE: Procedure is described in the document "Replacing front left or right spring
CARMANUALSUSA
2008 BMW 328xi
strut". See 31 31 041 Replacing Front Left or Right Spring Strut (AWD).
35 SPRING STABILIZER BAR

31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER (AWD)
IMPORTANT: To avoid complaints being made by the customer about noise, set the car on
its wheels and tighten down the stabilizer mounting to specified torque.
 Remove front assembly underside protection. See 51 47 490 REMOVING AND INSTALLING /
REPLACING FRONT ASSEMBLY UNDERSIDE PROTECTION
 Remove stabilizer link on both sides from stabilizer. See 31 35 005 Removing and Installing/Replacing
Push Rod (Stabilizer Link) for Left or Right Stabilizer (AWD)
NOTE: The following illustrations was created using the E91 with M57T2 as an
example. Other vehicles and engines may show differences in detail.
N52:
Remove coolant pipe from front axle carrier.
Release screws (1).
Remove bracket (2) with pressure line for power steering from front axle carrier.
Remove stabilizer (3).
Installation:
Check rubber mount on both sides, replace if necessary.
Set car on its wheels and tighten down nuts to tightening torque 31 35 1AZ.
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2008 BMW 328xi
Fig. 65: Identifying Bracket And Screws

Replacement:
Remove rubber mount on both sides from stabilizer.
31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR

LEFT OR RIGHT STABILIZER (AWD)
Release nuts (1); if necessary, grip with open-end wrench.
Remove stabilizer link (2).
Installation:
Tightening torque 31 35 2AZ. See 35 STABILIZER BAR .
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Fig. 66: Identifying Stabilizer Link And Nuts

31 35 021 REPLACING BOTH RUBBER MOUNTS OF STABILIZER MOUNTING ON FRONT AXLE

CARRIER (AWD)
 Remove stabilizer from front axle carrier. See 31 35 000 Removing and Installing/Replacing Front
Stabilizer (AWD) and set down on tie rods.
Remove retaining bracket (1) and rubber mount (2) on both sides.
Installation:
Keep retaining bracket (1), rubber mount (2) and stabilizer clean and free from oil and grease.
Fig. 67: Identifying Retaining Bracket And Rubber Mount

50 FRONT AXLE GEARBOX

31 50 ... CHANGING FRONT DIFFERENTIAL OIL
IMPORTANT: Use only the approved front differential oil in this front differential.
Failure to comply with this requirement will result in serious damage to the
differential!
NOTE: Only change oil when front differential is at normal operating temperature.
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 Remove reinforcement plate. See 31 10 010 Removing and Installing/Replacing Reinforcement Plate
(AWD)
Checking/correcting front differential oil level:
Undo oil filler plug (1).
Check front differential oil level.
If necessary, pour in front differential oil up to lower edge of opening for oil filler plug (1).
Installation:
Tightening torque 31 50 2AZ. See 31 50 FRONT AXLE DIFFERENTIAL E90
Fig. 68: Identifying Oil Filler Plug

Changing front differential oil:
Place oil collecting apparatus underneath.
Remove oil drain plug (1).
Drain front differential oil.
Replace sealing ring, screw in oil drain plug (1) and tighten down.

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2008 BMW 328xi
Pour in front differential oil up to lower edge of opening for oil filler plug (2).
Installation:
Fig. 69: Identifying Oil Drain Plug

31 50 001 REMOVING AND INSTALLING/REPLACING FRONT DIFFERENTIAL

Secure engine in installation position. See 11 00 670 SECURING ENGINE
IN INSTALLATION POSITION (N52) to prevent it from falling down.
 Secure engine in installation position. See 11 00 670 SECURING ENGINE IN INSTALLATION

POSITION (N52)
 Drain and dispose of front differential oil. See 31 50 ... Changing Front Differential Oil
 Remove left output shaft. See 31 60 000 Removing and Installing/Replacing Left or Right Output
Shaft
 Press right output shaft. See 31 60 ... Pressing Output Shaft Out of Drive Flange (Wheel Hub) and
Drawing in approx. 6 to 7 cm out of front differential
 Replacement only:
 Replace front axle output flange on transfer box. See 27 10 050 REPLACING OUTPUT
FLANGE FOR FRONT AXLE OUTPUT (ATC 300)
NOTE: Replace the output flange to ensure a clean seal on the transfer case.
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 Lower front axle support. See 31 11 506 Lowering / Raising Front Axle Carrier (AWD)
IMPORTANT: Grip front differential firmly while releasing last bolt in order to avoid damage
caused by the differential falling.
Version with automatic transmission: If necessary, disconnect hydraulic lines from oil sump.
Release screws (1).
Detach front differential from oil sump and remove towards rear.
Installation:
Replace O-ring. See 31 51 060 Replacing O-ring for Front Differential on Rightif necessary.
Coat O-ring with front differential oil.

After installation:
 fill with front differential oil. See 31 50 ... Changing Front Differential Oil
 Check transfer case oil level. See 27 00 ... REPLENISHING / CHANGING TRANSFER CASE OIL
(ATC 300) , correct if necessary
SENSOR ADJUSTMENT
31 51 010 REPLACING RADIAL SEAL FOR DRIVE FLANGE OF FRONT DIFFERENTIAL

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 23 0 020. See 23 0 020 HOLDER

 31 5 130. See 31 5 130 SET OF IMPACT DRIFTS
 33 1 150. See 33 1 150 FIXTURE
 Remove reinforcement plate. See 31 10 010 Removing and Installing/Replacing Reinforcement Plate
(AWD)
Mark position of nut with respect to shaft with punch marks (arrow).
Lever out lockplate (1) with a suitable tool.
Fig. 71: Locating Lockplate Nut


Do not place special tool on threaded holes of drive flange.
Secure drive flange with special tool 23 0 020. See 23 0 020 HOLDER against turning and release nut (1).
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Fig. 72: Identifying Nut


Mount special tool only with longer screws (M10x30) on drive flange.
Pull drive flange off drive shaft with special tool 33 1 150. See 33 1 150 FIXTURE .
Fig. 73: Identifying Drive Flange And Special Tool

Lever shaft seal (1) out of front differential with a suitable screwdriver (2).
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Fig. 74: Identifying Lever Shaft Seal

Installation:
Drive in shaft seal with special tool 31 5 130. See 33 1 150 FIXTURE as far as it will go.
Coat sealing lips of new shaft seal (1) with front differential oil.
Fig. 75: Identifying Drive Shaft Seal And Using Special Tool
Do not tighten nut beyond punch marks.
Otherwise the clamping sleeve will be damaged.
Clean drive flange and attach.
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Tighten down nut until punch marks on nut and shaft are aligned.
Install new lockplate (1).
Fig. 76: Locating Lockplate Nut

After installation:
 Check front differential oil level. See 31 50 ... Changing Front Differential Oil, correct if necessary
31 51 015 REPLACING SHAFT SEAL FOR LEFT OUTPUT SHAFT
Shaft
Lever shaft seal (1) with a screwdriver (2) out of front differential (3).
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Fig. 77: Identifying Lever Shaft Seal And Using Screwdriver

NOTE: Protective sleeve (2) serves to protect the sealing lips of shaft seal (1) from
being damaged when the output shaft is inserted into the front differential.
Fig. 78: Identifying Protective Sleeve

Installation:
Drive in shaft seal with special tool 31 5 130. See 31 5 130 SET OF IMPACT DRIFTS as far as it will go.
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After installation:
31 51 020 REPLACING SHAFT SEAL FOR RIGHT OUTPUT SHAFT
 Remove right output shaft. See 31 60 000 Removing and Installing/Replacing Left or Right Output
Shaft
Lever shaft seal (1) with a screwdriver (2) out of bearing block (3).
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Fig. 80: Identifying Lever Shaft Seal And Screwdriver

being damaged when the output shaft is inserted into the bearing block.

Installation:
Drive in shaft seal with special tool 31 5 130 . See 31 5 130 SET OF IMPACT DRIFTS as far as it will go.

31 51 060 REPLACING O-RING FOR FRONT DIFFERENTIAL ON RIGHT
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 Remove front differential. See 31 50 001 Removing and Installing/Replacing Front Differential
Remove O-ring (1) with a suitable tool from front differential.
Installation:
Insert O-ring (1) in groove and coat with front differential oil.
Fig. 83: Identifying O-Ring

31 51 065 REPLACING O-RING FOR BEARING BLOCK
 Remove bearing block. See 31 53 040 Removing and Installing/Replacing Right Output Shaft
Bearing Block
Remove O-ring (1) with a suitable tool from bearing block (2).
Installation:
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Fig. 84: Identifying O-Ring

53 DIFFERENTIAL WITH BEARINGS

31 53 040 REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT BEARING
BLOCK
 Remove right output shaft. See 31 60 000 Removing and Installing/Replacing Left or Right Output
Shaft
Release screws (1).
Remove bearing block from oil sump.
Installation:
Replace O-ring. See 31 51 065 Replacing O-ring for Bearing Block.
Tightening torque: 31 60 1AZ . See OUTPUT SHAFT for specs.
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60 OUTPUT SHAFT
Shaft
Fig. 86: Identifying Lever Shaft Seal And Using Screwdriver

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Installation:
After installation:
 Check front differential oil level . See 31 50 ... Changing Front Differential Oil, correct if necessary

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 31 5 130 . See 31 5 130 SET OF IMPACT DRIFTS
 Remove right output shaft . See 31 60 000 Removing and Installing/Replacing Left or Right Output
Shaft
Fig. 89: Identifying Lever Shaft Seal And Screwdriver


Installation:
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31 60... NOTES ON REMOVING AND INSTALLING LOW PROFILE BAND CLAMPS
 31 5 200. See 31 5 200 PLIERS
IMPORTANT: During removal Low Profile band clamp (dotted line) is overstretched and must
not be reused!
Fig. 92: Identifying Low Profile Band Clamp

Removing:
Place special tool 31 5 200. See 31 5 200 PLIERS on lugs (1, 2).
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NOTE: Make sure that the movable piece (3) of the special tool is placed on lug (1).
Fig. 93: Identifying Lugs

Compress Low Profile band clamp with special tool 31 5 200. See 31 5 200 PLIERS until end of band clamp
(1) lifts up.
Relieve tension on special tool and remove Low Profile band clamp.
Fig. 94: Identifying Band Clamp And Special Tool 31 5 200

Assembly:
Position Low Profile band clamp in installation position (A) on gaiter.
Place special tool 31 5 200. See 31 5 200 PLIERS on lugs (1, 2).
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Fig. 95: Identifying Lugs And Movable Piece

Check and if necessary correct positions of gaiter and Low Profile band clamp.
Compress Low Profile band clamp with special tool 31 5 200. See 31 5 200 PLIERS and press on end of band
clamp (1).
Relieve tension on special tool and remove.
Check hook fastener (H); if necessary, repeat operation with new Low Profile band clamp.
Fig. 96: Identifying Hook Fastener

31 60 ... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE (WHEEL HUB) AND DRAWING IN
 33 2 111. See 33 2 110 REMOVAL AND INSTALLATION TOOL

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 33 2 115. See 33 2 110 REMOVAL AND INSTALLATION TOOL

 33 2 116 . See 33 2 110 REMOVAL AND INSTALLATION TOOL
 33 2 160 . See 33 2 160 SPACER RING
 33 2 201 . See 33 2 200 FIXTURE
 33 2 202 . See 33 2 200 FIXTURE
 33 2 203 . See 33 2 200 FIXTURE
 33 2 205 . See 33 2 200 FIXTURE
 33 2 207 . See 33 2 200 FIXTURE
 33 2 208 . See 33 2 200 FIXTURE
 33 5 070 . See 33 5 070 EXTENSION PIECE (2)
WARNING: Risk of injury!

It is not permitted to use the impact screwdriver to press out and draw in
the output shaft.

To avoid damaging the output shaft and adjoining parts, it is essential during
the pressing-out process to repeatedly check and if necessary correct the
position of the output shaft.
IMPORTANT: To avoid damaging the dust sleeve, use special tool 33 2 160 to press out and
draw in the output shaft after removing the brake disk.
NOTE: Rounded inside edge of special tool 33 2 160 must point to drive flange.
Fig. 97: Identifying Dust Sleeve And Special Tool

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Special tool 33 2 200:
Screw on special tool 33 2 203, 33 2 207 and 33 2 201 . See 33 2 200 FIXTURE with all wheel studs to drive
flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 201 with special tools 33 2 202 . See 33
2 200 FIXTURE and 33 5 07033 5 070 EXTENSION PIECE (2) .
Fig. 98: Identifying Grip Basic Body With Special Tools 33 2 202
IMPORTANT: No oil permitted on shaft journal thread!
Lightly oil spline teeth of output shaft.
Insert output shaft into drive flange.
Screw special tool 33 2 205 . See 33 2 200 FIXTURE onto output shaft.
Fig. 99: Identifying Special Tool 33 2 205 On Output Shaft

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2008 BMW 328xi
Mount special tool 33 2 201 . See 33 2 200 FIXTURE with three wheel studs to drive flange.
Draw in output shaft with special tool 33 2 208 up to stop; in so doing, grip basic body 33 2 201 with special
tools 33 2 202 33 2 200 FIXTURE and 33 5 07033 5 070 EXTENSION PIECE (2) .
Fig. 100: Identifying Special Tool 33 2 201 On Drive Flange

Screw on special tool 33 2 111, 33 2 117 and 33 2 116 . See 33 2 110 REMOVAL AND INSTALLATION
TOOL with all wheel studs to drive flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 116 . See 33 2 110 REMOVAL AND
INSTALLATION TOOL with special tools 33 2 202 33 2 200 FIXTURE and 33 5 07033 5 070
EXTENSION PIECE (2) .

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Screw special tool 33 2 118 onto output shaft. See 33 2 110 REMOVAL AND INSTALLATION TOOL .
Fig. 102: Identifying Special Tool 33 2 118 On Output Shaft

Mount special tool 33 2 116 with . See three wheel studs to drive flange.
Draw in output shaft with special tool 33 2 115 33 2 110 REMOVAL AND INSTALLATION TOOL up to
stop; in so doing, grip basic body 33 2 116 . See 33 2 110 REMOVAL AND INSTALLATION TOOL with
special tools 33 2 202 . See 33 2 200 FIXTURE and 33 5 070 . See 33 5 070 EXTENSION PIECE (2) .

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2008 BMW 328xi
31 60 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT OUTPUT SHAFT
 31 5 110 . See 31 5 110 REMOVAL FORK

Do not drive output shaft out of wheel hub with an impact tool.
Remove front wheel . See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .
collar nut.
Installation:
Tightening torque 31 21 2AZ. See 31 21 WHEEL BEARINGS AND STEERING KNUCKLE .

Remove reinforcement plate. See 31 10 010 Removing and Installing/Replacing Reinforcement Plate
(AWD).
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Remove tie rod end from swivel bearing. See 32 21 151 REPLACING LEFT OR RIGHT TIE ROD .
Right side only: Remove guide joint from swivel bearing. See 31 12 026 Removing and Installing/Replacing
Guide Joint In Swivel Bearing (AWD).
Remove control arm from swivel bearing. See 31 12 000 Removing and Installing/Replacing Left Or Right
Control Arm (AWD).
Remove stabilizer link from spring strut. See 31 35 005 Removing and Installing/Replacing Push Rod
(Stabilizer Link) for Left or Right Stabilizer (AWD).
Press output shaft out of wheel hub. See 31 60 ... Pressing Output Shaft Out of Drive Flange (Wheel Hub)
and Drawing in and tie up.
Front differential:
Press output shaft with special tool 31 5 110 . See 31 5 110 REMOVAL FORK out of front differential and
remove.
Installation:
Replace shaft seal in front differential. See 31 51 015 Replacing Shaft Seal for Left Output Shaftand coat
sealing lips with front differential oil.
Replace retaining ring and slide in output shaft over resistance of retaining ring. Output shaft must snap audibly
into place.
Fig. 105: Identifying Special Tool 31 5 110

IMPORTANT: High installation forces indicate that the spline teeth on the output shaft/rear
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2008 BMW 328xi
differential side gear are damaged/deformed!

Check spline teeth, replaced damaged parts.
Bearing block:
Press output shaft with special tool 31 5 110. See 31 5 110 REMOVAL FORK out of bearing block and
remove.
Installation:
Replace shaft seal in bearing block. See 31 51 020 Replacing Shaft Seal for Right Output Shaftand coat
sealing lips with front differential oil.
into place.
Fig. 106: Identifying Special Tool 31 5 110 And Bearing Block

After installation:
31 60 530 REPLACING AN OUTPUT SHAFT GAITER (ON TRANSMISSION SIDE) (OUTPUT

SHAFT REMOVED)
NOTE: Procedure is described in the document "both output shaft gaiters..." . See 31
60 535 Replacing Both Gaiters on Left and Right of Output Shaft (Output Shaft
Removed).
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2008 BMW 328xi
31 60 535 REPLACING BOTH GAITERS ON LEFT AND RIGHT OF OUTPUT SHAFT (OUTPUT
SHAFT REMOVED)
Grip output shaft (1) in vice with aluminum clamping jaws.
NOTE: 2 = Joint, wheel side

3 = Joint, transmission side
Fig. 107: Identifying Grip Output Shaft

Replacing gaiter of wheel-side joint:
Release Low Profile band clamp . See 31 60 ... Notes on Removing and Installing Low Profile Band Clamps
(1) and band clamp (2).
Pull back rubber gaiter (3).
Installation:
Feed gaiter (3) into groove of joint.
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Fig. 108: Identifying Low Profile Band Clamp And Band Clamp
Press off joint (1) via contact pressure of retaining ring on shaft (2).
Installation:
Push on joint until retaining ring can be heard to snap into place.
Fig. 109: Identifying Retaining Ring On Shaft

Installation:
Replace retaining ring (1).
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Fig. 110: Identifying Retaining Ring

Pull off gaiter (1) over shaft (2).
Carefully clean all parts with a cloth.
NOTE: Regrease constant-velocity joint with the grease from the repair kit.
Fig. 111: Locating Gaiter And Shaft

Replacing gaiter of transmission-side joint:
Release band clamps (1, 2).
Detach tulip element (4).
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Installation:
Feed gaiter (3) into groove of tulip element (4).
Align band clamp (1) so that hook fastener is as at flat end of tulip element (4).
Fig. 112: Identifying Band Clamps And Tulip Element

Remove retaining ring (1).
Installation:
Replace retaining ring (1).
Detach tripod element (2) from shaft (3).
Pull off gaiter over shaft (3).
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Fig. 113: Identifying Tripod Element And Retaining Ring

Installation:
Flat side (2) of tripod element (1) must point to retaining ring.
NOTE: Regrease constant-velocity joint (tripod element) with the grease from the repair
kit.
Fig. 114: Identifying Flat Side Of Tripod Element

90 TROUBLESHOOTING
31 90 ... TROUBLESHOOTING ON FRONT AXLE (AWD)
Follow troubleshooting for steering/shock absorbers. See 32 90 ... TROUBLESHOOTING ON STEERING .
TROUBLESHOOTING ON FRONT AXLE (AWD)

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Fault Cause Remedy

Grinding noise
Replace wheel bearings . See 31 21 180 Replacing
(louder when Wheel bearings faulty
Bearing for Front Wheel (AWD)
negotiating bends)
Balance wheels . See 36 10 508 STATIONARY
Wheel imbalance
WHEEL BALANCING
Check rims . See 36 10 715 CHECKING RIM FOR
Vibration Radial/lateral rim runout FACE AND RADIAL RUNOUT , replace if
necessary
Match or replace tires . See 36 12 001 REPLACING
Radial tire runout
A TYRE
Balance wheels . See 36 10 508 STATIONARY
Wheel imbalance
WHEEL BALANCING
Check rims . See 36 10 715 CHECKING RIM FOR
Radial/lateral rim runout FACE AND RADIAL RUNOUT , replace if
necessary
Ball joint (on front axle
Replace control arms . See 31 12 000 Removing and
carrier side or swivel
Installing/Replacing Left Or Right Control Arm
bearing side) of control arm
Steering-wheel shake backlash (AWD)
Replace rubber mounts on both traction struts . See
Rubber mount of
31 12 148 Replacing Rubber Mounts on Both
compression strut faulty
Compression Struts (AWD)
Replace guide joint . See 31 12 026 Removing and
Guide joint worn Installing/Replacing Guide Joint In Swivel
Bearing (AWD)
Refer to for steering . See 32 90 ... TROUBLESHOOTING ON STEERING
(AWD)
faulty
Excessive steering Replace rubber mounts on both traction struts. See 31
Rubber mount of
wheel play/steering compression strut faulty 12 148 Replacing Rubber Mounts on Both
wheel inclination Compression Struts (AWD)
Replace guide joint. See 31 12 026 Removing and
Bearing (AWD)
Refer to 32 90 ... TROUBLESHOOTING ON STEERING for steering
Tighten down bolts (refer to 31 10 010 Removing
Bolts for reinforcement
and Installing/Replacing Reinforcement Plate
plate loose
(AWD))
Bolts for front axle carrier Replace bolts (refer to 31 11 506 Lowering / Raising
to engine carrier loose Front Axle Carrier (AWD) )
Bolt for spring strut to Replace bolt & nut (refer to 31 31 041 Replacing
swivel bearing loose Front Left or Right Spring Strut (AWD) )
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(AWD)
backlash
Replace guide joint . See 31 12 026 Removing and
Bearing (AWD)
Rattling noise Replace both rubber mounts of stabilizer bar bracket .
Rubber mounts for stabilizer See 31 35 021 Replacing Both Rubber Mounts of
bar bracket faulty Stabilizer Mounting on Front Axle Carrier
(AWD)
Replace both stabilizer links . See 31 35 005
Ball joints on stabilizer link Removing and Installing/Replacing Push Rod
(s) worn (Stabilizer Link) for Left or Right Stabilizer
(AWD)
Check suspension components for damage; if
Front or rear axle alignment necessary, carry out chassis/wheel alignment check.
Excessive tire wear
incorrectly adjusted See 32 00 ... CHASSIS/WHEEL ALIGNMENT
CHECK PROCEDURE
31 90 ... TROUBLESHOOTING SHOCK ABSORBER
Read and comply with Information on replacing shock absorbers. See 31 00 ... Information on Replacing
Shock Absorbers.
TROUBLESHOOTING SHOCK ABSORBER

Fault Cause Remedy
Visually inspect auxiliary spring for cracking,
replace auxiliary spring. See 31 31 041
Replacing Front Left or Right Spring Strut
Auxiliary spring faulty
(AWD)
Wheel knocking AWD only: Visually inspect support ring for
(bottoming) damage
Replace shock absorber. See 31 31 041
Shock absorber leaking
(oil/gas)
(AWD)
Shock absorber mounting
Tighten shock absorber
loose
Support bearing
Replace support bearing
Rattling noise faulty/hardened
Replace shock absorber. See 31 31 041
(gas/oil)
(AWD)
Worn down areas Shock absorber leaking Replace shock absorber. See 31 31 041
(flattened areas) on tire (gas/oil) Replacing Front Left or Right Spring Strut
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profile (AWD)
Long after-swinging of Shock absorber leaking Replace shock absorber. See 31 31 041
body after driving over (insufficient shock absorber Replacing Front Left or Right Spring Strut
rough road effect) (AWD)
Building-up of body in Shock absorber leaking Replace shock absorber. See 31 31 041
case of successive uneven (insufficient shock absorber Replacing Front Left or Right Spring Strut
surfaces effect) (AWD)
Shock absorber leaking Replace shock absorber. See 31 31 041
Wheels jumping even on
(insufficient shock absorber Replacing Front Left or Right Spring Strut
normal road surfaces
effect) (AWD)
Separating skin in vent
Whistling noises Remove separating skin
holes of auxiliary spring
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SUSPENSION Front Axle - Repair
SUSPENSION
Front Axle - Repair
3100 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness
Protective measures/rules of conduct

First aid measures
31 00... FRONT AXLE + STEERING (AWD): WHEEL/CHASSIS ALIGNMENT CHECK AFTER

SPECIFIED WORK
A wheel/chassis alignment check must be carried out after the following work:

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2008 BMW 328xi

 Compression strut to front axle carrier

2. Steering gear
4. Control arm
6. Swivel bearing
7. Compression strut or compression strut rubber mount
8. Tie rod end
9. Tie rod
See ALIGNMENT CHECK WITH VEHICLE LOAD UP TO DESIGN POSITION or ALIGNMENT

CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD .
Fig. 1: Identifying Front Axle And Steering (AWD) Components

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31 00... INFORMATION ON REPLACING SHOCK ABSORBERS
Situation
Effect
removed shock absorbers as defective parts. Unnecessarily high costs for the customer can be avoided by
Procedure
If one shock absorber is damaged, it is only necessary to replace both shock absorbers when the car has driven
in excess of 80 000 km.
Information on replacing shock absorbers on E65/E66 models with EDC before production 03/07
Component version (build date) before 03/07:
 Both shock absorbers must be replaced
Component version (build date) after 03/07:
 The shock absorbers can be replaced again individually.
If in doubt, always replace both shock absorbers.
64 00 000 INFORMATION ON USING CLEANING AGENT/PAINTS (PERSONAL PROTECTION

EQUIPMENT)
WARNING: Use of cleaning agents/paints not compliant with instructions can cause
serious injuries or burns!
Handling cleaning agents/paints can trigger allergic skin and respiratory
reactions!
IMPORTANT: Observe following instructions:
 Store cleaning agents/paints only in a secure cabinet.

 Keep cleaning agents/paints away from naked flames and other sources
of ignition.
 Protect cleaning agents/paints from high temperatures and direct
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sunlight.
 Always keep an eye bath on hand, change the water regularly (once a
month).
IMPORTANT: Observe following instructions before use:
 Manufacturer's instructions (on container/packaging)

 Hazard warnings (on container/packaging)
 Manufacturer's instructions on package insert
 Material safety data sheet of manufacturer
 Product information in EPC
 National market regulations
IMPORTANT: Observe following instructions during use:
 Do not eat, drink or smoke while working with these products.

 Avoid direct contact with skin and eyes.
 Wear personal protective clothing/equipment.
 Ensure that all enclosed areas are well ventilated or extract fumes
directly.
 Immediately change working clothes soiled with cleaning agent/paint.
 After finishing work, wash your hands and apply protective skin cream.
IMPORTANT: Follow hazard warnings and wear personal protection equipment!
First Aid:
 If product comes in contact with eyes, immediately flush with running water for about 10 - 15 minutes.
Seek the advice of eye specialist.
 In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas
immediately with soap and water and then apply silicone-free skin cream. Seek advice of physician.
 If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink 1-
2 glasses of water. Do not induce vomiting. Consult a doctor.
 After inhaling vapors ensure ample supply of fresh air. Keep calm, keep respiratory tracks clear and call
doctor.
Recycling
Dispose of cleaning agents/paints in a professional manner!
Observe national/country-specific disposal regulations.
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31 00... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)

bristles!
 Do not expose to temperatures > 80°C, even for brief periods! Temperatures in paint facilities do not have
the same impact
31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER
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Fig. 2: Spring Strut Shock Absorber Layout

31 00 MOBILE TABLE LIFT

Before beginning work, position table lift with the lower frame securely on
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the floor.
Danger area around mechanism below platform.
 Do not reach into or step into the danger area.

 Note permissible bearing capacity of table lift.
 Mount load centrally (danger of tipping) and secure against shifting.
Follow the operating instructions from the equipment manufacturer.
The mobile table lift is used for collision repairs and when removing large engines.
Adaptations for mounting front axle with engine and transmission.
ADAPTATIONS FOR MOUNTING FRONT AXLE WITH ENGINE AND TRANSMISSION

REFERENCE CHART
No. 10 For mounting swivel bearing with brake disc
No. 20 Retaining element for adjustable fixture
No. 30 Adjustable fixture
No. 40 Distance pin 40 x 160 mm
No. 70 Fixture with U-profile
No. 80 Plate fixture Ø=100 mm
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Fig. 3: Adaptations For Mounting Front Axle With Engine And Transmission
Release star knob screw on working plate (B) of table lift; the working surface (B) can be extended by approx.
310 mm.
Release all push-pull clamps and the working plates can be shifted by approx. 20 mm.
Working plate (A and B) can be raised and lowered by 3° on the long side and by 5° on the transverse side.
Working plate (A and B) is subdivided by a coordinate system and a possible installation position is
recommended in the respective repair manual.
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Fig. 4: Identifying Working Plates

IMPORTANT: Follow the operating instructions from the equipment manufacturer.
31 00... NOTES ON REPAIRING THREADS
IMPORTANT: Install Helicoil thread inserts so that they are flush with the original thread.
NOTE: Damaged threads in engine support may be repaired with Helicoil thread
inserts. Comply with the procedure described in the example.
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Fig. 5: Identifying Damaged Helicoil Thread

Procedure
1. Create a clean core hole; if necessary, drill out screw remnants
Fig. 6: Creating Clean Core Hole

2. Create locating thread for Helicoil thread insert
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2008 BMW 328xi
Fig. 7: Creating Thread For Helicoil Thread Insert

3. Pick out Helicoil thread insert and screw into the locating thread until flush with the original thread
Fig. 8: Inserting Helicoil Thread Into Locating Thread

4. Break drive pin and remove
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Fig. 9: Breaking Drive Pin

31.... OVERVIEW OF FRONT AXLE (AWD)
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Fig. 10: Overview Of Front Axle (AWD)

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31..... OVERVIEW OF FRONT DIFFERENTIAL/OUTPUT SHAFTS
Fig. 11: Overview Of Front Differential/Output Shafts

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00...... RAISING VEHICLE WITH TROLLEY JACK

contact points.
3. Check the rubber plate on the trolley jack prior to each use, replacing if
necessary.
Fig. 12: Identifying Trolley Jack With Rubber Plate

points!

Risk of damage: It is not permitted to raise the vehicle at the rear differential cover!
4. Bolting point for rear axle tension struts
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Fig. 13: Identifying Car Jacking And Side Car Points On Reinforcement Strut With Rear
Differential

Danger of injury!
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 Impaired sight
Protective measures/rules of conduct

First aid measures
 Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an
eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
00 SAFETY INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE

START-STOP FUNCTION (MSA)
WARNING: If the engine hood/bonnet contact is pulled upwards (workshop mode),

the information "switch closed" is output. The automatic engine start stop
function is active.
An automatic engine start is possible.
Observe safety precautions when working on MSA vehicles
Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as
to prevent automatic engine starting while work is being carried out in the engine compartment.
MSA function is deactivated by
 Deactivate MSA by means of button (1) in passenger compartment

 Open seat belt buckle and driver's door
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Fig. 15: Identifying Automatic Engine Start/Stop Button (MSA)

 Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode
 Workshop mode
A = 10 mm
 Basic setting (engine hood/bonnet open)
B = 7 mm
Fig. 16: Identifying Basic Setting For Engine Hood/Bonnet Basic

To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the
hood/bonnet contact up to the limit position before starting work and slowly release.
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When working with diagnosis tools
 Observe instructions in diagnosis tool
WARNING: DANGER OF POISONING if oil is ingested/absorbed through the skin!

RISK OF INJURY if oil comes into contact with eyes and skin!
Recycling
Measures if oil is unintentionally released
3110 FRONT AXLE SUSPENSION

51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION
(AWD)
NOTE: Illustration created using 330xi as an example. There may be differences in

detail in the case of other vehicle models.
Remove screws (1 to 4).
Pull underbody protection (5) forward under bumper trim (6).
Installation
Centre underbody protection (5) and tighten down screws (1 to 4).
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Fig. 17: Identifying Under Bumper Trim And Underbody Protection With Screws
51 47 491 REMOVING AND INSTALLING/REPLACING REAR UNDERBODY PROTECTION
WARNING: Scalding hazard!

This work may only be carried out on an exhaust system which has
cooled down.
Single-part underbody protection (except E90/E91/E92 AWD)
Release screws (1).
Pull underbody protection (2) in direction of arrow out of bracket (3).
Installation:
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Fig. 18: Removing Underbody Protection From Bracket

Single-part underbody protection (E90/E91/E92 AWD)
Release screws (1).
Remove underbody protection (2) downwards.
Installation:
Fig. 19: Identifying Underbody Protection With Screws

Two-part underbody protection
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Release screws (1).
Detach underbody protection (2) from bracket (3) and remove.
Installation:
Fig. 20: Removing Underbody Protection From Bracket

31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE (AWD)
IMPORTANT: Observe safety instructions for raising the vehicle. See LIFTING VEHICLE WITH
A LIFTING PLATFORM .
Driving without reinforcement plate is not permitted!
Release screws (1).
Remove reinforcement plate (2).
Installation:
Replace screws.
Tightening torque 31 10 3AZ .
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Fig. 21: Identifying Reinforcement Plate With Screws

3111 FRONT SUB-FRAME

31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (AWD)

IN INSTALLATION POSITION (N52K, N53) to prevent it from falling down.
IMPORTANT: N47, N57: Danger of short-circuiting at starter!
Necessary preliminary tasks

POSITION (N52K, N53)
 Remove UNDERBODY PROTECTIVE PLATE
 Remove diesel enclosure on left and right
 Remove reinforcement cover on left and right. See REMOVING AND INSTALLING/REPLACING
LEFT/RIGHT REINFORCEMENT COVER (AWD) .
 Remove REINFORCEMENT PLATE
 Remove DOUBLE JOINT FROM POWER STEERING GEAR
 N52: Remove coolant pipe from front axle support
 If necessary, disconnect plug connection on ride-height sensor and expose line up to engine carrier
 M57T2: Disconnect vacuum line from electrically operated valve to engine mounts at T-piece

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 the vehicle does not lift off the locating plates on the lifting platform
If necessary, position special tool 00 2 040 with 2nd person helping on workshop jack.
Insert special tools 31 4 081 and 31 4 082 into corresponding mountings of special tool 00 2 040 .
Align special tool 00 2 040 to front axle support.
NOTE: Make sure when raising that the special tools 31 4 081 are correctly inserted
into the corresponding recesses of the front axle support.
Fig. 22: Inserting Special Tools 31 4 081 And 31 4 082 Into Mountings Of Special Tool 00 2 040
If necessary, drain special tool 33 3 274.
Support front axle support by raising special tool 00 2 040 .
IMPORTANT: Pay attention to power steering hoses and lines when lowering and raising.
Hoses/lines must not be kinked/tensioned/bent!
Release screws (1, 2).
M57T2: Remove cooler return line from front axle support.
Lower front axle carrier.
Installation:
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Check threads for damage; if necessary, repair with Helicoil thread inserts .
Tighten down first screws (1) and then screws (2).
Tightening torque, see 31 10 1AZ in 31 10 FRONT AXLE SUSPENSION .
Fig. 23: Identifying Front Axle Support With Screws

After installation
 Carry out STEERING ANGLE SENSOR ADJUSTMENT
31 11 001 REPLACING FRONT AXLE CARRIER (AWD)


POSITION (N52K, N53) to prevent it from falling down.
 Remove front wheels.
 Remove STABILIZER
 Only on right side: Remove front ride-height sensor with bracket from front axle carrier
 Remove BOTH COMPRESSION STRUTS FROM FRONT AXLE CARRIER
 Remove BOTH CONTROL ARMS ON BOTH SIDES FROM FRONT AXLE CARRIER
 Lower FRONT AXLE CARRIER
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Tie up power steering gear (2).
Installation:
Fig. 24: Identifying Power Steering Gear With Screw

Lower front axle carrier and take down from special tool.
Remove heat shield(s).
Remove both ENGINE MOUNTS and if necessary remove with vacuum lines from front axle carrier.
Take front axle carrier down and set down on a suitable surface.
Installation:
Use previous front axle carrier as a template for modifying or replacing small parts.
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Fig. 25: Identifying Front Axle Carrier

After installation
 Perform CHASSIS ALIGNMENT CHECK

3112 STRUTS WITH RUBBER MOUNTS

31 12 090 REMOVING AND INSTALLING/REPLACING BOTH COMPRESSION STRUTS (AWD)
NOTE: If the compression strut is detached from the front axle carrier, it is necessary
Replace both compression struts in event of hydro-mount damage.
 Remove GUIDE JOINT ON BOTH SIDES FROM SWIVEL BEARING

 If necessary, remove reinforcement cover on left and right. See REMOVING AND
INSTALLING/REPLACING LEFT/RIGHT REINFORCEMENT COVER (AWD) .
Slacken nut (1).
Remove screw (2) to one side and remove compression strut (3) with guide joint.
Installation:
Tighten bolt connection in NORMAL POSITION .

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2008 BMW 328xi
Fig. 26: Identifying Compression Strut With Self Locking Nut And Screw
If necessary, replace lower section 31 2 242 with lower section 31 2 246.
Press guide joint with out of compression strut with special tool 31 2 240.
Fig. 27: Pressing Guide Joint With Out Of Compression Strut Using Special Tool 31 2 240
Installation:
After installation
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2008 BMW 328xi
 Perform chassis alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT CHECK
WITH VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS CHASSIS/WHEEL
ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD
31 12 026 REMOVING AND INSTALLING/REPLACING GUIDE JOINT IN SWIVEL BEARING

(AWD)
 Remove front wheel.
Slacken nut (1), grip with Allen key if necessary.
Installation:
Remove guide joint with compression strut from opening in swivel bearing.
Fig. 28: Identifying Compression Strut With Self Locking Nut

Installation:
Recondition thread in swivel bearing.
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2008 BMW 328xi
Keep guide joint and opening in swivel bearing clean and free from oil and grease.
Replace microencapsulated screws.
Guide joint tightly seated in swivel bearing:
IMPORTANT: The guide joint must be replaced once it has been driven out with the special
tool.
33 4 205 Unscrew nut and screw special tool onto guide joint.
33 4 200 Drive guide joint out of swivel bearing with special tool.
Fig. 29: Driving Guide Joint Out Of Swivel Bearing Using Special Tool 33 4 200
If necessary, replace lower section 31 2 242 with lower section 31 2 246
Press guide joint with special tool out of compression strut.
Installation:
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2008 BMW 328xi
Fig. 30: Pressing Guide Joint Using Special Tool 31 2 240

31 12 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CONTROL ARM (AWD)
NOTE: If the control arm is detached from the front axle carrier, it is necessary after
 Remove front wheel.
Release nut (1) and remove jointed rod (2) from control arm (3).
Installation:
Tightening torque, see 3 14 3AZ in 37 14 ELECTRIC COMPONENTS .
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Fig. 31: Identifying Jointed Rod Of Control Arm With Nut

Release nut (1) and remove bolt (2) towards front.
Press swivel bearing in area of compression strut outwards and remove control arm from front axle carrier.
Installation:
Make sure that diesel enclosure is correctly positioned to side of control arm.
Fig. 32: Identifying Compression Strut With Nut And Bolt

Release nut (1) approx. 3[]-4 thread turns; if necessary, grip at hexagon.
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2008 BMW 328xi
If necessary, replace lower section 31 2 242 with lower section 31 2 246.
Press off wishbone from swivel bearing using special tool 31 2 240 (consisting of 31 2 241, 31 2 243, 31 2 244,
31 2 245 and 31 2 246).
Unscrew nut (1) and remove control arm.
Fig. 33: Pressing Of Wishbone From Swivel Bearing Using Special Tool 31 2 240
Installation:
Keep journal on ball head and bushing in swivel bearing clean and free from oil and grease.
After installation
31 12... REPLACING GUIDE JOINT ON BOTH COMPRESSION STRUTS (AWD)
Carry out check
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2008 BMW 328xi
Fig. 34: Identifying Guide Joint

Play is OK: Check bolt connection

 Play is not OK: Replace guide joint
6AZ and listening for cracking sound. See 31 12 CONTROL ARMS AND STRUTS
 Torque wrench cracking sound: Guide joint does not have to be replaced
 Bolt connection turns: Replace compression strut and guide joint
31 12 148 REPLACING RUBBER MOUNTS ON BOTH COMPRESSION STRUTS (AWD)
IMPORTANT: The rubber mounts on both compression struts must always be replaced!
Carry out check
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2008 BMW 328xi
Fig. 35: Identifying Guide Joint

Play is OK: Check bolt connection (see Point 2)


 Play is not OK: Replace RUBBER MOUNT AND GUIDE JOINT
6AZ and listening for cracking sound
 Torque wrench cracking sound: Replacing rubber mount
 Bolt connection turns: Replace compression strut and guide joint . See 3200150 KDS
CHASSIS/WHEEL ALIGNMENT CHECK WITH VEHICLE LOAD UP TO DESIGN
POSITION or 3200155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE
HEIGHT MEASUREMENT WITHOUT VEHICLE LOAD
Replacing rubber mount
Remove both COMPRESSION STRUTS.
Using a press and special tools 31 3 031 and 31 3 032, press rubber mount out of tension strut.
NOTE: Special tool 31 3 031 must be exactly flush with rubber mount bush.
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Fig. 36: Pressing Rubber Mount Using 31 3 031 And 31 3 032

Installation:
Keep rubber mount and bushing in compression strut clean and free from grease.
Align rubber mount by way of opening (1) in bushing to marking (2) on compression strut and press in. The
deviation (A) must not exceed ± 5°.
Fig. 37: Identifying Rubber Mount Alignment Position

Installation:

After installation
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31 12 134 REPLACING RUBBER MOUNT IN LEFT OR RIGHT TRAILING LINK
IMPORTANT: The mounts on both tension struts must be replaced! Note that the mounts
may only be changed once.
On some models faulty rubber mounts are replaced by hydro mounts!
Procedure remains the same!
 Check ball joints of tension struts while installed, replace TENSION STRUTS if necessary
 Remove TENSION STRUTS
IMPORTANT: If the tension struts already feature an identification mark with a center punch,
it is necessary to replace both tension struts.
Mark tension struts with a punch mark in area (A).
Fig. 39: Identifying Punch Mark Area On Tension Strut

Using a press and special tools 31 3 031 and 31 3 032, press rubber mount out of tension strut.
NOTE: Special tool 31 3 031 must be exactly flush with rubber mount bush.
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2008 BMW 328xi
Fig. 40: Pressing Rubber Mount Using 31 3 031 And 31 3 032

Installation:
Keep rubber mount and bushing in tension strut clean and free from grease.
Align rubber mount by way of arrow to marking on tension strut and press in. The deviation must not exceed ±
5°.
Fig. 41: Identifying Rubber Mount Aligning Arrow On Tension Strut

Installation:
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3121 WHEEL BEARINGS AND STUB AXLE

31 21 090 REPLACING (REMOVING AND INSTALLING) LEFT OR RIGHT SWIVEL BEARING
(AWD)
Remove front wheel.
collar nut.
Installation:
Fig. 43: Locating Collar Nut

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Remove brake disc. See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH FRONT
BRAKE DISCS .
Replacement only: Drive out WHEEL HUB.
Remove pulse generator from swivel bearing. See REPLACING ONE FRONT PULSE SENSOR .
Remove TIE ROD END FROM SWIVEL BEARING .
Remove GUIDE JOINT FROM SWIVEL BEARING.
Remove CONTROL ARM FROM SWIVEL BEARING.
Remove STABILIZER LINK FROM SPRING STRUT.
Press OUTPUT SHAFT OUT OF WHEEL HUB and tie up.
IMPORTANT:  Check sensor head and line from pulse generator prior to installation for
external damage, replacing if necessary.
Support swivel bearing with workshop jack and a suitable mounting.
Release nut (1), remove holder (2) and remove screw (3).
Spread swivel bearing with special tool 31 2 230 .
Lower workshop jack and remove swivel bearing.
Installation:
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Fig. 44: Identifying Holder With Nut And Screw

Screw head must point in direction of travel.
Installation:
Expand swivel bearing with special tool 31 2 230, align by way of gap to positioning pins (1) on back of spring
strut and raise up to stop.
Fig. 45: Aligning Gap To Positioning Pins On Back Of Spring Strut

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Replacement
 Replace dust sleeve (1)

 Modify or replace brake carrier/brake guard plate. See 3411250 REMOVING AND
INSTALLING/REPLACING A BRAKE CARRIER/BRAKE GUARD PLATE AT FRONT
 Install new WHEEL BEARING.
 Draw in WHEEL HUB.
After installation
 Replacement only: Perform chassis alignment check . See 3200150 KDS CHASSIS/WHEEL
ALIGNMENT CHECK WITH VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS
CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT
VEHICLE LOAD
31 21 180 REPLACING BEARING FOR FRONT WHEEL (AWD)
IMPORTANT: Bearing cannot be dismantled.

Do not wash out bearing.
Remove front wheel.
collar nut.

Remove front brake disk. See 34 11 220 REMOVING AND INSTALLING OR REPLACING BOTH
FRONT BRAKE DISCS .
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Force drive flange with special tools 33 2 116/33 2 201, 33 2 160, 33 4 200 and 5 wheel bolts out of wheel
bearing.
Detach INNER WHEEL BEARING RACE FROM DRIVE FLANGE.
Fig. 47: Installing Drive Flange Using Special Tools

Remove SWIVEL BEARING and clamp with aluminum clamping jaws in vice.
IMPORTANT: The bearing was destroyed when the wheel hub was removed and must not be
reused!
Fig. 48: Lifting Retaining Ring

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2008 BMW 328xi
Pull out bearing with special tools 31 2 113, 33 4 261, 33 3 266 and 33 3 261.
Check dust sleeve, replace if necessary.
Fig. 49: Removing Bearing Using Special Tools

IMPORTANT: Keep press-fit areas clean and free of oil and grease.
Wider chamfer (1) of bearing must point to swivel bearing!
Clean new bearing on press-fit area and bearing seat in swivel bearing.
Fig. 50: Identifying Wider Chamfer Of Bearing

Align bearing by way of wider chamfer to swivel bearing and draw in up to stop with special tools 31 2 113, 22
1 018, 33 4 262 and 33 3 261.
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Fig. 51: Pressing Bearing To Forced Out Of Swivel Bearing

NOTE: Make sure circlip (1) is correctly seated.
Fig. 52: Installing Circlip

Draw in wheel hub (1) up to stop with special tools 31 2 113, 33 3 268, 33 3 266 and 33 3 261.
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2008 BMW 328xi
Fig. 53: Installing Wheel Hub Using Special Tools

Install SWIVEL BEARING.
Draw OUTPUT SHAFT INTO WHEEL HUB.
Install front brake disk. See 34 11 020 REMOVING AND INSTALLING OR REPLACING FRONT LEFT
OR RIGHT BRAKE CALIPER (TEVES) .
Install front brake calliper. See 34 11 520 REMOVING AND INSTALLING/REPLACING FRONT LEFT
OR RIGHT BRAKE CALIPER (BREMBO) .
Install front wheel.
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31 21 121 REPLACING LEFT OR RIGHT WHEEL HUB
NOTE: Procedure is described in the document "REPLACING FRONT WHEEL

BEARING".
3131 SPRING STRUT

31 00... INFORMATION ON REPLACING SHOCK ABSORBERS
Situation
Effect
removed shock absorbers as defective parts. Unnecessarily high costs for the customer can be avoided by
Procedure
If one shock absorber is damaged, it is only necessary to replace both shock absorbers when the car has driven
in excess of 80 000 km.
Exception: On all M models, when a limit value is exceeded on one side, it is still necessary always to replace
both shock absorbers on the relevant axle.
Information on replacing shock absorbers on E65/E66 models with EDC before production 03/07
CARMANUALSUSA
2008 BMW 328xi
Component version (build date) before 03/07:
 Both shock absorbers must be replaced (refer to BMW Parts Department information) (See Note BMW
Parts Department)
Component version (build date) after 03/07:
 The shock absorbers can be replaced again individually.
If in doubt, always replace both shock absorbers.
31.... LAYOUT OF SPRING STRUT SHOCK ABSORBER
CARMANUALSUSA
2008 BMW 328xi
Fig. 55: Spring Strut Shock Absorber Layout

31 31 003 REMOVING AND INSTALLING COMPLETE FRONT LEFT OR RIGHT SPRING STRUT
(AWD)
IMPORTANT: If the centering pin is missing from the support bearing, the position of the
CARMANUALSUSA
2008 BMW 328xi
studs to the wheel arch must be marked so that the original camber is
approximately maintained.
Only one nut may ever be released for marking.
FRONT BRAKE DISCS .
 Remove STABILIZER LINK FROM SPRING STRUT
 Remove TIE ROD END FROM SWIVEL BEARING
 Remove GUIDE JOINT FROM SWIVEL BEARING
 Remove CONTROL ARM FROM SWIVEL BEARING


 the vehicle does not lift off the locating plates on the lifting platform
Secure special tool 31 5 220 with wheel studs to drive flange and support swivel bearing with workshop jack.
Fig. 56: Securing Special Tool 31 5 220 With Wheel Studs To Drive Flange
Unclip line for brake pad sensor on swivel bearing.
Release nut, remove holder (2) and remove screw (1).
Installation:
CARMANUALSUSA
2008 BMW 328xi
Screw head must point in direction of travel.
Fig. 57: Identifying Holder With Screw


When the swivel bearing is lowered, the tripod (2) can be pulled out of the tulip
(1) and fall into the rubber gaiter (3). In this event, it will be necessary to install
a new output shaft because the tripod (2) can jam or a roller of the tripod (2)
can slip off the molding. The roller would then be located in the gaiter (3) or
bellows and result in rapid failure.
Fig. 58: Identifying Tripod, Tulip And Rubber Gaiter

Expand swivel bearing with special tool 31 2 230.

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2008 BMW 328xi
Carefully lower swivel bearing.
Installation:
Fig. 59: Expanding Swivel Bearing Using Special Tool 31 2 230

Installation:
Expand swivel bearing with special tool 31 2 230, align by way of gap to positioning pins (1) on back of spring
strut and raise up to stop.
Fig. 60: Aligning Gap To Positioning Pins On Back Of Spring Strut

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2008 BMW 328xi
Centering pin missing: Make position of studs in relation to wheel arch.
Secure spring strut against falling out.
Unscrew nuts (1).
Remove spring strut downwards out of wheel arch.
Installation:
Clean contact surface in spring strut dome.
Fig. 61: Identifying Spring Strut Nuts

Align spring strut using centering pin to bore in wheel arch or studs to wheel arch and push upwards.
IMPORTANT: Replace faulty sealing washer (1).

Reinstall sealing washer (1) and plate insert (2).
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Fig. 62: Identifying Sealing Washer And Plate

After installation
 Carry out chassis/wheel alignment check See 3200150 KDS CHASSIS/WHEEL ALIGNMENT
CHECK WITH VEHICLE LOAD UP TO DESIGN POSITION or 3200155 KDS
CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE HEIGHT MEASUREMENT WITHOUT
VEHICLE LOAD if a spring strut with support bearing was or has been installed without centering pin.
51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT

SPRING STRUT DOME

Driving without the tension strut is not permitted as otherwise the body may be
damaged.
Tension strut screws must be tightened to torque and then tightened down
with special tool 00 9 120.
Catch (2) and seal (3) of cover (1) must not be damaged.
Even a minimally damaged cover (1) may result in water leaking in; if necessary, replace cover (1).
NOTE: Two possible versions of cover (1):
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Fig. 63: Removing Cover

A. Turn cover (with notch) approx. 45° counterclockwise

B. Snap out cover (without notch) in upward direction
Remove cover (1) and release screw underneath.
NOTE: Grommet (3) must not be pulled out of bulkhead because this eliminates the
possibility of correct feeding in when installed.
Release screw (1).
Grip grommet (3) and pull out tension strut (2) in direction of arrow.
Fig. 64: Pulling Tension Strut

Installation:
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Replace screws.
Carefully feed tension strut (1) into grommet (2).
Tighten down screws to specified torque and then retighten to angle of rotation using special tool 00 9 120.
Tightening torque, see 51 71 2AZ in 51 71 GASKETS AND LOOSE BODY COMPONENTS .
Fig. 65: Identifying Tension Strut And Grommet

31 31 041 REPLACING FRONT LEFT OR RIGHT SPRING STRUT (AWD)
IMPORTANT:  When replacing shock absorber/spring strut, renew auxiliary damper!
WARNING: Before using the special tool 31 3 340 take care to read through the
Owner's Handbook!
All the safety information and instructions contained in the Owner's
Handbook must be strictly observed!
Failure to observe these safety precautions and instructions increases
the risk of serious physical injury, damage to your health and damage to
property and equipment!
IMPORTANT: 1. Prior to each use, check the special tools for defects, modifications and
operational reliability.
3. No changes or modifications may be made to the special tools!
4. These special tools are intended solely for the purpose of tightening and
relieving cylindrical and tapered suspension springs.
5. Keep special tools dry, clean and (down to the spindle) free from grease.
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2008 BMW 328xi
6. Impact screwdrivers are prohibited!

Necessary preliminary work
 Remove FRONT SPRING STRUT.
Removing
Clamp special tool 31 3 341 in vice.
Install insert 31 3 358 in special tool 31 3 354.
Position special tools 31 3 355 and 31 3 354 with insert 31 3 358 from above on special tool 31 3 341 until
retaining bolts (1) can be felt and heard snapping into place.
Fig. 66: Identifying Retaining Bolt And Special Tools

Check seating of special tools 31 3 355 and 31 3 354 with insert 31 3 358, correct if necessary.
Clean coil spring to remove coarse contamination and take up with special tools 31 3 355 and 31 3 354 with
insert 31 3 358.
Twist spring strut until end of coil spring (1) is flush with end of special tool 31 3 355.
WARNING: Special tool 31 3 354 and centering ring 31 3 358 must rest correctly on
the upper spring cup!
Bottom coil of coil spring must rest completely in recess of special tool
31 3 355!

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Fig. 67: Pressing Spring Strut Using Special Tool

Take off protective cap.
Release nut with special tool 31 2 210 (grip piston rod in the process).
Fig. 68: Tightening Nut Using Special Tool (31 2 210)

Remove support bearing (1), dust boot and supporting ring (2).
Remove shock absorber with auxiliary damper, gaiter and lower spring pad sideways from tensioned coil
spring.
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2008 BMW 328xi
Fig. 69: Identifying Support Bearing And Supporting Ring

If necessary, remove auxiliary damper (1), gaiter (2) and spring pad (3) from shock absorber.
Fig. 70: Identifying Auxiliary Damper, Gaiter And Spring Pad

Relieve tension on coil spring.
Remove coil spring with spring cup from special tools 31 3 355, 31 3 358 and 31 3 354.
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Fig. 71: Compressing Coil Spring Using Special Tools

Installation
Check spring pad (1) for damage, replace if necessary.
Attach spring cup (2) with spring pad (1) to coil spring.
NOTE: End of coil spring must be positively aligned to spring pad (1).
Fig. 72: Identifying Spring Cup And Spring Pad

Hold coil spring and spring cup with special tools 31 3 355, 31 3 358 and 31 3 354.
Twist coil spring until lower end of coil spring (1) is flush with end (2) of special tool 31 3 355.
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Fig. 73: Compressing Coil Spring Using Special Tool (31 3 355)
WARNING: Do not compress coil spring to full extent.

Special tool 31 3 354 and centering ring 31 3 358 must rest correctly on
the upper spring cup!
Bottom coil of coil spring must rest completely in recess of special tool
31 3 355!
Fig. 74: Compressing Coil Spring Using Special Tools

Tension coil spring.
Check auxiliary damper (1), gaiter (2) and spring pad (3) for damage, replace if necessary.
NOTE: Make sure spring pad (3) is correctly seated on shock absorber.
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Fig. 75: Identifying Auxiliary Damper, Gaiter And Spring Pad

Insert shock absorber in tensioned coil spring.
Attach support disc (2) to piston rod.
Check support bearing (1) for damage, replace if necessary.
Attach dust boot and support bearing to piston rod.
Fig. 76: Identifying Support Bearing And Support Disc

Replace nut and tighten down with special tool 31 2 210 (grip piston rod in the process).
Fit cover cap.
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Fig. 77: Tightening Nut Using Special Tool (31 2 210)

IMPORTANT: Spring pad (1) must rest positively on spring cup (2)!
Upper end of coil spring must rest on stop of spring pad (1)!
Fig. 78: Identifying Spring Cup And Spring Pad

IMPORTANT: Lower end of coil spring (2) must rest on stop of spring pad (1)!
Relieve tension on coil spring.
Check installation position of gaiter, correct fold if necessary.
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Fig. 79: Identifying Coil Spring And Spring Pad

After installation
 Carry out wheel alignment check . See 3200150 KDS CHASSIS/WHEEL ALIGNMENT CHECK
if a spring strut with support bearing was or is installed without centering pin.
3133 SPRING WITH SUSPENSION

31 33 001 (REMOVING AND INSTALLING) REPLACING FRONT LEFT OR RIGHT SPRING
STRUT SUPPORT BEARING
NOTE: Procedure is described in REPLACING FRONT LEFT OR RIGHT SPRING STRUT.
Replacement
Vehicle with spacer ring:
NOTE: Spacer ring (A) is fitted in vehicles with "rough road package" version.
Unscrew nuts.
Remove spacer ring (A) from support bearing.
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Fig. 80: Identifying Spacer Ring And Centering Pin

Installation:
Align spacer ring (A) using centering pin (1) to support bearing and place in position.
If necessary, twist/drive out centering pin (1).
NOTE: If a support bearing (2) was fitted without centering pin (1), the centering pin (1)
of the new support bearing (2) must be driven or twisted out.
Fig. 81: Identifying Support Bearing And Centering Pin

31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE

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 Move vehicle into NORMAL POSITION .
Determine actual ride height (A) to do so, attach tape measure to rim flange (2) at bottom middle and measure
Fig. 82: Identifying Actual Ride Height From Lower Edge Of Wheel Arch To Rim Flange
31 33 100 REMOVING AND INSTALLING/REPLACING COIL SPRING FOR LEFT OR RIGHT

FRONT SPRING STRUT
corrosion breakage!
NOTE: The coil spring is allocated in the Electronic Parts Catalogue (EPC) under the
menu item "Spring table" after the vehicle identification number has been
entered and the relevant optional equipment of the car has been selected.
NOTE: Procedure is described in the document "REPLACING FRONT LEFT OR RIGHT

SPRING STRUT ".
3135 STABILIZER BAR

31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER (AWD)
IMPORTANT: To avoid complaints being made by the customer about noise, set the car on
its wheels and tighten down the stabilizer mounting to specified torque.
 Remove FRONT ASSEMBLY UNDERSIDE PROTECTION

 Remove STABILIZER LINK ON BOTH SIDES FROM STABILIZER
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NOTE: The following illustrations was created using the E91 with M57T2 as an
example. Other vehicles and engines may show differences in detail.
N52:
Remove coolant pipe from front axle carrier.
Release screws (1).
Remove bracket (2) with pressure line for power steering from front axle carrier.
Remove stabilizer (3).
Fig. 83: Identifying Stabilizer, Bracket With Screws

Installation:
Check RUBBER MOUNT ON BOTH SIDES, replace if necessary.
Set car on its wheels and tighten down nuts to tightening torque 31 35 1AZ .
Replacement
Remove RUBBER MOUNT ON BOTH SIDES FROM STABILIZER.
31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR

LEFT OR RIGHT STABILIZER (AWD)
Release nuts (1); if necessary, grip with open-end wrench.
Remove stabilizer link (2).
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Installation:
Fig. 84: Identifying Stabilizer Link With Self-Locking Nuts

31 35 021 REPLACING BOTH RUBBER MOUNTS OF STABILIZER MOUNTING ON FRONT AXLE

CARRIER (AWD)
 Remove STABILIZER FROM FRONT AXLE CARRIER and set down on tie rods.
Remove retaining bracket (1) and rubber mount (2) on both sides.
Installation:
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3150 FRONT AXLE GEARBOX

31 50... CHANGING FRONT DIFFERENTIAL OIL
IMPORTANT: Use only the approved front differential oil in this front differential. See FRONT
AXLE - OPERATING FLUIDS
Failure to comply with this requirement will result in serious damage to the
differential!
NOTE: Only change oil when front differential is at normal operating temperature.
 Remove REINFORCEMENT PLATE
Checking/correcting front differential oil level
Check front differential oil level.
If necessary, pour in front differential oil up to lower edge of opening for oil filler plug (1).
Installation:
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Fig. 86: Identifying Filler Plug

Changing front differential oil
Place oil collecting apparatus underneath.
Remove oil drain plug (1).
Drain front differential oil.
Replace sealing ring, screw in oil drain plug (1) and tighten down.
Fig. 87: Identifying Oil Drain Plug And Oil Filler Plug
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Pour in front differential oil up to lower edge of opening for oil filler plug (2).
Installation:
31 50 001 REMOVING AND INSTALLING/REPLACING FRONT DIFFERENTIAL

 Secure ENGINE IN INSTALLATION POSITION

 Drain and dispose of FRONT DIFFERENTIAL OIL
 Remove LEFT OUTPUT SHAFT
 Press right output shaft approx. 6-7 cm out of front differential.
 Remove FRONT PROPELLER SHAFT
 Replacement only:
 Replace FRONT AXLE OUTPUT FLANGE ON TRANSFER BOX
NOTE: Replace the output flange to ensure a clean seal on the transfer case.
 Lower FRONT AXLE SUPPORT
IMPORTANT: Grip front differential firmly while releasing last bolt in order to avoid damage
caused by the differential falling.
Version with automatic transmission: If necessary, disconnect hydraulic lines from oil sump.
Release screws (1).
Detach front differential from oil sump and remove towards rear.
Installation:
Replace O-RING if necessary.
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Fig. 88: Identifying Front Differential Screws

Coat O-ring with front differential oil.
After installation
 fill with FRONT DIFFERENTIAL OIL

 Check TRANSFER CASE OIL LEVEL , correct if necessary
31 51 060 REPLACING O-RING FOR FRONT DIFFERENTIAL ON RIGHT
 Remove FRONT DIFFERENTIAL
Remove O-ring (1) with a suitable tool from front differential.
Installation:
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Fig. 89: Identifying O-Ring On Groove

31 51 010 REPLACING RADIAL SEAL FOR DRIVE FLANGE OF FRONT DIFFERENTIAL
 Remove REINFORCEMENT PLATE.

 Remove FRONT PROPELLER SHAFT
Mark position of nut with respect to shaft with punch marks (arrow).
Lever out lockplate (1) with a suitable tool.
Fig. 90: Locating Lockplate


Do not place special tool on threaded holes of drive flange.
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Secure drive flange with special tool 23 0 020 against turning and release nut (1).
Fig. 91: Securing Drive Flange Using Special Tool 23 0 020


Mount special tool only with longer screws (M10x30) on drive flange.
Pull drive flange off drive shaft with special tool 33 1 150.
Fig. 92: Pulling Drive Flange Of Drive Shaft Using Special Tool 33 1 150
Lever shaft seal (1) out of front differential with a suitable screwdriver (2).
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Fig. 93: Removing Shaft Seal Of Front Differential Using Suitable Screwdriver
Installation:
Drive in shaft seal with special tool 31 5 130 as far as it will go.
Coat sealing lips of new shaft seal (1) with front differential oil.
Fig. 94: Installing Shaft Seal Using Special Tool 31 5 130


Do not tighten nut beyond punch marks. Otherwise the clamping sleeve will be
damaged.
Clean drive flange and attach.
Tighten down nut until punch marks on nut and shaft are aligned.
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Install new lockplate (1).
Fig. 95: Locating Lockplate

After installation
 Check FRONT DIFFERENTIAL OIL LEVEL, correct if necessary
 Remove LEFT OUTPUT SHAFT
Fig. 96: Removing Shaft Seal From Front Differential Using Screwdriver
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Fig. 97: Identifying Sleeve Of Shaft Seal

Installation:

After installation
 Check FRONT DIFFERENTIAL OIL level , correct if necessary
3153 DIFFERENTIAL WITH BEARINGS

31 53 040 REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT BEARING
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BLOCK
 Remove RIGHT OUTPUT SHAFT
Release screws (1).
Remove bearing block from oil sump.
Installation:
Replace O-RING.
Fig. 99: Identifying Oil Sump Screws

31 51 065 REPLACING O-RING FOR BEARING BLOCK
 Remove BEARING SUPPORT
Remove O-ring (1) with a suitable tool from bearing block (2).
Installation:
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Fig. 100: Identifying O-Ring Of Bearing Block

See REPLACING SHAFT SEAL FOR LEFT OUTPUT SHAFT.
Fig. 101: Removing Shaft Seal From Bearing Block Using Screwdriver
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Fig. 102: Identifying Sleeve And Shaft Seal

Installation:

3160 OUTPUT SHAFT

31 60... NOTES ON REMOVING AND INSTALLING LOW PROFILE BAND CLAMPS
IMPORTANT: During removal Low Profile band clamp (dotted line) is overstretched and must
not be reused!
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Fig. 104: Identifying Low Profile Band Clamp (Dotted Line)

Removing
Place special tool 31 5 200 on tabs (1, 2).
Fig. 105: Identifying Special Tool (31 5 200) On Tabs

Compress Low Profile band clamp with special tool 31 5 200 until end of band clamp (1) lifts up.
Relieve tension on special tool and remove Low Profile band clamp.
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Fig. 106: Compressing Low Profile Band Clamp Using Special Tool (31 5 200)
Assembly
Position Low Profile band clamp in installation position (A) on gaiter.
Place special tool 31 5 200 on tabs (1, 2).
Fig. 107: Identifying Low Profile Band Clamp Installation Position

Check and if necessary correct positions of gaiter and Low Profile band clamp.
Compress Low Profile band clamp with special tool 31 5 200 and press on end of band clamp (1).
Relieve tension on special tool and remove.
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Check hook fastener (H); if necessary, repeat operation with new Low Profile band clamp.
Fig. 108: Compressing Low Profile Band Clamp Using Special Tool (31 5 200)
31 60... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE (WHEEL HUB) AND DRAWING IN

the output shaft.

E53 and M3 only:
IMPORTANT: To avoid damaging the dust boot, use special tool 33 2 160 to press out and
draw in the output shaft after removing the brake disc.
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2008 BMW 328xi

Screw on special tools 33 2 203, 33 2 207 and 33 2 201 with all wheel bolts to drive flange.
Press output shaft out of drive flange; in so doing, grip basic body 33 2 201 with special tools 33 2 202 and 33 5
070.
Fig. 110: Pressing Output Shaft Out Of Drive Flange Using Special Tools
Screw special tool 33 2 205 onto output shaft.

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2008 BMW 328xi
Fig. 111: Installing Special Tool 33 2 205 On To Output Shaft

Mount special tool 33 2 201 with three wheel bolts to drive flange.
tools 33 2 202 and 33 5 070.
Fig. 112: Installing Output Shaft Using Special Tool 33 2 208

Screw on special tools 33 2 111, 33 2 117 and 33 2 116 with all wheel bolts to drive flange.
070.
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Fig. 113: Pressing Output Shaft Out Of Drive Flange Using Special Tools
Screw special tool 33 2 118 onto output shaft.
Fig. 114: Installing Special Tool 33 2 118 Onto Output Shaft

Mount special tool 33 2 116 with three wheel bolts to drive flange.
tools 33 2 202 and 33 5 070.
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Fig. 115: Installing Output Shaft With Special Tool 33 2 115

31 60 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT OUTPUT SHAFT

Do not drive output shaft out of wheel hub with an impact tool.
Remove front wheel.
IMPORTANT: Expand anti-twist lock sufficiently to avoid damaging thread when releasing
collar nut.
Installation:
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Remove REINFORCEMENT PLATE.
Remove diesel enclosure.
Remove TRACK ROD END FROM SWIVEL BEARING .
Right side only: Remove GUIDE JOINT FROM SWIVEL BEARING.
Remove WISHBONE FROM SWIVEL BEARING.
Remove ANTI-ROLL BAR LINK FROM SPRING STRUT.
Press OUTPUT SHAFT OUT OF WHEEL HUB and tie up.
Front differential
Press output shaft with special tool 31 5 110 out of front differential and remove.
Installation:
Replace SHAFT SEAL IN FRONT DIFFERENTIAL and coat sealing lips with front differential oil.
into place.
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Fig. 117: Pressing Output Shaft Using Special Tool 31 5 110 Out Of Front Differential
Bearing block
Press output shaft with special tool 31 5 110 out of bearing block and remove.
Installation:
Replace SHAFT SEAL IN BEARING BLOCK and coat sealing lips with front differential oil.
into place.
Fig. 118: Pressing Output Shaft Using Special Tool 31 5 110 Out Of Bearing
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After installation
 Check FRONT DIFFERENTIAL OIL LEVEL, correct if necessary
31 60 530 REPLACING AN OUTPUT SHAFT GAITER (ON TRANSMISSION SIDE) (OUTPUT

SHAFT REMOVED)
NOTE: Procedure is described in BOTH OUTPUT SHAFT GAITERS.
Fig. 119: Removing Shaft Seal From Bearing Block Using Screwdriver
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Fig. 120: Identifying Sleeve And Sealing Lips Of Shaft Seal

Installation:

31 60 535 REPLACING TWO GAITERS ON OUTPUT SHAFT(S) (OUTPUT SHAFT(S) REMOVED)
Grip output shaft (1) in vice with aluminum clamping jaws.
NOTE: 2 = Joint, wheel side

3 = Joint, transmission side
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Fig. 122: Identifying Output Shaft With Joints

Replacing gaiter of wheel-side joint
Release LOW PROFILE BAND CLAMP (1) and band clamp (2).
Installation:
Feed gaiter (3) into groove of joint.
Fig. 123: Pulling Rubber Gaiter

Press off joint (1) via contact pressure of retaining ring on shaft (2).
Installation:
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Push on joint until retaining ring can be heard to snap into place.
Fig. 124: Identifying Joint And Retaining Ring On Shaft

Installation:
Replace circlip (1).
Fig. 125: Lifting Retaining Ring

Pull off gaiter (1) over shaft (2).
NOTE: Re-grease constant-velocity joint with the grease from the repair kit.
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Fig. 126: Pulling Of Gaiter Onto Shaft

Replacing gaiter of transmission-side joint
Release band clamps (1, 2).
Detach tulip element (4).
Installation:
Feed gaiter (3) into groove of tulip element (4).
Align band clamp (1) so that hook fastener is as at flat end of tulip element (4).
Fig. 127: Removing Tulip Element

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Remove retaining ring (1).
Installation:
Replace circlip (1).
Detach tripod element (2) from shaft (3).
Pull off gaiter over shaft (3).
Fig. 128: Identifying Retaining Ring And Tripod Element Of Shaft

Installation:
Flat side (2) of tripod element (1) must point to retaining ring.
NOTE: Re-grease constant-velocity joint (tripod element) with the grease from the
repair kit.
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Fig. 129: Identifying Flat Side Of Tripod Element

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DRIVELINE/AXLES Propeller Shaft - Repair
DRIVELINE/AXLES
Propeller Shaft - Repair
2600 PROPELLER SHAFT, GENERAL

26 00... PROPELLER SHAFT DEFLECTION ANGLES
IMPORTANT: Specifications on propeller shaft deflection angles
Only possible on request with the vehicle identification number of the problem
vehicle via PuMA.
26 20 000 REMOVING AND INSTALLING FRONT PROPELLER SHAFT
IMPORTANT: Do not move vehicle with drive power once propeller shaft has been removed.
IMPORTANT: Replacement only
Necessary Preliminary Tasks
 Remove underbody protection.
Release screws. Installation note: Replace ZNS bolts. Tightening torque: jointing torque: 20 Nm, angle of
rotation: 45 degrees.
Fig. 1: Identifying 4 Propeller Shaft Screws (1 Of 2)

Release screws. Remove propeller shaft. Installation note: Replace ZNS bolts. Tightening torque: jointing
torque: 20 Nm, angle of rotation: 45 degrees.
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2008 BMW 328xi
Fig. 2: Identifying 4 Propeller Shaft Screws (2 Of 2)

26 20 001 REPLACING FRONT PROPELLER SHAFT
IMPORTANT: Do not move vehicle with engine power once propeller shaft has been
removed.
Replace propeller shaft only in conjunction with a new drive flange and radial
shaft seal for front axle output.
IMPORTANT:  Replacement only: according to installation with BMW diagnosis and

information system under control unit function
Perform functional check of transfer box (calibration)
 Remove front propeller shaft.

 Replace OUTPUT FLANGE for front axle output.
 Replace RADIAL SHAFT SEAL for output front axle.
2611 PROPELLER SHAFT ASSEMBLY

26 11... OVERVIEW OF PROPELLER SHAFT
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Fig. 3: Overview Of Propeller Shaft

26 12 001 REPLACING COMPLETE PROPELLER SHAFT CENTER MOUNT
 Remove PROPELLER SHAFT .
NOTE: The propeller shaft is balanced. The front and rear propeller shafts must be
reassembled in the same position.
Detach gaiter (1) from groove (2).
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Mark front propeller shaft (3) and rear propeller shaft (4) in one plane.
Installation:
Make sure gaiter (1) is securely seated in groove (2).
Fig. 4: Marking Front Propeller Shaft And Rear Propeller Shaft In One Plane
Pull propeller shaft apart.
Fig. 5: Pulling Propeller Shaft Apart

Installation:
If necessary, insert new clamping ring (1) into front propeller shaft (2).
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Fig. 6: Identifying Front Propeller Shaft With Clamping Ring

Release gaiter (1) with screwdriver from groove (2) and pull off over longitudinal splines.
Installation:
Apply a coating of grease to longitudinal splines on shaft.
Push gaiter (1) during installation into groove (2) and make sure it is firmly seated.
Observe markings and force front propeller shaft onto longitudinal splines (markings must be flush).
Fig. 7: Identifying Gaiter And Groove

Install special tool 00 7 500 between center mount (1) and universal joint (2).
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Fig. 8: Installing Special Tool 00 7 500 Between Centre Mount And Universal Joint
Using a hydraulic press, force center mount (1) off propeller shaft (2).
Fig. 9: Pressing Centre Mount Of Propeller Shaft Using Hydraulic Press

Force new center mount (1) onto propeller shaft. Collar (2) must point in direction of travel towards front
propeller shaft. Drive center mount firmly home with special tool 23 1 160.
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Fig. 10: Driving Centre Mount Onto Propeller Shaft Using Special Tool 23 1 160
26 12 011 REPLACING GROOVED BALL BEARING IN CENTER MOUNT OF PROPELLER SHAFT
 Replace PROPELLER SHAFT CENTRE MOUNT
Press grooved ball bearing using special tool 23 1 160 out of center mount (1).
NOTE: Illustration shows E46.
Fig. 11: Pressing Grooved Ball Bearing Using Special Tool 23 1 160 Out Of Centre Mount
Coat rubber-coated bearing seat of center mount (2) with Circolight.
Circolight, refer to BMW Parts Service.
Use special tools 33 3 202/33 3 203 to press deep groove ball bearing (1) into center mount (2).
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NOTE: Illustration shows E46.
Fig. 12: Pressing Deep Groove Ball Bearing Into Centre Mount Using Special Tools 33 3 202/33 3 203
26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT (FLEXIBLE DISC AT

REAR)
IMPORTANT:  With four-wheel drive and on renewal only:
according to installation with BMW diagnosis and information system

under control unit function
Perform functional check of transfer box (calibration)
 Remove assembly underside protection with brackets

 Remove complete exhaust system. See 18 00 020 REMOVING AND INSTALLING/REPLACING
COMPLETE EXHAUST SYSTEM (N52/ N52K/ N51)
 Remove heat shields.
Release screws.
Installation
 Replace ZNS bolts and self-locking nuts.

 Grip mounting bolts of flexible disc at nuts and tighten down by way of bolts.
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Fig. 13: Identifying Flexible Disc Mounting Bolts

Tighten down screws/bolts to specified torque.
Secure angle-of-rotation special tool 00 9 120 with magnets 00 9 130 to vehicle underbody and screw down
further according to angle of rotation.
Tightening torque: 26 11 1AZ .
Fig. 14: Securing Angle-Of-Rotation Using Special Tool 00 9 120 With Magnets 00 9 130
Release flexible disc screws at rear.

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Installation:
Replace ZNS bolts and nuts.
Fig. 15: Identifying Flexible Disc Screws

Tighten down screws/bolts to specified torque.
Secure angle-of-rotation special tool 00 9 120 with magnets 00 9 130 to vehicle underbody and screw down
further according to angle of rotation.
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Fig. 16: Securing Angle-Of-Rotation Using Special Tool 00 9 120 With Magnets 00 9 130
Grip propeller shaft at center mount and release screws.
Detach propeller shaft from transmission output flange and remove towards bottom.
Fig. 17: Identifying Propeller Shaft Centre Mount With Screws

Installation:
Check centering mount.
If necessary, replace damaged CENTRE BEARING.
Grease centering mount.
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Fig. 18: Locating Centering Mount

26 11 090 REMOVING AND INSTALLING/REPLACING FRONT CENTERING MOUNT FOR

PROPELLER SHAFT
 REMOVE PROPELLER SHAFT.
Completely fill centering hole (1) with viscous grease.
Drive special tool 11 1 310 with a plastic hammer into centering hole.
The centering mount (1) is forced out of the propeller shaft by the pressure on the grease filling.
If necessary, top up grease repeatedly.
NOTE: To drive out the mount, you can also fill the centering bore with water instead of
grease.
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Fig. 19: Driving Special Tool 11 1 310 Using Plastic Hammer Into Centering Hole
Installation:
Remove grease/water from mount bore.
Drive in centering mount (1) with special tools 11 2 030 and 00 5 500 into propeller shaft (observe protrusion).
Grease centering mount.
 Grease: BMW Service.
Fig. 20: Installing Centering Mount Using Special Tools 11 2 030 And 00 5 500 Into Propeller Shaft
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Installation
Observe protrusion A = 4+2 mm of centering (1).

26 11 090 REMOVING AND INSTALLING/REPLACING REAR CENTERING MOUNT FOR

PROPELLER SHAFT
 REMOVE PROPELLER SHAFT.
Completely fill centering bore (1) with viscous grease.
Drive special tool 11 1 310 with a plastic hammer into centering bore.
The centering mount (1) is forced out of the propeller shaft by the pressure on the grease filling.
If necessary, top up grease repeatedly.
NOTE: To drive out the mount, you can also fill the centering bore with water instead of
grease.
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Fig. 22: Driving Special Tool 11 1 310 Using Plastic Hammer Into Centering Bore
Installation:
The grease or water must be removed from the bearing bore.
Drive in centering mount (1) with special tools 11 2 030 and 00 5 500 into propeller shaft (observe protrusion).
IMPORTANT: Plastic centering mount must not be greased.
Fig. 23: Installing Centering Mount Using Special Tools 11 2 030 And 00 5 500 Into Propeller Shaft
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Installation
Observe protrusion A = 4+2 mm of centering (1).

26 11 020 REPLACING CENTER MOUNT GAITER
 Remove PROPELLER SHAFT .
NOTE: The propeller shaft is balanced. The front and rear propeller shafts must be
reassembled in the same position.
Detach gaiter (1) from groove (2).
Mark front propeller shaft (3) and rear propeller shaft (4) in one plane.
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Fig. 25: Marking Front Propeller Shaft And Rear Propeller Shaft In One Plane
Pull propeller shaft apart.
Fig. 26: Pulling Propeller Shaft Apart

Installation:
If necessary, insert new clamping ring (1) into front propeller shaft (2).
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Fig. 27: Identifying Front Propeller Shaft With Clamping Ring

Release gaiter (1) with screwdriver from groove (2) and pull off over longitudinal splines.
Installation:
Apply an even coating of grease to longitudinal splines on shaft.
Observe markings and force front propeller shaft onto longitudinal splines (markings must be flush).
Push gaiter (1) during installation into groove (2) and make sure it is firmly seated.
Fig. 28: Identifying Gaiter And Groove

26 11 051 REPLACING FLEXIBLE DISC FOR FRONT PROPELLER SHAFT
 Remove PROPELLER SHAFT from transmission and center bearing
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NOTE: To protect universal joints, tie back propeller shaft in area of center mount.
Release screws and remove flexible disc (1) from propeller shaft.
IMPORTANT: Replace shiny ZNS bolts and self-locking nuts.
Tightening torque and angle of rotation: 26 11 1AZ .
Fig. 29: Locating Flexible Disc Screws

Installation
 Arrows (3) on circumference of flexible disc must point to flange arms (2).
 Grip mounting bolts of flexible disc at propeller shaft flange at nuts and tighten down at bolt heads.
Installation:
Check centering mount.
Replace damaged CENTERING MOUNT .
GREASE CENTERING MOUNT.
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Fig. 30: Locating Centering Mount

26 11 052 REPLACING FLEXIBLE DISC FOR REAR PROPELLER SHAFT
 Remove PROPELLER SHAFT from rear axle final drive and center mount
NOTE: To protect universal joints, tie back propeller shaft in area of center mount.
Release screws and remove flexible disc (1) from propeller shaft.
IMPORTANT: Replace shiny ZNS bolts and self-locking nuts.
Tightening torque and angle of rotation: 26 11 1AZ .
Installation
 Arrows (3) on circumference of flexible disc must point to flange arms (2).
 Grip mounting bolts of flexible disc at propeller shaft flange at nuts and tighten down at bolt heads.
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Fig. 31: Identifying Flexible Disc With Mounting Bolts

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2008 BMW 328xi
2006 SUSPENSION Rear Axle - Repair Instructions - 325xi
2006 SUSPENSION
Rear Axle - Repair Instructions - 325xi
00 GENERAL
 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
Danger of injury!
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2008 BMW 328xi
 Impaired sight

First aid measures:
WARNING: 00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH

THE SKIN
Recycling:
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contact points.
necessary.
Fig. 1: Identifying Rubber Plate On Trolley Jack

points!

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Fig. 2: Identifying Side Car Jacking Point, Rear Differential & Reinforcement Strut

33 .. . REAR AXLE LAYOUT
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Fig. 4: Identifying Rear Axle Carrier, Arm & Wheel Bearing

Facts:
E32, E34, E38, E39 : In the case of rear spring struts with ride-height control, there is always a slight oil
spillage on the piston rod. These spring struts are permitted to be wet with oil over a maximum of half the shock
absorber length on the outer tube, i.e. they are permitted to "sweat".
Consequence:
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Procedure:
33 00 ... INSTRUCTIONS (CHASSIS COMPONENTS MADE OF ALUMINUM)

bristles!
 Do not expose to temperatures > 80°C, even for brief periods! Temperatures in paint facilities do not have
the same impact
33 00 ... NOTES ON REPAIRING THREADS
IMPORTANT: Install Heli-coil thread inserts so that they are flush with the original thread.
NOTE: Damaged threads in the frame side member may be repaired with Heli-coil
thread inserts. Comply with the procedure described in the example. See 31
00 ... NOTES ON REPAIRING THREADS
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Fig. 5: Identifying Spring

33 00 ... REAR AXLE: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER
THE FOLLOWING WORK
Fig. 6: Identifying Rear Axle Carrier, Guide Arm & Control Arm
A 32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE must be carried out after the
following work:

 Camber arm to rear axle carrier/wheel carrier
 Trailing arm to rear axle carrier/wheel carrier
 Guide arm to rear axle carrier
 Toe arm to rear axle carrier/wheel carrier
 Control arm to rear axle carrier

1. Rear axle carrier
2. Camber arm/rubber mount/ball joint
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3. Trailing arm/rubber mount

4. Guide arm
5. Wheel carrier/rubber mount/ball joint
6. Toe arm
7. Control arm
33 10 ... OVERVIEW OF REAR DIFFERENTIAL/OUTPUT SHAFTS
Fig. 7: Identifying Rear Differential, Output Shaft & Output Shaft Gaiters
33 31 ... OVERVIEW OF REAR AXLE CARRIER WITH RUBBER MOUNTS
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Fig. 8: Identifying Rear Axle Carrier Rubber Mount, Rear Axle Carrier & Differential Rubber Mount
33 32 ... OVERVIEW OF STEERING LINKS
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Fig. 9: Identifying Trailing Arm, Traction Arm & Toe Arm

10 FINAL DRIVE
33 10 ... REAR DIFFERENTIAL: ASSIGNMENT TO MODEL SERIES
REAR DIFFERENTIAL SPECIFICATION

Model series Engine Rear differential
E81 N43, N46 168L
N47, N52 188L/188LW
E87 N45, N46, M47T2 (118d) 168L
M47T2 (120d), N52 (130i) 188L/188LW
E90 N46, N45, N52 (323i) 168L
N51, N52 (325i/xi, 328i/xi, 188L/188LW
330i/xi), M47T2, M57T2 (325d)
N54, M57T2 (330d, 335d) 215L/215LW
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E91 N46, N52 (323i) 168L

N52 (325i/xi, 328i/xi, 330i/xi), 188L/188LW
M47T2, M57T2 (325d)
N54, M57T2 (330d, 335d) 215L/215LW
E92 N51, N52 188L/188LW
N54, M57T2 (330d, 335d) 215L/215LW
E93 N51, N52, N53 188L/188LW
N54 215L/215LW
L Light-running
LW Light-running, efficiency-optimized
33 10 ... REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER
Variant A:
Release screw (1).
Tightening torque 33 17 2AZ. See 33 17 REAR AXLE DIFFERENTIAL MOUNTINGS
Remove vibration damper (2).
Fig. 10: Identifying Vibration Damper & Screw

Variant B:
Release bolt (1) and remove vibration damper (2).
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Fig. 11: Identifying Vibration Damper & Bolt

Variant C:
NOTE: Removal depicted on left vibration damper.
Release bolt (1) and remove vibration damper (2).
Fig. 12: Identifying Left Vibration Damper & Bolt

33 10 010 REMOVING AND INSTALLING/REPLACING REAR DIFFERENTIAL
 33 4 420
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IMPORTANT: Use only approved rear differential oils!
NOTE: The following sequence was created using the E87 with N45 as an example.
Differences in detail (e.g. due to vibration damper) in other engines are
possible. See 33 10 ... REMOVING AND INSTALLING/REPLACING VIBRATION
DAMPER
 Remove propeller shaft from rear differential. See 26 11 000 REMOVING AND INSTALLING
PROPELLER SHAFT (CARDAN UNIVERSAL JOINT) COMPLETELY
 Remove output shaft from rear differential at both ends and tie back. See 33 21 001 REMOVING AND
INSTALLING OR REPLACING LEFT OUTPUT SHAFT and/or 33 21 002 REMOVING AND
INSTALLING/REPLACING RIGHT OUTPUT SHAFT

IMPORTANT: Observe gap between special tool 33 4 420 SUPPORT and dust plates.
To avoid grinding noises, make sure the dust plates are not damaged (e.g.
bent).
Support rear differential with workshop jack and special tool 33 4 420 SUPPORT .
Release screws (1).
Release nut (2) and remove screw towards rear.
Slowly lower workshop jack and remove rear differential towards rear.
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IMPORTANT: Adhere to the following installation sequence in order to prevent distortion of

the rear differential during installation and thereby avoid potential complaints
about noise.
Installation sequence:
1. Install rear differential with workshop jack and special tool 33 4 420 SUPPORT .
2. Insert bolts (1) (do not tighten down)
3. Insert screw from rear and replace nut (2) (do not tighten down)
4. Lower workshop jack
5. Tighten screws (1)
Fig. 14: Identifying Special Toll (33 4 420)

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6. Tighten nut (2)
After installation:
 Check rear differential oil level, correct if necessary. See 00 11 ... CHECKING/TOPPING UP OIL
LEVEL IN REAR DIFFERENTIAL
11 FINAL DRIVE WITH COVER

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (168L)
IMPORTANT: To avoid leaks from the rear differential cover, do not use a paper gasket in
cars with liquid gaskets!
To prevent the differential oil from foaming over, make sure that no remnants
of the liquid gasket are pressed into the rear differential housing.
Release screws (1).
Tightening torque (M10x60) 33 11 1AZ. See 33 11 REAR DIFFERENTIAL CASE WITH COVER
Unscrew screws (2).
Remove cover.
If necessary, remove remnants of liquid gasket with scraper.
Clean sealing face on cover and rear differential.
Installation:
If a paper gasket was fitted, a paper or liquid gasket can be used.
The liquid gasket can be found in Main Group 33 in the Electronic Parts Catalog.
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Fig. 15: Identifying Differential Cover Screw

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (188L/188LW)
Release screws (1).
Unscrew screws (2).
Remove cover.
Installation:
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Fig. 16: Identifying Rear Differential Housing Screw

33 11 ... REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL (215L/215LW)
Unscrew screws (1) and (2).
Remove cover.
Installation:
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Fig. 17: Identifying Rear Differential Housing Cover Screw

33 11 021 REPLACING SHAFT SEAL FOR INPUT FLANGE ON FINAL DRIVE
 00 5 010
 00 5 500
 23 0 020
 23 1 300
 23 1 302
 23 1 303
 31 2 101
 31 2 102
 31 2 103
 31 2 104
 33 1 150
 33 1 341
 33 3 390
 33 3 440
 33 3 470
 33 3 480
 33 3 490
IMPORTANT: Use only approved gear oils.
Failure to comply with this instruction will result in serious damage to the rear
differential!
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 Remove propeller shaft from rear differential drive flange, remove complete propeller shaft is necessary.
See 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL
JOINT) COMPLETELY
Removing drive flange:
Lift out retaining plate.
Mark position of collar nut (1) on drive shaft with peening tool.
Fig. 18: Marking Position Of Collar Nut On Drive Shaft

Brace drive flange with special tool 23 0 020 HOLDER and release collar nut.
Fig. 19: Releasing Collar Nut With Special Tool (23 0 020)
NOTE: Read and comply with 33 10 ... REAR DIFFERENTIAL: ASSIGNMENT TO MODEL
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SERIES.
215L:
Remove drive flange with special tools 31 2 101, 31 2 102, 31 2 103/31 2 104.
Fig. 20: Identifying Special Tools (31 2 101), (31 2 102), (31 2 103) & (31 2 104)
168L, 188L:
Remove drive flange with special tool 33 1 150 FIXTURE .
Fig. 21: Removing Drive Flange With Special Tool (33 1 150)
Replacing shaft seal:
Withdraw shaft seal with special tool 00 5 010 UNIVERSAL PULLER .
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Drive in new shaft seal with following special tools (depending on rear differential) as far as it will go.
 168L: Use special tools 00 5 500 HANDLE FOR DRIFTS and 33 3 390 DRIFT
Fig. 23: Identifying Special Tool (00 5 500), (33 3 390) & (33 3 470)
Installing drive flange:
Coat sealing lips of shaft seal and sealing surface of drive flange with differential oil.
Fit drive flange.
Press on drive flange with special tools 23 1 300 FIXTURE , 33 1 341 and 23 1 303, if necessary 23 1 302 until
collar nut can be screwed on.
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Fig. 24: Identifying Special Tools (23 1 300), (33 1 341) & (23 1 303)
IMPORTANT: Do not under any circumstances tighten down collar nut beyond marker points
in order to avoid damaging the clamping sleeve.
Tighten down collar nut (1) to point where marker points are aligned.
Fig. 25: Identifying Down Collar Nut To Point Marker Points

Drive in new retaining plate with following special tools (depending on rear differential) as far as it will go.
 168L, 188L: Use special tools 00 5 500 HANDLE FOR DRIFTS and 33 3 480 DRIFT
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After installation:
 Correct rear differential fluid level. See 00 11 ... CHECKING/TOPPING UP OIL LEVEL IN REAR
DIFFERENTIAL
33 11 091 REPLACING DRIVE FLANGE ON LEFT OR RIGHT OF REAR DIFFERENTIAL
WARNING: Risk of burning on the exhaust system!
IMPORTANT: When replacing the drive flange, you must also replace the shaft seal! See 33
11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
 Remove output shaft from rear differential and tie back. See 33 21 001 REMOVING AND
INSTALLING OR REPLACING LEFT OUTPUT SHAFT and/or 33 21 002 REMOVING AND
Using a suitable screwdriver and a hammer (acting as a rest), force drive flange (1) off rear differential.
Installation:
Replaced deformed or damaged dust plates.
Insert drive flange and rotate until spline on flange meshes with teeth on differential bevel gear.
Press drive flange in further until circlip locates with an audible click.
IMPORTANT: High installation forces indicate that the spline teeth on the drive
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flange/differential bevel gear are damaged/deformed!

Fig. 27: Identifying Drive Flange Off Rear Differential

Install retaining ring (1).
Installation:
Clean shaft seal race on drive flange thoroughly.
Coat drive flange at contact face of shaft seal with approved rear differential oil.

Replacement:
Replace shaft seal. See 33 11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
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After installation:
 Check rear differential oil level, correct if necessary. See 00 11 ... CHECKING/TOPPING UP OIL
LEVEL IN REAR DIFFERENTIAL
33 11 151 REPLACING SHAFT SEAL FOR DRIVE FLANGE LEFT OR RIGHT
 00 5 010
 00 5 500
 32 1 060
 33 1 308
 33 3 400
 33 4 240
 33 4 250
 33 5 030
 Remove drive flange from rear differential. See 33 11 091 REPLACING DRIVE FLANGE ON LEFT
OR RIGHT OF REAR DIFFERENTIAL
 If necessary, press off dust cover
Withdraw shaft seal with special tools 00 5 010 UNIVERSAL PULLER and 32 1 060 DRIFT /33 1 308.
Coat housing plate flange and sealing lips of new shaft seal with approved rear differential oil.
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Drive in new shaft seal as far as it will go with following special tool(s) (depending on rear differential/outside
diameter).
00 5 500 HANDLE FOR DRIFTS + 33 3 400 DRIFT : 168K/L - 78x44x10
00 5 500 HANDLE FOR DRIFTS + 33 4 240 DRIFT : 188K/L/LW - 90x44x10
00 5 500 HANDLE FOR DRIFTS + 33 4 250 DRIFT : 215K/L/LW, 220K to 230K - 100x50x10
33 5 030: 210, 215 with lock - 76x50x10
After installation:
 Correct gearbox oil level/change differential oil. See 00 11 ... CHECKING/TOPPING UP OIL LEVEL
IN REAR DIFFERENTIAL and/or 00 11 259 OIL CHANGE IN REAR DIFFERENTIAL INCL.
USED OIL DISPOSAL
33 11 271 REPLACING REAR COVER GASKET ON REAR DIFFERENTIAL
IMPORTANT: In event of oil loss, always check rear differential for traces of wear and
damage.
 Draw off rear differential oil. See 00 11 259 OIL CHANGE IN REAR DIFFERENTIAL INCL.
USED OIL DISPOSAL
 Remove rear differential. See 33 10 010 REMOVING AND INSTALLING/REPLACING REAR
DIFFERENTIAL
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NOTE: Read and comply with 33 10 ... REAR DIFFERENTIAL: ASSIGNMENT TO MODEL
SERIES.
Select rear differential:
 168L
 188L/188LW
 215L/215LW
After installation:
 Add rear differential oil. See 00 11 259 OIL CHANGE IN REAR DIFFERENTIAL INCL. USED
OIL DISPOSAL
17 FINAL DRIVE MOUNTING

33 17 004 REPLACING ALL FRONT RUBBER MOUNTS FOR REAR DIFFERENTIAL MOUNTING
 33 3 312
 33 4 161
 33 4 162
 33 4 166
 33 4 311
 33 4 312
 33 4 465
 33 4 466

DIFFERENTIAL
Withdrawing front rubber mount:
Withdraw front rubber mount with special tools 33 3 312, 33 4 161, 33 4 162, 33 4 466 and 33 4 465.
NOTE: Milled recess of special tool 33 4 161 must point upwards to rear axle carrier.
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Fig. 31: Identifying Special Tools 33 3 312, 33 4 161, 33 4 162, 33 4 466 And 33 4 465
Installing front rubber mount:
IMPORTANT: Coat bearing bushing in rear axle carrier and front rubber mount with Circolight
(refer to BMW Parts Service).
Front rubber mount must be aligned by way of slots (1) to vehicle transversal direction.
Fig. 32: Identifying Front Rubber Mount Of Slots

Insert front rubber mount in special tool 33 4 311.
Align front rubber mount so that side slots (1) line up with marking (M) on tool.
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Fig. 33: Identifying Front Rubber Mount Special Tool (33 4 311)
Draw in front rubber mount with special tools 33 4 465, 33 4 466, 33 4 166, 33 4 311 and 33 4 312 as far as it
will go.
33 17 005 REPLACING RUBBER MOUNT FOR REAR DIFFERENTIAL MOUNTING AT REAR

DIFFERENTIAL
IMPORTANT: Rubber mounts must not be mixed up!
A. = Remove rubber mount.

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B. = Remove rubber mount (with hydraulic damping).
Fig. 35: Identifying Rubber Mount

21 OUTPUT SHAFTS
33 21 ... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE AND DRAWING IN (OUTPUT
SHAFT REMOVED FROM REAR DIFFERENTIAL)
 33 2 111
 33 2 115
 33 2 116
 33 2 117
 33 2 118
 33 2 119
 33 2 160
 33 2 201
 33 2 202
 33 2 203
 33 2 205
 33 2 206
 33 2 207
 33 5 070
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the output shaft.
IMPORTANT: To avoid damaging the dust sleeve, use special tool 33 2 160 SPACER RING to
press out and draw in the output shaft after removing the brake disk.
NOTE: Rounded inside edge of special tool 33 2 160 SPACER RING must point to drive
flange.

Secure output shaft against falling out.
Screw on special tool 33 2 203, 33 2 207 and 33 2 201 with all wheel studs to drive flange.
070 EXTENSION PIECE (2) .
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Screw special tool 33 2 205/33 2 206 onto output shaft.
Fig. 38: Identifying Special Tool (33 2 205) & (33 2 206)
Mount special tool 33 2 201 with three wheel studs to drive flange.
tools 33 2 202 and 33 5 070 EXTENSION PIECE (2) .
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Secure output shaft against falling out.
Screw on special tool 33 2 111, 33 2 117 and 33 2 116 with all wheel studs to drive flange.
070 EXTENSION PIECE (2) .

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Screw special tool 33 2 118/33 2 119 onto output shaft.
Mount special tool 33 2 116 with three wheel studs to drive flange.
tools 33 2 202 and 33 5 070 EXTENSION PIECE (2) .
33 21 ... RIBBED TEETH
IMPORTANT: Bolts with ribbed teeth must be replaced after they have been released!
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Fig. 43: Identifying Ribbed Teeth

33 21 001 REMOVING AND INSTALLING OR REPLACING LEFT OUTPUT SHAFT
WARNING: Risk of burning on the exhaust system!
 Remove tension strut if necessary.

 Lower exhaust system in rear area. See 18 00 020 REMOVING AND INSTALLING/REPLACING
COMPLETE EXHAUST SYSTEM (N52/N52K/N51)
The subsequent procedure is described in 33 21 002 REMOVING AND INSTALLING/REPLACING

RIGHT OUTPUT SHAFT.
33 21 002 REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT
Remove rear wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
collar nut.
Release collar nut (1), activate handbrake for this purpose.
Installation:
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Tightening torque 33 41 1AZ. See 33 41 WHEEL BEARINGS
Fig. 44: Releasing Collar Nut

Remove tension strut if necessary.
Release bolts and remove with washers (1).
Press output shaft off drive flange using a suitable tool; if necessary, raise wheel carrier with workshop jack
approx. 20 mm. See 33 21 ... PRESSING OUTPUT SHAFT OUT OF DRIVE FLANGE AND DRAWING
IN (OUTPUT SHAFT REMOVED FROM REAR DIFFERENTIAL)
Installation:
Before installing output shaft, make sure that drive flange is fully engaged in rear differential.
Replace bolts and washers (1).
Tightening torque 33 21 1AZ. See 33 21 OUTPUT SHAFT
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Fig. 45: Releasing Bolts & Washers

Press output shaft out of drive flange and remove towards center of vehicle.
After installation:
 Check that output shaft is correctly seated in rear differential.
33 21 035 REPLACING GAITER ON LEFT OUTPUT SHAFT (ALTERED SEALING COVER)
 21 2 120
 26 1 110
 33 2 100
 Remove output shaft. See 33 21 001 REMOVING AND INSTALLING OR REPLACING LEFT
OUTPUT SHAFT and/or 33 21 002 REMOVING AND INSTALLING/REPLACING RIGHT
OUTPUT SHAFT
Removing inner gaiter:
Clean output shaft and clamp with a cloth in vice.
Using a suitable tool, force gaiter cap (2) off joint or sealing cover.
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Fig. 46: Identifying Gaiter Cap And Hose Clip

Push back gaiter with cap.
Make sure that joint does not fall apart.
Clamp joint (1) in vice.
Using a suitable tool, force sealing cover (2) off joint (1).
Fig. 47: Identifying Sealing Cover And Off Joint

IMPORTANT: Mark positions in relation to each other of ball hub, ball cage and joint at ends.
NOTE: If the joint falls apart, it can only be reassembled correctly with the aid of the
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markings.
Fig. 48: Marking Positions Of Ball Hub

Remove circlip (1).
Fig. 49: Identifying Circlip

Grip output shaft.
Using special tool 26 1 110 REMOVAL DISK and a suitable tool (for hollow shaft 21 2 120 DRIFT ), press
output shaft out of joint (1).
Clean joint (1) carefully.
NOTE: All traces off old grease must be removed.
Detach gaiter from output shaft.

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Removing and installing outer gaiter:
Release hose clamps (1, 3) and detach gaiter (2) from output shaft.
Clean joint and output shaft carefully.
NOTE: All traces off old grease must be removed.
Check joint for damage; if necessary, replace output shaft. See 33 21 001 REMOVING AND INSTALLING
OR REPLACING LEFT OUTPUT SHAFT and/or 33 21 002 REMOVING AND
Fill joint with propeller shaft grease.
Fit gaiter (2) on bellows and secure with hose clamps (1, 3).
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Fig. 51: Identifying Gaiter & Hose Clamps

Installing inner gaiter:
Push gaiter with cap onto output shaft (1).
Mount special tool 33 2 100 CLAMPING FIXTURE with corresponding shell inserts on output shaft (1).
Press joint (2) over bearing inner race onto output shaft.
Fig. 52: Identifying Special Tool (33 2 100) On Output Shaft

Fig. 53: Identifying Circlip

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IMPORTANT: Keep sealing faces of cap and joint (on both sides) clean and free from grease.
Fill joint at both ends with high-temperature grease.
Fig. 54: Identifying Sealing Faces Of Cap & Joint


Do not install gaiter with cap and sealing cover on joint without shims.
Apply a thin coating of sealing compound to sealing faces of sealing cover and cap.
Install sealing cover (1) with two bolts, shims and nuts on joint.
Fig. 55: Identifying Sealing Cover With Two Bolts

Install cap (1) with two bolts, shims and nuts on joint.
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Fit hose clamp (2).
Fig. 56: Identifying Hose Clamp

33 21 036 REPLACING GAITER ON RIGHT OUTPUT SHAFT
Procedure is described in REPLACING GAITER ON LEFT OUTPUT SHAFT.
31 REAR SUB FRAME

33 31 000 REMOVING AND INSTALLING COMPLETE REAR AXLE CARRIER
 00 2 040
 33 3 274
 33 4 491
 33 4 492
 Remove rear wheels. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
 Remove propeller shaft. See 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT
(CARDAN UNIVERSAL JOINT) COMPLETELY
 Remove both rear coil springs. See 33 53 000 REMOVING AND INSTALLING/REPLACING
REAR LEFT OR RIGHT COIL SPRING
 Remove pulse generator on both sides from wheel carrier, unclip line from control arm and rear axle
carrier. See 34 52 535 REPLACING A REAR PULSE GENERATOR
 Disconnect plug connection from brake pad sensor, unclip line from control arm and rear axle carrier. See
34 35 001 REPLACING A BRAKE LINING SENSOR
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 Disconnect plug connection from ride-height sensor and unclip line from rear axle carrier
 Disengage handbrake cable on both sides from expander lock and then remove from hanging hooks. See
34 41 120 REMOVING AND INSTALLING OR REPLACING BOTH HANDBRAKE BOWDEN
CABLES
 Remove shock absorber on both sides from camber arm rubber mount. See 33 52 000 REMOVING
AND INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER
IMPORTANT: To prevent brake fluid from escaping from the expansion tank when the brake
lines are opened, do not remove the pedal support until the brake lines have
been reconnected.
Fig. 57: Locating Clutch Pedal To Floor & Pedal Support

Position an oil tray underneath to catch brake fluid.
Release banjo bolts (1), gripping brake hoses (2) at square head in the process.
Disconnect brake hoses (2) and seal off with plugs.
Installation:
Make sure brake hoses are laid without tension and with sufficient spacing to adjoining components.
Tightening torque 34 32 1AZ.
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Fig. 58: Identifying Banjo Bolts & Brake Hoses


Insert special tools 33 4 491 and 33 4 492 into corresponding receptacle of special tool 00 2 040.
Align special tool 00 2 040 BASIC TAKE-UP FIXTURE to rear axle carrier.
If necessary, lower special tool 33 3 274.
Support rear axle carrier by raising special tool 00 2 040 BASIC TAKE-UP FIXTURE
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Remove tension struts.
Release screws (1) and swivel/remove stop plates (2) to one side.
Lower rear axle completely.
Installation:
Check threads for damage; if necessary, repair with Heli-coil thread inserts. See 33 00 ... NOTES ON
REPAIRING THREADS
First install tension struts and then tighten down bolts (1).
Tightening torque 33 33 1AZ. See 33 33 REAR AXLE SUSPENSION
Fig. 60: Identifying Stop Plate & Screw

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After installation:
 Bleed braking system. See 34 00 050 BLEEDING BRAKE SYSTEM WITH DSC
 Adjusting handbrake. See 34 10 014 ADJUSTING HANDBRAKE
IMPORTANT: If the pedal support is removed or slips before the brake lines are connected, it
will be necessary to bleed the brake system at front and rear!
33 31 011 REPLACING REAR AXLE CARRIER

DIFFERENTIAL
 Remove complete rear axle carrier. See 33 31 000 REMOVING AND INSTALLING COMPLETE
REAR AXLE CARRIER
Remove brake discs (disconnect brake hose from brake line). See 34 21 320 REMOVING AND
INSTALLING OR REPLACING BOTH REAR BRAKE DISCS
Remove brake lines from rear axle carrier.
Remove stabilizer bar (remove stabilizer links from wheel carrier). See 33 55 000 REMOVING AND
INSTALLING/REPLACING REAR STABILIZER
Remove ride-height sensor with bracket. See 37 14 512 REPLACING REAR RIDE-HEIGHT SENSOR
Fig. 61: Identifying Brake Lines From Rear Axle Carrier

Remove camber arm on both sides from rear axle carrier. See 33 32 190 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT CAMBER ARM
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Remove toe arm on both sides from rear axle carrier. See 33 32 180 REMOVING AND
INSTALLING/REPLACING LEFT OR RIGHT TOE ARM
Remove trailing arm on both sides from rear axle carrier. See 33 32 021 REPLACING LEFT OR RIGHT
TRAILING ARM
Remove guide arm on both sides from rear axle carrier. See 33 32 091 REPLACING A GUIDE ARM
Remove control arm on both sides from rear axle carrier. See 33 32 071 REPLACING ONE UPPER
CONTROL ARM
Remove wheel carrier on both sides with output shaft and all suspension arms.
Fig. 62: Identifying Wheel Carrier On Both Sides With Output Shaft & Suspension Arms
After installation:
 Bleed brakes. See 34 00 050 BLEEDING BRAKE SYSTEM WITH DSC

 Adjusting handbrake. See 34 10 014 ADJUSTING HANDBRAKE
PROCEDURE
33 31 503 LOWERING/RAISING REAR AXLE CARRIER
 00 2 040
 33 3 274
CARMANUALSUSA
2008 BMW 328xi
 33 4 491
 33 4 492
cooled down.
 E91, E92, E93: Remove tension strut.
IMPORTANT: To prevent brake fluid from escaping from the expansion tank when the brake
lines are opened, do not remove the pedal support until the brake lines have
been reconnected.
Fig. 63: Locating Clutch Pedal To Floor And Pedal Support

Position an oil tray underneath to catch brake fluid.
Release banjo bolts (1), gripping brake hoses (2) at square head in the process.
Disconnect brake hoses (2) and seal off with plugs.
Installation:
Make sure brake hoses are laid without tension and with sufficient spacing to adjoining components.
CARMANUALSUSA
2008 BMW 328xi
Tightening torque 34 32 1AZ. See 34 32 BRAKE LINES
Fig. 64: Identifying Banjo Bolts And Brake Hoses

Unclip cables for pulse generator and ride-height sensor/brake pad sensor on rear axle carrier at side.
Unscrew nut (1).
Turn bracket (2) for exhaust system towards rear.
Unscrew heat shield.
Fig. 65: Locating Bracket For Exhaust System & Nut

CARMANUALSUSA
2008 BMW 328xi

Insert special tools 33 4 491 and 33 4 492 into corresponding receptacle of special tool 00 2 040 BASIC
TAKE-UP FIXTURE .
Align special tool 00 2 040 BASIC TAKE-UP FIXTURE to rear axle carrier.
If necessary, lower special tool 33 3 274.
Support rear axle carrier by raising special tool 00 2 040 BASIC TAKE-UP FIXTURE .
Remove tension struts.
Release screws (1) and swivel/remove stop plates (2) to one side.
Lower rear axle carrier.
Installation:
Check threads for damage; if necessary, repair with Heli-coil thread inserts. See 33 00 ... NOTES ON
REPAIRING THREADS
First install tension struts and then tighten down bolts (1).
CARMANUALSUSA
2008 BMW 328xi
Fig. 67: Identifying Stop Plate & Screw

After installation:
32 CONTROL ARMS AND STRUTS

33 32 021 REPLACING LEFT OR RIGHT TRAILING ARM
NOTE: If the trailing arm is detached from the rear axle carrier/wheel carrier, it is
necessary after reinstallation to carry out a wheel/chassis alignment check.
Release nuts (1, 3).
Unscrew bolts.
Remove trailing arm (2) downwards.
Installation:
NOTE: Note insertion direction of bolts.
Tightening torque (on rear axle carrier) 33 32 1AZ. See 33 32 CONTROL ARMS AND STRUTS
CARMANUALSUSA
2008 BMW 328xi
Tightening torque (on wheel carrier) 33 32 2AZ. See 33 32 CONTROL ARMS AND STRUTS
Fig. 68: Identifying Trailing Arm & Nuts

After installation:

PROCEDURE
33 32 031 REPLACING RUBBER MOUNT FOR TRAILING ARM IN WHEEL CARRIER
 33 4 450
 33 4 451
 33 4 452
 33 4 453
 33 4 454
 33 4 465
 33 4 466
 33 4 472
 33 4 473
 33 4 474
 33 4 475
 Remove trailing arm from wheel carrier
Removing rubber mount:

CARMANUALSUSA
2008 BMW 328xi
Pull out rubber mount with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 472.
Installing new rubber mount:
Insert rubber mount with spray-on points facing upwards in special tools 33 4 451, 33 4 452, 33 4 454, 33 4 453
and pull together.
Insert rubber mount in special tool 33 4 473.
IMPORTANT: Spray-on points of rubber mount must point to rear!
Align rubber mount by way of slot (1) at an angle to wheel carrier.
CARMANUALSUSA
2008 BMW 328xi
Fig. 71: Identifying Rubber Mount Of Slot & Angle To Wheel Carrier
Draw rubber mount with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 473 a little into wheel
carrier.
Remove special tool 33 4 450 CLAMPING STRAP and draw in rubber mount as far as it will go.
After installation:
 Carry out wheel/chassis alignment check. See 32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK
PROCEDURE
33 32 035 REPLACING A RUBBER MOUNT FOR TRAILING ARM IN REAR AXLE CARRIER
CARMANUALSUSA
2008 BMW 328xi
 33 4 450
 33 4 451
 33 4 452
 33 4 453
 33 4 454
 33 4 465
 33 4 466
 33 4 471
 33 4 472
 33 4 474
 33 4 475
 Remove trailing arm from rear axle carrier
Mark installation position of rubber mount by way of slot to rear axle carrier.
If necessary, release knurled screws 33 4 452 and pull off mounting 33 4 455 with spring steel 33 4 456.
Insert rubber mount with spray-on points facing upwards in special tools 33 4 451, 33 4 452, 33 4 454, 33 4 453
CARMANUALSUSA
2008 BMW 328xi
and pull together.
IMPORTANT: Coat rubber mount with Loctite 638 prior to installation.
Spray-on points of rubber mount must point to rear!
Align rubber mount by way of slot (1) at an angle to rear axle carrier.
Fig. 75: Identifying Angle To Rear Axle Carrier

Align rubber mount by way of slot to marking on rear axle carrier.
Draw rubber mount a little into rear axle carrier with special tools 33 4 471, 33 4 474, 33 4 475, 33 4 466 and 33
4 465.
CARMANUALSUSA
2008 BMW 328xi
Remove special tool 33 4 450 CLAMPING STRAP
Apply a thin coating of Loctite 638 to new rubber mount.
Draw in rubber mount as far as it will go.
After installation:
 Carry out wheel/chassis alignment check. See 32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK
PROCEDURE
33 32 071 REPLACING ONE UPPER CONTROL ARM
NOTE: If the control arm is detached from the rear axle carrier, it is necessary after
 Remove rear wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
Release screw (1).
Installation:
If necessary, raise brake disc in drive flange area with workshop jack.
Replace screw.
CARMANUALSUSA
2008 BMW 328xi
Fig. 77: Identifying Rear Wheel Screw

IMPORTANT: Make sure during installation that in the connection area to the wheel carrier
the tapered end of the bearing bushing (of the rubber mount) points in the
direction of the wheel carrier.
Fig. 78: Identifying Connection Area To Wheel Carrier Tapered End Of Bearing Bushing
Release nut (1) and remove screw towards front.
Remove lines (3) for pulse generator/brake pad sensor with retaining clips from control arm.
Remove control arm (2).
Installation:
NOTE: Note insertion direction of bolt.

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2008 BMW 328xi
Fig. 79: Identifying Control Arm

After installation:

PROCEDURE
33 32 091 REPLACING A GUIDE ARM
NOTE: If the guide arm is detached from the rear axle carrier, it is necessary after
 Remove stabilizer links on both sides from stabilizer and rotate stabilizer in upward direction. See 33 55
040 REPLACING STABILIZER LINKS FOR STABILIZER
Release screw.
Installation:
If necessary, raise wheel carrier in area of brake caliper by hand.
Replace screw.
CARMANUALSUSA
2008 BMW 328xi
Fig. 80: Locating Wheel Carrier Of Brake Caliper

IMPORTANT: Make sure during installation that in the connection area to the wheel carrier
the tapered end of the bearing bushing (of the rubber mount) points in the
direction of the wheel carrier.
Fig. 81: Identifying Connection Area To Wheel Carrier Tapered End Of Bearing Bushing
Release nut (1) and remove bolt towards rear.
Remove guide arm (2).
Installation:

CARMANUALSUSA
2008 BMW 328xi
Fig. 82: Identifying Guide Arm & Nut

After installation:

PROCEDURE
33 32 125 REPLACING A BALL JOINT IN LOWER STEERING KNUCKLE/WHEEL CARRIER
 33 4 465
 33 4 466
 33 4 474
 33 4 475
 33 4 481
 33 4 482
 Remove coil spring at rear. See 33 53 000 REMOVING AND INSTALLING/REPLACING REAR
LEFT OR RIGHT COIL SPRING
 If necessary, remove jointed rod of ride-height sensor from camber arm bracket
 Remove rear shock absorber from rubber mount. See 33 52 000 REMOVING AND
INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK ABSORBER
 Remove camber arm from wheel carrier. See 33 32 190 REMOVING AND
 Remove trailing arm from wheel carrier. See 33 32 021 REPLACING LEFT OR RIGHT TRAILING
CARMANUALSUSA
2008 BMW 328xi
ARM
Pull out ball joint with special tools 33 4 465, 33 4 466, 33 4 475, 33 4 474 and 33 4 482.
Installation:
Draw in new ball joint with special tools 33 4 481, 33 4 474, 33 4 475, 33 4 466 and 33 4 465 as far as it will
go.
After installation:

PROCEDURE
CARMANUALSUSA
2008 BMW 328xi
33 32 131 REMOVING AND INSTALLING/REPLACING A STEERING KNUCKLE/WHEEL

CARRIER
OUTPUT SHAFT and/or 33 21 002 REMOVING AND INSTALLING/REPLACING RIGHT
OUTPUT SHAFT
REAR BRAKE DISCS
 Replacement only: drive out drive flange for rear axle shaft. See 33 41 005 REPLACING LEFT
DRIVE FLANGE ON REAR AXLE SHAFT and/or 33 41 007 REPLACING RIGHT DRIVE
FLANGE ON REAR AXLE SHAFT
 Disconnect handbrake Bowden cable from expander lock. See 34 41 120 REMOVING AND
INSTALLING OR REPLACING BOTH HANDBRAKE BOWDEN CABLES
 Remove pulse generator from wheel carrier. See 34 52 535 REPLACING A REAR PULSE
GENERATOR
 Remove stabilizer link from wheel carrier
 Remove coil spring. See 33 53 000 REMOVING AND INSTALLING/REPLACING REAR LEFT
OR RIGHT COIL SPRING
 Remove shock absorber from camber arm
 Remove trailing arm from wheel carrier. See 33 32 021 REPLACING LEFT OR RIGHT TRAILING
ARM
 Remove guide arm from wheel carrier. See 33 32 091 REPLACING A GUIDE ARM
 Remove toe arm from wheel carrier. See 33 32 180 REMOVING AND INSTALLING/REPLACING
LEFT OR RIGHT TOE ARM
 Secure wheel carrier against falling out.
 Remove upper control arm from wheel carrier. See 33 32 071 REPLACING ONE UPPER CONTROL
ARM
 Remove camber arm from wheel carrier. See 33 32 190 REMOVING AND
Remove wheel carrier.
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2008 BMW 328xi
Fig. 85: Identifying Wheel Carrier

Replacement:
Modify brake carrier/brake guard plate.
After installation:
 Adjust handbrake. See 34 10 014 ADJUSTING HANDBRAKE

PROCEDURE
33 32 180 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TOE ARM
NOTE: If the toe arm is detached from the rear axle carrier/wheel carrier, it is necessary
Mark position of eccentric screw to rear axle carrier.
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2008 BMW 328xi
Fig. 86: Marking Position Of Eccentric Screw To Rear Axle Carrier

Release screw.
Installation:
If necessary, turn toe arm by hand.
Fig. 87: Locating Rear Axle Screw

Release nut (1) and remove eccentric washer (2).
Pull out eccentric screw and remove toe arm (3).
Installation:
CARMANUALSUSA
2008 BMW 328xi
NOTE: Note insertion direction of eccentric screw.
Align eccentric screw by means of marking to rear axle carrier.
Fit eccentric washer (2).
Replace nut (1).
Fig. 88: Identifying Eccentric Washer, Toe Arm & Nut

After installation:

PROCEDURE
33 32 190 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT CAMBER ARM
cooled down.
NOTE: If the camber arm is detached from the rear axle carrier/wheel carrier, it is
necessary after reinstallation to carry out a wheel/chassis alignment check.
 Remove coil spring at rear. See 33 53 000 REMOVING AND INSTALLING/REPLACING REAR
LEFT OR RIGHT COIL SPRING
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2008 BMW 328xi
 Remove rubber mount for shock absorber mounting on camber arm. See 33 52 031 REPLACING
REAR LEFT OR RIGHT RUBBER MOUNT FOR SHOCK ABSORBER MOUNTING
 Remove jointed rod of ride-height sensor from camber arm bracket
Support wheel carrier with workshop jack.
Mark position of eccentric screw (1) to camber arm.
Replacement only: Carry over marking from old part to new part.
Release nut (2) and remove bolt towards rear.
Installation:
Fig. 89: Marking Position Of Eccentric Screw To Camber Arm

If necessary, remove exhaust system bracket from rear axle carrier. See 18 00 020 REMOVING AND
INSTALLING/REPLACING COMPLETE EXHAUST SYSTEM (N52/N52K/N51)
If necessary, remove rear muffler from body. See 18 00 020 REMOVING AND
INSTALLING/REPLACING COMPLETE EXHAUST SYSTEM (N52/N52K/N51)
Release nut (1) and remove eccentric washer (2).
Pull out eccentric screw and remove camber arm (3).

CARMANUALSUSA
2008 BMW 328xi
Installation:
NOTE: Note insertion direction of eccentric screw.
Align eccentric screw by means of marking to camber arm.
Fit eccentric washer (2).
Replace nut (1).
Fig. 90: Identifying Camber Arm, Eccentric Washer & Nut

Replacement:
Replace lower spring pad (refer to REMOVING AND INSTALLING/REPLACING coil spring).
Release screw (1) and remove bracket (2).
Tightening torque 37 14 4AZ. See 37 14 ELECTRIC COMPONENTS
CARMANUALSUSA
2008 BMW 328xi
Fig. 91: Identifying Lower Spring Pad

After installation:

PROCEDURE
33 32 195 REPLACING RUBBER MOUNT FOR CAMBER ARM IN REAR AXLE CARRIER
 33 4 450
 33 4 451
 33 4 452
 33 4 455
 33 4 456
 33 4 461
 33 4 462
 33 4 463
 33 4 464
 33 4 465
 33 4 466
cooled down.

CARMANUALSUSA
2008 BMW 328xi
 Remove coil spring. See 33 53 000 REMOVING AND INSTALLING/REPLACING REAR LEFT
OR RIGHT COIL SPRING
 Remove camber arm from rear axle carrier. See 33 32 190 REMOVING AND
Pull rubber mount together with special tools 33 4 455, 33 4 456, 33 4 452 and 33 4 451.
CARMANUALSUSA
2008 BMW 328xi
Draw rubber mount into rear axle carrier so that slot (1), rubber mount center point and notch (2) form a line.
Fig. 94: Identifying Rubber Mount Centre Point & Notch Form Line
Draw rubber mount as far as possible into rear axle carrier with special tools 33 4 461, 33 4 463, 33 4 466 and
33 4 465.
Remove special tool 33 4 450 CLAMPING STRAP and draw in rubber mount as far as it will go.
After installation:

PROCEDURE
51 75 001 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY COVER
CARMANUALSUSA
2008 BMW 328xi
Release clips (1).
Remove cover (3).
Installation:
Replace damaged clips.
Make sure underbody cover is correctly seated.
Fig. 96: Identifying Clips, Cover & Screw

33 AXLE MOUNTING
33 33 001 REPLACING LEFT OR RIGHT REAR AXLE CARRIER COMPRESSION STRUT
IMPORTANT: Observe safety instructions for raising the vehicle. See 00 .. ... LIFTING
VEHICLE WITH A LIFTING PLATFORM
Driving without compression struts is not permitted!
Risk of damage!
The rear axle carrier must be supported at the front is both compression struts
have to be replaced!
 Remove underbody cover. See 51 75 001 REMOVING AND INSTALLING/REPLACING LEFT OR
CARMANUALSUSA
2008 BMW 328xi
RIGHT UNDERBODY COVER
Release screws (1).
Installation:
Replace screws.
Release screw (3) and remove compression strut (2).
Installation:
Check threads for damage; if necessary, repair with Heli-coil thread inserts.
Fig. 97: Identifying Compression Strut & Screw

33 33 101 REPLACING TWO RUBBER MOUNTS FOR REAR AXLE CARRIER (RUBBER
MOUNTS, FRONT)
 33 4 140
 33 4 142
 33 4 147
 33 4 149
 33 4 431
 33 4 432
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2008 BMW 328xi
 33 4 433
 33 4 434
 33 4 435
 33 4 436
 33 4 437
 33 4 441
 Lower rear axle carrier
If necessary, assemble special tools 33 4 140 UNIVERSAL SUPPORT , 33 4 142 and 33 4 147.
If necessary, position new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140
UNIVERSAL SUPPORT .
Coat top edge of rubber mount with Circo Light (refer to BMW Parts Service).
Fit special tool 33 4 441 on rubber mount in such a way that edge of rubber mount disappears in special tool.
Oil special tool 33 4 436 slightly before use.
Align special tool 33 4 140 UNIVERSAL SUPPORT by way of openings in rubber mount.
NOTE: Ensure it is correctly supported on bearing bushing of rear axle carrier.
Withdraw rubber mount from bearing bushing with special tools 33 4 436, 33 4 437, 33 4 140 UNIVERSAL
SUPPORT and 33 4 431.
CARMANUALSUSA
2008 BMW 328xi
Installation:
Coat new rubber mount with Circo Light (refer to BMW Parts Service).
Assemble special tools 33 4 432, 33 4 433, 33 4 435 and 33 4 434.
Align rubber mount by way of arrow to direction of travel.
After installation:
CARMANUALSUSA
2008 BMW 328xi
 Bleed brakes
33 33 515 REPLACING TWO RUBBER MOUNTS FOR REAR AXLE CARRIER (RUBBER
MOUNTS, REAR)
 33 4 140
 33 4 142
 33 4 147
 33 4 149
 33 4 431
 33 4 434
 33 4 435
 33 4 436
 33 4 437
 33 4 441
 33 4 442
 33 4 443
 33 4 444
 Lower rear axle carrier
If necessary, assemble special tools 33 4 140, 33 4 142 and 33 4 147.
If necessary, screw new thrust pieces 33 4 149 with countersunk screws on special tool 33 4 140 UNIVERSAL
SUPPORT .
CARMANUALSUSA
2008 BMW 328xi
Coat top edge of rubber mount with Circo Light (refer to BMW Parts Service).
Fit special tool 33 4 441 on rubber mount in such a way that edge of rubber mount disappears in special tool.
Align special tool 33 4 140 UNIVERSAL SUPPORT by way of openings in rubber mount.
NOTE: Ensure it is correctly supported on bearing bushing of rear axle carrier.
Withdraw rubber mount from bearing bushing with special tools 33 4 436, 33 4 437, 33 4 140 UNIVERSAL
SUPPORT and 33 4 431.
CARMANUALSUSA
2008 BMW 328xi
Installation:
Coat new rubber mount with Circo Light (refer to BMW Parts Service).
Insert special tool 33 4 444 in opening on rear axle carrier to avoid damaging the rear axle carrier when drawing
in the rubber mount.
Assemble special tools 33 4 442, 33 4 443, 33 4 435 and 33 4 434.
Align rubber mount by way of arrow to direction of travel.
After installation:
 Bleed brakes
41 WHEEL BEARINGS
33 41 ... DETACHING WHEEL BEARING INNER RACE FROM DRIVE FLANGE (DRIVE FLANGE
REMOVED)
 33 1 307
CARMANUALSUSA
2008 BMW 328xi
 33 4 400
 33 4 401
 33 4 402
 33 4 403
 33 4 404
 33 4 405
 33 4 406
 33 4 407
NOTE: Detach wheel bearing inner race with special tool 33 4 400 through groove in
wheel bearing inner race.
Position special tool 33 1 307 on drive flange.
Select one of the following special tools using the wheel bearing inner race and insert into special tool 33 4 401.
33 4 405 for dia. 45 - 51 mm
33 4 406 for dia. 50 - 55 mm
33 4 407 for dia. 55 - 61 mm
Screw in special tool 33 4 402 until tapered attachment of spindle comes into contact with special tool 33 4 401.
Position special tool 33 4 401 with corresponding insert on groove of wheel bearing inner race.
Fig. 104: Positioning Special Tool 33 4 401 With Corresponding Insert On Groove Of Wheel Bearing
Inner Race
Compress special tool 33 4 401 with wrenches 33 4 403 and 33 4 404 until special tool can still just be turned in
CARMANUALSUSA
2008 BMW 328xi
groove.
Detach wheel bearing inner race by turning special tool 33 4 402.
Fig. 105: Compressing Special Tool 33 4 401 With Wrenches 33 4 403 And 33 4 404 Until Special Tool
Can Still Just Be Turned In Groove
33 41 005 REPLACING LEFT DRIVE FLANGE ON REAR AXLE SHAFT
 33 2 116
 33 2 160
 33 2 201
 33 4 200
OUTPUT SHAFT
 Remove brake disk. See 34 21 320 REMOVING AND INSTALLING OR REPLACING BOTH
REAR BRAKE DISCS
 Remove pulse generator. See 34 52 535 REPLACING A REAR PULSE GENERATOR
Force drive flange with special tools 33 2 116/33 2 201, 33 2 160 SPACER RING , 33 4 200 TOOL
KIT/STRIKER FIXTURE and 5 wheel bolts out of wheel bearing.
NOTE: Rounded inside edge of special tool 33 2 160 SPACER RING must point to drive
flange.
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: The wheel bearing is destroyed when the drive flange is removed and cannot
be reused!
Replace wheel bearing.
Installation:
Install output shaft.
Oil drive flange lightly and attach to splines of output shaft.
Draw drive flange into wheel bearing. See 33 21 ... PRESSING OUTPUT SHAFT OUT OF DRIVE
FLANGE AND DRAWING IN (OUTPUT SHAFT REMOVED FROM REAR DIFFERENTIAL)
After installation:
33 41 007 REPLACING RIGHT DRIVE FLANGE ON REAR AXLE SHAFT
NOTE: The procedure is described in 33 41 005 REPLACING LEFT DRIVE FLANGE ON

REAR AXLE SHAFT .
33 41 153 REPLACING WHEEL BEARING (75 MM) ON REAR AXLE SHAFT ON LEFT
 33 4 031
 33 4 041
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2008 BMW 328xi
 33 4 042
 33 4 043
 33 4 047
 33 4 048
 33 4 049
 Remove drive flange of rear axle shaft. See 33 41 005 REPLACING LEFT DRIVE FLANGE ON
REAR AXLE SHAFT
Press retaining ring (1) together using pliers and remove.
Installation:
Install retaining ring (1).
Check seating of retaining ring (1), correct if necessary.

Pull out wheel bearing with special tools 33 4 041, 33 4 042, 33 4 031, 33 4 048 and 33 4 043.
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: Do not reuse old wheel bearing!
Installation:
Draw in new wheel bearing (1) with special tools 33 4 041, 33 4 042, 33 4 049, 33 4 047 and 33 4 043.
After installation:
33 41 153 REPLACING WHEEL BEARING (85 MM) ON REAR AXLE SHAFT ON LEFT

CARMANUALSUSA
2008 BMW 328xi
 33 3 261
 33 3 262
 33 3 263
 33 3 264
 33 3 265
 Remove drive flange of rear axle shaft. See 33 41 005 REPLACING LEFT DRIVE FLANGE ON
REAR AXLE SHAFT
Press retaining ring (1) together using pliers and remove.
Installation:
Replace circlip.
Check seating of circlip, correct if necessary.

Pull out wheel bearing with special tools 33 3 261, 33 3 263 and 33 3 262.
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2008 BMW 328xi
IMPORTANT: Do not reuse old wheel bearing!
Black-dyed multipole seal (1) must point to centre of vehicle!
Fig. 112: Identifying Black-Dyed Multipole Seal

Installation:
Check installation position of wheel bearing (1), correct if necessary.
Draw in wheel bearing (1) with special tools 33 3 261, 33 3 265 and 33 3 264.
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2008 BMW 328xi
After installation:
33 41 155 REPLACING RIGHT WHEEL BEARING ON REAR AXLE SHAFT
NOTE: Procedure is described in 33 41 153 REPLACING WHEEL BEARING (75 MM) ON

REAR AXLE SHAFT ON LEFT and 33 41 153 REPLACING WHEEL BEARING (85
MM) ON REAR AXLE SHAFT ON LEFT .
52 SHOCK ABSORBER
33 52 000 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT SHOCK
ABSORBER
IMPORTANT: Installing shock absorbers of different manufacturers on a single axle is not

permitted!
NOTE: Use BMW part number (1) to find the matching shock absorber.
NOTE: Read and comply with Information on replacing shock absorbers.
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2008 BMW 328xi
Fig. 114: Identifying BMW Part Number Label

 Remove rear wheel

 Remove luggage compartment wheel arch trim
Remove protective cap.
Release nut (1); if necessary, grip at hexagon head.
Remove support bearing upper section (2).
Installation:
Replace support bearing upper section (2).
Tightening torque 33 52 1AZ. See 52 SHOCK ABSORBER
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2008 BMW 328xi
Fig. 115: Identifying Support Bearing Upper Section & Nut

Car may tilt off lifting platform if the workshop jack is incorrectly handled.
Release nut; if necessary brace on hex head.
Raise wheel carrier with workshop jack until shock absorber can be removed from rubber mount.
Compress shock absorber and remove through wheel arch.
Installation:
Fig. 116: Locating Self-Locking Nut

Replacement:
Remove thrust bearing (lower section), check for damage and replace if necessary.
Remove support pot (1) and auxiliary damper (2) with protective tube (3) from rear shock absorber (4).
Installation:
Check auxiliary damper (2) for damage and replace if necessary.
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2008 BMW 328xi
Fig. 117: Identifying Support Pot, Auxiliary Damper & Protective Tube
33 52 031 REPLACING REAR LEFT OR RIGHT RUBBER MOUNT FOR SHOCK ABSORBER
MOUNTING
Car may tilt off lifting platform if the workshop jack is incorrectly handled.
Release nut; if necessary brace on hex head.
Raise wheel carrier with workshop jack until shock absorber can be removed from rubber mount.
Installation:
Fig. 118: Locating Self-Locking Nut

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2008 BMW 328xi
Release screws (1).
Press shock absorber upwards and remove rubber mount (2) from camber arm.
Fig. 119: Identifying Rubber Mount & Screw

33 52 161 REPLACING THRUST BEARING (LOWER SECTION) FOR REAR LEFT OR RIGHT
SPRING STRUT/SHOCK ABSORBER
 Remove rear shock absorber
Press support bearing lower section (1) with seal grommet (2) out of shock absorber mounting.
Installation:
Clean shock absorber mounting including contact surface (3) all round.
Insert thrust bearing lower section (1) in sealing grommet (2).
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2008 BMW 328xi
Fig. 120: Identifying Support Bearing Lower Section With Seal Grommet
Installation:
Coat sealing grommet as illustrated with Circolight and press into shock absorber mounting.
Fig. 121: Identifying Shock Absorber Mounting

53 SPRINGS WITH SUSPENSION

33 53 ... MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
 Move vehicle into normal position
Determine actual ride height (A) - to do so, attach tape measure to rim flange (2) at bottom middle and measure
CARMANUALSUSA
2008 BMW 328xi
Fig. 122: Measuring Rim Flange

33 53 000 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT COIL SPRING
 33 5 011
 33 5 012
 33 5 013
 33 5 014
 33 5 015
 33 5 016
 33 5 017
 33 5 020
WARNING: Observe the following instructions to avoid any risk of injury by the coil
springs.
1. Prior to each use, check the special tools for defects, modifications
and operational reliability.
3. No changes or modifications may be made to the special tools!
4. These special tools are intended solely for the purpose tightening
and relieving cylindrical and tapered suspension springs.
5. Keep special tools dry, clean and free of grease.
6. Impact screwdrivers may not be used!
CARMANUALSUSA
2008 BMW 328xi
8. Observe manufacturer's instructions.
corrosion breakage!
Removal:
Insert lower spring plate 33 5 012 centrally into coil spring and turn to lowest coil.
Guide spindles 33 5 013, 33 5 014, 33 5 015 from below through camber arm and lower spring plate 33 5 012.
Fig. 123: Inserting Lower Spring Plate (33 5 012)

Insert upper spring plate 33 5 011 sideways into coil spring and turn to uppermost coil.
IMPORTANT: Make sure spindle (hexagon) is correctly seated in upper spring plate 33 5 011.
Pull spindle 33 5 013 downwards.
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2008 BMW 328xi
Fig. 124: Inserting Upper Spring Plate (33 5 011)

Make sure coil spring is correctly positioned in spring plates.
Fig. 125: Identifying Coil Spring Correctly Positioned In Spring Plates

IMPORTANT: Align special tools 33 5 011, 33 5 012, 33 5 013, 33 5 014, 33 5 015 centrally to
obtain the biggest possible contact surface on the coil spring.
Check installation position of special tools 33 5 011, 33 5 012 and 33 5 013, 33 5 014, 33 5 015, correct if
necessary.
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Tension coil spring using special tools 33 5 016 and 33 5 020 REVERSIBLE RATCHET WITH HEXAGON
SOCKET WAF 22 , gripping spindle of spring tensioner with special tool 33 5 017 in the process.
Remove coil spring upwards.
Fig. 127: Identifying Special Tools (33 5 016) & (33 5 020)
If necessary, relieve tension on coil spring.
IMPORTANT: Replacement only:
Bottom end of coil spring (1) must be flush with opening of spring plate 33 5
012 (see Fig. 128).
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2008 BMW 328xi

Installation:
Check spring mounts (2, 3) for damage, replace if necessary.
Remove spring plate (1) and position with upper spring pad (2) on coil spring.
NOTE: Upper spring pad (2) must come into contact with end of coil spring.
Version with rough road package: Install adapter as well.
Fig. 129: Identifying Spring Mounts

IMPORTANT: Observe the following when installing and relieving tension on coil spring:
 Lower spring pad must be positively seated in the designated receptacle

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2008 BMW 328xi
in the camber arm
NOTE: Otherwise there is a risk of the coil spring jumpin sideways.
 Lower spring pad must come into contact with end of c spring (see arrow)
 Lower spring pad must rest flush on last coil (see broke line)
Fig. 130: Identifying Lower Spring Pad

Align coil spring by way of spring plate to opening in side member and relieve tension.
Remove special tools 33 5 011, 33 5 012 and 33 5 013, 33 5 014, 33 5 015.
After installation:
CARMANUALSUSA
2008 BMW 328xi
 Check headlight adjustment, correct if necessary. See 63 10 004 ADJUSTING HEADLIGHTS
55 STABILIZER BAR
33 55 000 REMOVING AND INSTALLING/REPLACING REAR STABILIZER
 Remove left control arm on wheel carrier. See 33 32 071 REPLACING ONE UPPER CONTROL
ARM
 Remove stabilizer link on both sides from stabilizer. See 33 55 040 REPLACING STABILIZER
LINKS FOR STABILIZER
 Lower rear axle carrier. See 33 31 503 LOWERING/RAISING REAR AXLE CARRIER
NOTE: To simplify the Fig. 132, removal of the stabilizer is depicted on the removed
rear axle.
Release screws (1).
Remove rubber mount on both sides from stabilizer. See 33 55 021 REPLACING BOTH RUBBER
MOUNTS FOR STABILIZER MOUNTING
Turn stabilizer (2) and remove sideways.
Installation:
Check rubber mount on both sides for damage, replace if necessary. See 33 55 021 REPLACING BOTH
RUBBER MOUNTS FOR STABILIZER MOUNTING
Tightening torque 33 55 1AZ. See 33 55 STABILIZER BAR
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Fig. 132: Identifying Stabilizer & Screw

After installation:
33 55 021 REPLACING BOTH RUBBER MOUNTS FOR STABILIZER MOUNTING
 Remove rear wheels. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
Release screws (1).
Remove retaining bracket (2) and rubber mount (3).
Installation:
Clean rear stabilizer on both sides.
Position rubber mount on rear stabilizer.
Position retaining bracket on rubber mount.
Push rubber mount with retaining bracket on rear stabilizer to installation position.
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33 55 040 REPLACING STABILIZER LINKS FOR STABILIZER
 31 1 140
Release nut (1), gripping with special tool 31 1 140 OPEN-END WRENCH WAF 16/18 in the process.
Installation:
Release screw (3).
Remove stabilizer link (2) towards top.
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90 TROUBLESHOOTING
33 90 ... REAR AXLE TROUBLESHOOTING
Observe troubleshooting for shock absorbers. See 33 90 ... TROUBLESHOOTING SHOCK ABSORBER
REAR AXLE TROUBLESHOOTING TABLE

Fault Cause Remedy
Refer to TROUBLESHOOTING brake system
Replace wheel bearings. See 33 41 153 REPLACING WHEEL
Grinding noise BEARING (75 MM) ON REAR AXLE SHAFT ON LEFT,
(only when Wheel bearings 33 41 153 REPLACING WHEEL BEARING (85 MM) ON
cornering) faulty REAR AXLE SHAFT ON LEFT and/or 33 41 155
REPLACING RIGHT WHEEL BEARING ON REAR
AXLE SHAFT
Balance wheels. See 36 10 508 STATIONARY WHEEL
Wheel imbalance
BALANCING
Radial/lateral rim Check rims, replace if necessary. See 36 10 715 CHECKING
runout RIM FOR FACE AND RADIAL RUNOUT
Vibration (90 - Match or replace tires. See 36 10 209 CHECKING FRONT
160 km/h) Radial tire runout
AND REAR WHEEL FOR FACE AND RADIAL RUNOUT
Replace output shaft. See 33 21 001 REMOVING AND
Imbalance in output INSTALLING OR REPLACING LEFT OUTPUT SHAFT
shaft and/or 33 21 002 REMOVING AND
Rubber mount of Replace rubber mount. See 33 17 004 REPLACING ALL

final drive FRONT RUBBER MOUNTS FOR REAR DIFFERENTIAL
suspension faulty MOUNTING and 33 17 005 REPLACING RUBBER
MOUNT FOR REAR DIFFERENTIAL MOUNTING AT
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2008 BMW 328xi
REAR
Replace rubber mount. See 33 33 101 REPLACING TWO
Drumming Rubber mount of RUBBER MOUNTS FOR REAR AXLE CARRIER
rear axle carrier (RUBBER MOUNTS, FRONT) and 33 33 515 REPLACING
faulty TWO RUBBER MOUNTS FOR REAR AXLE CARRIER
(RUBBER MOUNTS, REAR)
Refer to TROUBLESHOOTING for shock absorbers.
Check screw connection, replace stabilizer link if necessary. See
Stabilizer link loose
33 55 040 REPLACING STABILIZER LINKS FOR
or defective
STABILIZER
Rattling noise Check seat, replace rubber mount if necessary. See 33 33 101
Rubber mount of REPLACING TWO RUBBER MOUNTS FOR REAR
rear axle carrier AXLE CARRIER (RUBBER MOUNTS, FRONT) and 33 33
loose or faulty 515 REPLACING TWO RUBBER MOUNTS FOR REAR
AXLE CARRIER (RUBBER MOUNTS, REAR)
Replace rubber mount. See 33 33 101 REPLACING TWO
Rubber mount of RUBBER MOUNTS FOR REAR AXLE CARRIER
rear axle carrier (RUBBER MOUNTS, FRONT) and 33 33 515 REPLACING
faulty TWO RUBBER MOUNTS FOR REAR AXLE CARRIER
(RUBBER MOUNTS, REAR)
Rubber mount on Replace traction strut. See 33 32 091 REPLACING A GUIDE
traction strut faulty ARM
Rubber mount of Replace control arms. See 33 32 071 REPLACING ONE
control arm faulty UPPER CONTROL ARM
Poor straight-
Rubber mount for Replace rubber mount. See 33 32 031 REPLACING RUBBER
running stability
trailing arm in rear MOUNT FOR TRAILING ARM IN WHEEL CARRIER
(steering wheel
axle carrier or and/or 33 32 035 REPLACING A RUBBER MOUNT FOR
inclination)
wheel carrier faulty TRAILING ARM IN REAR AXLE CARRIER
Rubber mount of Replace toe arm. See 33 32 180 REMOVING AND
toe arm faulty INSTALLING/REPLACING LEFT OR RIGHT TOE ARM
Rubber mount/ball Replace rubber mount/ball joint. See 33 32 195 REPLACING
joint for camber RUBBER MOUNT FOR CAMBER ARM IN REAR AXLE
arm faulty CARRIER
Carry out chassis/wheel alignment check, align rear axle if
Rear axle alignment
necessary. See 32 00 ... CHASSIS/WHEEL ALIGNMENT
incorrectly adjusted
CHECK PROCEDURE
Unsteady taking of
curves due to self- Refer to "Poor straight-running stability"
steering or poor
rear end track Refer to TROUBLESHOOTING for shock absorbers.
stability
Carry out chassis/wheel alignment check, align rear axle if
Excessive tire Rear axle alignment
necessary. See 32 00 ... CHASSIS/WHEEL ALIGNMENT
wear incorrectly adjusted
CHECK PROCEDURE
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33 90 ... TROUBLESHOOTING SHOCK ABSORBER
Read and comply with Information on replacing shock absorbers. See 33 00 ... INFORMATION ON
REPLACING SHOCK ABSORBERS
SHOCK ABSORBER TROUBLESHOOTING TABLE

Fault Cause Remedy
Visually inspect auxiliary spring for cracking, replace
auxiliary spring. See 33 52 000 REMOVING AND
Auxiliary spring faulty
INSTALLING/REPLACING REAR LEFT OR RIGHT
Wheel knocking SHOCK ABSORBER
(bottoming)
Replace shock absorber. See 33 52 000 REMOVING AND
(oil/gas)
SHOCK ABSORBER
Tighten shock absorber. See 33 52 000 REMOVING AND
Shock absorber
mounting loose
SHOCK ABSORBER
Support bearing loose Secure support bearing. See 33 52 SHOCK ABSORBERS
Visually inspect for cracking, replace support bearing. See
Support bearing 33 52 161 REPLACING THRUST BEARING (LOWER
defective (cracked) SECTION) FOR REAR LEFT OR RIGHT SPRING
STRUT/SHOCK ABSORBER
Rattling noise Protective tube Visually inspect protective tube for cracking, replace
defective/failed protective tube
Rubber mount/joint eye
Replace rubber mount/joint eye. See 33 52 031
for lower shock
REPLACING REAR LEFT OR RIGHT RUBBER
absorber mounting
MOUNT FOR SHOCK ABSORBER MOUNTING
defective
Replace shock absorber. See 33 52 000 REMOVING AND
(oil/gas)
SHOCK ABSORBER
Worn down areas Replace shock absorber. See 33 52 000 REMOVING AND
(flattened areas) on INSTALLING/REPLACING REAR LEFT OR RIGHT
(gas/oil)
tire profile SHOCK ABSORBER
Long after-
Shock absorber leaking Replace shock absorber. See 33 52 000 REMOVING AND
swinging of body
(insufficient shock INSTALLING/REPLACING REAR LEFT OR RIGHT
after driving over
absorber effect) SHOCK ABSORBER
rough road
Building-up of
Shock absorber leaking Replace shock absorber. See 33 52 000 REMOVING AND
body in case of
(insufficient shock INSTALLING/REPLACING REAR LEFT OR RIGHT
successive uneven
absorber effect) SHOCK ABSORBER
surfaces
Wheels jumping Shock absorber leaking Replace shock absorber. See 33 52 000 REMOVING AND
even on normal (insufficient shock INSTALLING/REPLACING REAR LEFT OR RIGHT
road surfaces absorber effect) SHOCK ABSORBER
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2008 BMW 328xi
2006-08 SUSPENSION Steering and wheel alignment - Repair Instructions - 325i, 330i, 328i, 335i
2006-08 SUSPENSION
Steering and wheel alignment - Repair Instructions - 325i, 330i, 328i, 335i
00 ELECTRONIC CHASSIS ALIGNMENT

 Headaches
 Dizziness
 Stomach aches
 Vomiting
 Diarrhoea
 Cramps/fits
 Unconsciousness

First aid measures:
If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery
position and seek immediate medical attention.
Danger of injury!
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2008 BMW 328xi
 Impaired sight

First aid measures:
WARNING: Danger Of Poisoning if oil is ingested/absorbed through the skin!
Risk Of Injury if oil comes into contact with eyes and skin!
Recycling:

CARMANUALSUSA
2008 BMW 328xi

contact points.
necessary.
Fig. 1: Identifying Trolley Jack

points!

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2008 BMW 328xi
Fig. 2: Identifying Car Jacking Point On Reinforcement Strut (Rear-Wheel Drive)

Fig. 3: Identifying Car Jacking Point On Front Axle Carrier (All-Wheel Drive)
31 00 ... FRONT AXLE + STEERING: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE

CARRIED OUT AFTER THE FOLLOWING WORK
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Fig. 4: Identifying Front Axle Carrier, Steering Gear, Control Arm, Swivel Bearing And Tie Rod End
A Wheel/Chassis Alignment Check must be carried out after the following work:


2. Steering gear
4. Control arm
6. Swivel bearing
7. Tie rod end
8. Tie rod
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32 .. . OVERVIEW OF STEERING
Fig. 5: Identifying Steering Components

32 .. .. OVERVIEW OF STEERING WHEEL/CASING COMPONENTS
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2008 BMW 328xi
Fig. 6: Identifying Steering Wheel/Casing Components

32 00 ... CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE
CHASSIS/WHEEL ALIGNMENT CHECK PROCEDURE

Check adherence to Test
Conditions
I
V
Position vehicle on measuring
stand
I
V
Measure vehicle Ride Height OK -> Carry out Chassis/Wheel
Alignment Check with ride-
height measurement without load
Read off setpoint value in KDS
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2008 BMW 328xi
Tolerance -20 / +40 mm per wheel

permissible
Difference between left / right
max. 10 mm permissible
Not OK / no data
I
V
Move vehicle into Normal
Position
Introduce load and measure ride
heights
Read off setpoint value in KDS Not OK ->
Tolerance ± 10 mm per wheel
permissible
OK Check suspension for damage,
I repair if necessary
V
Move vehicle into Design <- Not OK
Position
Add/distribute weights and
measure ride heights
Read off setpoint value in KDS
Tolerance ± 2 mm per wheel
permissible
I
V
Carry out KDS Chassis/Wheel
Alignment Check with load up to
design position
32 00 ... GENERAL CHASSIS AND SUSPENSION DEFINITIONS
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2008 BMW 328xi
Fig. 7: Identifying Chassis And Suspension Dimensions

32 00 ... GENERAL INFORMATION AND DEFINITIONS
Toe angle difference
a Toe angle difference
D Center point of operating circle
The toe angle difference is the angle adjustment of the inner cornering wheel relative to the outer cornering
wheel when negotiating a curve. Steering is designed in such a way that angular position of wheels changes as
steering lock progresses.
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2008 BMW 328xi
A correctly adjusted toe angle difference produces equal values for left and right lock with consideration of
factory tolerances.
Toe angle difference provides information on corresponding operation of steering trapezoid for left or right
steering lock from center position.
Fig. 8: Identifying Toe Angle Difference

Camber
Inclination of the wheel from the perpendicular.
Fig. 9: Identifying Inclination Of Wheel From Perpendicular

Toe
Reduction in distance of front of front wheels to rear of front wheels. The toe-in prevents the wheels from
moving apart during driving and thus:
 the wheels from vibrating and grinding

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2008 BMW 328xi
 excessive tire wear

 excessive strain on the steering linkage and its links/joints
 heavy vehicle steering
Measurement is performed in "straight-ahead mode".
Fig. 10: Checking Toe Angle

Caster
Is the inclination of the kingpin in the direction of travel viewed from the side. The line through the center point
of the spring strut support bearing and the control arm ball joint corresponds to the "kingpin".
Thanks to caster, wheels are pulled and not pushed. In a similar manner to king pin inclination, when driving in
curves or around corners, returning forces are reproduced to help return wheels to straight-ahead position.
Fig. 11: Identifying Caster Angle

Geometrical axis 1
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Is the angle bisector from the total rear-wheel toe.
Front-wheel measurements are taken in reference to this axis.
Symmetrical axis 2
Center line running through front and rear axles.
Fig. 12: Identifying Geometrical Axis And Symmetrical Axis

Wheel offset
Angle by which one front wheel is displaced more towards front or rear than the other front wheel. The wheel
offset angle is positive when the right wheel is displaced towards the front and negative when it is displaced
towards the rear.
Fig. 13: Identifying Wheel Offset Angle

Kingpin offset/scrub radius
Is the distance from the center of the wheel contact face to the intersection point of the kingpin extension. The
line through the center point of the spring strut support bearing and the control arm ball joint corresponds to the
CARMANUALSUSA
2008 BMW 328xi
"kingpin".
The scrub radius is influenced by camber, kingpin angle and wheel offset of the wheel rim.
Fig. 14: Identifying Kingpin Offset/Scrub Radius

32 00 ... IDENTIFICATION OF SUSPENSION WITHOUT LABEL
NOTE: If the front spring strut does not have a label for suspension identification, the
type of suspension can be identified from the part number in the Electronic
Parts Catalogue.
32 00 ... IDENTIFYING SUSPENSION FROM LABEL ON FRONT AXLE
NOTE: The type of suspension can be identified from the label on the spring
strut/shock absorber.
Label:
1. BMW part number

2. Type of suspension
 BA = Standard suspension (basic)
 SP = Sport suspension or rough road package
 60BAX = E60, E61 AWD
 MSP = M Sport suspension
 CHL = China Long
 Option SA 815 = rough road package
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Fig. 15: Identifying Suspension Label

In the case of "SP" identification, there is a further distinction between:
 Sport suspension without spacer ring (A)

 Rough road package with spacer ring (A) above the support bearing
Fig. 16: Identifying Suspension Spacer Ring

32 00 ... INFORMATION ON REPLACING STEERING GEAR AFTER ACCIDENT DAMAGE
Facts:
In the event of accidents or driving conditions similar to accidents, shocklike loads can cause different types of
damage to steering gears. When a steering gear is externally undamaged, it is sometimes only possible to
identify damage with great difficulty and with great effort. However, damage of this nature poses an
unacceptable risk to the vehicle because it can result in failure of the steering system. This is the case
particularly when a wheel and wheel guide/control components are subjected to a jolting impact.
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2008 BMW 328xi
Because of the disproportionate amount of effort involved, it is generally not sensible to check thoroughly all
the individual components of the steering gear and as an alternative it is necessary to take into account other
components which can be checked more easily.
Procedure:
The steering gear must be replaced if one or more of the following points apply:
A. Visible or noticeable damage to the steering gear

 Version with electric steering gear (EPS): Examine in particular the control unit with all plug
connections for damage and hairline cracks.
B. Unacceptable torque increase and jamming when the steering gear is turned from lock to lock (without
hydraulic assistance)
C. Permissible tolerances exceeded during axle/wheel alignment check (if necessary, include alignment
record with invoice / report)
D. Fire damage
E. Damage, permanent deformation or breakage resulting from an accident to:
 Wheel rims in the event of a negative result from the wheel/axle alignment check
 Spring struts, steering knuckles, wheel carriers
 Control arms
 Compression or tension struts or stabilizer bars with this function
 If necessary, body-side screwing/bolting points for wheel guide/control components
 Front axle carrier
 Pitman arms
 Tie rods
 Steering gear fixtures
 Steering column
This guideline is binding for all accident repairs to BMW and MINI vehicles.
NOTE: If the steering gear replacement work which is required for safety reasons is
refused by the customer or an insurance company for cost reasons, a
memorandum to that effect must be drawn up and countersigned by the party
bearing the costs of the accident repair.
IMPORTANT: The vehicle's type approval will be invalidated whenever the function of any of
its safety components is compromised!
32 00 ... MOVING VEHICLE INTO DESIGN POSITION
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2008 BMW 328xi
 Move vehicle into Normal Position
 Add/distribute weights in area of spring struts until the vehicle ride height is within the tolerance (refer to
TECHNICAL DATA ).
Measure Ride-Level Height Of Vehicle
32 00 ... MOVING VEHICLE INTO NORMAL POSITION
 Check compliance with Test Conditions, bring vehicle to a stop if necessary.

 Version with air spring system:
 Carry out ride-height-calibration
 Pull fuse(s) for air supply unit control unit
 Version with air spring system: Carry out ride-height-calibration

 Check vehicle interior and luggage compartment (incl. luggage compartment recess) for load, unload
vehicle if necessary
 Introduce DIN load (refer to TECHNICAL DATA ) into vehicle
 Determine Vehicle Ride Height
NOTE: If the vehicle ride height is not inside the tolerance (refer to TECHNICAL DATA ),
the vehicle must be repaired (coil spring/leakage).
32 00 ... PERFORMING RIM RUNOUT COMPENSATION
NOTE: Rim runout compensation involves electronically recording the lateral runout of
the rim and the possible clamping error of the quick-clamping unit for one
wheel rotation and compensating the toe and camber for
measurement/alignment.
Raise body.
Perform rim runout compensation in accordance with equipment manufacturer's instructions.
Compress/deflect car.
32 00 ... TEACHING IN CENTRE POSITION FOR POWER STEERING (ACTIVE FRONT

STEERING) (FROM 03/2007)
NOTE: Carry out the following procedure after disconnecting the battery or
disconnecting electrical plug connections on the steering column switch
cluster.
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2008 BMW 328xi
Turn on ignition, start engine if necessary.
Turn steering wheel twice in both directions to full lock.
IMPORTANT: If the indicator lamp does not go out after the ignition is turned on again, an
adjustment of the active front steering must be carried out.
32 00 ... TEST CONDITIONS FOR CHASSIS/WHEEL ALIGNMENT CHECK
Observe the following test conditions prior to the chassis/wheel alignment check:
1. Correct and identical rim and tyre sizes.

2. Correct tread depth.
3. Correct tyre inflation pressure (see instruction plate on car).
4. Wheel bearing clearance OK
5. Steering backlash OK
6. Condition of suspension and shock absorbers OK
7. On cars with air springs, pull fuse from air supply unit so as to eliminate control up/down.
32 00 ... TROUBLESHOOTING AFTER CHASSIS/WHEEL ALIGNMENT CHECK
Substandard roadholding, atypical noises, tyres worn on one side and toe-in/camber values which deviate from
the nominal value are all indicators of damage to the suspension caused by road traffic accidents or similar
impacts.
You must also follow the Rules And Guidelines For Accident-Related Repairs To The Steering Gear.
Procedure:
 Ride-height problems:
I. Check Load , correct if necessary (e.g. luggage compartment)
II. Check Coil Springs for damage/correct seating, replace if necessary
 Setting problems:
I. Tighten all suspension screw/bolt connections to specified torque
II. Check all suspension components for deformation/damage or retrofits, replace if necessary
CAUTION: When replacing deformed or damaged suspension components,

also check the adjoining components for damage and replace if
necessary (comply with repair instructions).
NOTE: If after chassis/suspension components have been replaced

adjustment of camber/track alignment is not possible, the vehicle
must be placed on the body straightening bench.
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32 00 150 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH LOAD UP TO DESIGN POSITION

(E81 / E82 / E87 / E90 / E91 / E92 / E93)
Except M models:
IMPORTANT: Carry out chassis/wheel alignment with DIN load only :
 If the technical preconditions for alignment with ride height input are not
in place
 If, in spite of repairs having been carried out, the car's r height between
the left and right sides is still outside their tolerance
 If the vehicles in question have been involved in an accident.
NOTE:  Read and comply with General Information And Definitions.

 Read and comply with General Chassis Definition.
 If necessary, prepare lifting platform.

 Drive vehicle onto lifting platform.
NOTE: The front and rear wheels must be positioned centrally on the rotary and
sliding plates.
 Remove locking pins from both rotary and sliding plates, align pickup using bubble level and activate
Fig. 17: Identifying Rotary And Sliding Plates

 Attach quick-clamping holder/quick-clamping unit to vehicle and remove clamping levers in area of front
wheels
 Attach pickup to quick-clamping holder/quick-clamping unit, align using bubble level and connect to
rotary plates
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NOTE: When using quick-clamping units, perform rim runout compensation after
installing the pickups.
Fig. 18: Identifying Quick-Clamping Holder/Quick-Clamping Unit

 If necessary, attach spoiler adapter.
Fig. 19: Identifying Spoiler Adapter

 If necessary, switch on chassis alignment system

 Enter customer and vehicle data
 Identify Chassis Version and select vehicle
 Enter tyre pressure and tread depth
 Move vehicle into Design Position
 Install brake tensioner.
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Fig. 20: Secure Brake With Brake Tensioner

E81, E82, E87, E90, E91, E92, E93:
In order to avoid damaging the front side panel during the "Max. steering lock"
drive-in routine, make sure the pickups are removed from the quick-clamping
holders/quick-clamping units during output and input alignment. In the process
do not detach the connecting cable from the pickups or the rotary plates.
NOTE: After the drive-in routine, reconnect the pickups to the quick-clamping
holders/quick-clamping units, align using the bubble levels and secure in place.
 Perform input measurement in accordance with equipment manufacturer's instructions.

 Compare Specified Values with actual values.
Only in event of customer complaint (e.g. poor driving performance):
IMPORTANT: Do not remove screws/bolts (front axle carrier to engine carrier / body).
Slacken all screws/bolts (front axle carrier to engine carrier / body) and then retighten to specified torque.
Refer to Lowering front axle carrier .
 If necessary, Adjust Front Axle And Rear Axle

 Perform output measurement in accordance with equipment manufacturer's instructions.
 Save and print out test record.
 Carry out Steering Angle Sensor Adjustment/Adjustment For Active Front Steering
 Insert locking pins into both rotary and sliding plates
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2008 BMW 328xi
 Remove chassis/wheel alignment system

 Drive vehicle off lifting platform.
32 00 155 KDS CHASSIS/WHEEL ALIGNMENT CHECK WITH RIDE-HEIGHT MEASUREMENT

WITHOUT LOAD (E81 / E82 / E87 / E90 / E91 / E92 / E93)
IMPORTANT: Do not carry out chassis/wheel alignment without load:
 if the technical requirements for alignment with ride height input are not
in place
 if, in spite of repairs having been carried out, the car's r height between
the left and right sides is still outside their tolerance
 if the vehicles in question have been involved in an accident.
NOTE:  Read and comply with General Information And Definitions.

 Read and comply with General Chassis Definition.
 Check compliance with Test Conditions, bring vehicle to a stop if necessary.

 If necessary, prepare lifting platform.
 Drive vehicle onto lifting platform.
NOTE: The front and rear wheels must be positioned centrally on the rotary and
sliding plates.
 Remove locking pins from both rotary and sliding plates, align pickup using bubble level and activate
Fig. 21: Identifying Rotary And Sliding Plates

 Attach quick-clamping holder/quick-clamping unit to vehicle and remove clamping levers in area of front
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2008 BMW 328xi
wheels
 Attach pickup to quick-clamping holder/quick-clamping unit, align using bubble level and connect to
rotary plates
NOTE: When using quick-clamping units, perform rim runout compensation after
installing the pickups.
Fig. 22: Identifying Quick-Clamping Holder/Quick-Clamping Unit

 If necessary, attach spoiler adapter.
Fig. 23: Identifying Spoiler Adapter

 If necessary, switch on chassis alignment system

 Enter customer and vehicle data
 Identify Chassis Version and select vehicle
 Enter tyre pressure and tread depth
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2008 BMW 328xi
 Measure and enter Vehicle Ride Height

 Install brake tensioner.
Fig. 24: Identifying Brake Tensioner

E87, E90, E91, E92:

In order to avoid damaging the front side panel during the "Max. steering lock"
drive-in routine, make sure the pickups are removed from the quick-clamping
holders/quick-clamping units during output and input alignment. In the process
do not detach the connecting cable from the pickups or the rotary plates.
NOTE: After the drive-in routine, reconnect the pickups to the quick-clamping
holders/quick-clamping units, align using the bubble levels and secure in place.
 Perform input measurement in accordance with equipment manufacturer's instructions.

 Compare Specified Values with actual values
Only in event of customer complaint (e.g. poor driving performance):
IMPORTANT: Do not remove screws/bolts (front axle carrier to engine carrier / body).
Slacken all screws/bolts (front axle carrier to engine carrier / body) and then retighten to specified torque.
Refer to Lowering front axle carrier .
 If necessary, adjust front axle and rear axle

 Perform output measurement in accordance with equipment manufacturer's instructions.
 Save and print out test record.
CARMANUALSUSA
2008 BMW 328xi
 Insert locking pins into both rotary and sliding plates
 Remove chassis/wheel alignment system
 Drive vehicle off lifting platform.
32 00 610 ADJUSTING TOE-IN AND CAMBER ON FRONT AXLE
 32 3 140
 32 3 146
 32 3 147
IMPORTANT: Changes in axle geometry caused by accidents must under no circumstances

be rectified by camber adjustment!
NOTE: Camber and toe-in influence each other. Adjust the toe-in first in order to
simplify the adjustment procedure.
The centering pin may only be driven or twisted out if the camber is outside the
specified tolerance after toe adjustment.
Version with active front steering:
 Align steering wheel

 Set cumulative steering angle by means of the service function "Carry out initial operation/adjustment
for active front steering" to "zero".
 If necessary, secure with steering wheel arrester
Version without active front steering:
Move steering into straight-ahead position by means of markings on cap (1) and steering gear (2).
Align steering wheel and secure with steering wheel arrester.
CARMANUALSUSA
2008 BMW 328xi
Fig. 25: Identifying Cap And Steering Gear

Adjust toe-in:
Clean thread on tie rod.
Loosen screw (2).
Turn tie rod (3) and if necessary grip tie rod end (1) to adjust toe-in to setpoint value.
Tighten screw (2).
For tightening torque refer to 32 21 2AZ in 32 21 STEERING ARMS .
If necessary, correct installation position of gaiter.
Fig. 26: Identifying Tie Rod End, Screw And Tie Rod
CARMANUALSUSA
2008 BMW 328xi
Adjusting camber:
Remove Tension Strut For Spring Strut Dome .
Remove protective cap.
Twist/drive out centering pin (1).
Clean wheel arch from below in area of support bearing with compressed air.
Slacken nut (2).
Fig. 27: Identifying Centering Pin And Mounting Nut

Insert special tool 32 3 140 into opening in wheel arch.
NOTE: The spindle 32 3 146 must be aligned in such a way that the short end of the
guide sleeve (3) points upwards.
Screw knurled nut 32 3 147 onto stud.
Replace nuts (1) and screw on but do not tighten down fully.
Turn nut (2) of special tool 32 3 140 to adjust camber to setpoint value.
Tighten down nuts (1).
For tightening torque refer to 31 31 1AZ in 31 31 SPRING STRUTS .
Remove special tool 32 3 140.
CARMANUALSUSA
2008 BMW 328xi
Fig. 28: Identifying Special Tool (32 3 140), (32 3 147), Retaining Nuts And Guide Sleeve
Replace nut (1) and tighten down.
For tightening torque refer to 31 31 1AZ in 31 31 SPRING STRUTS .
Fig. 29: Identifying Front Axle Upper Cover Mounting Nut

After installation:
 Check directional stability of car; if necessary, repeat toe-in adjustment
32 00 620 ADJUSTING REAR AXLE
NOTE: A camber change always means a toe change as well. The camber must
therefore be adjusted first.
CARMANUALSUSA
2008 BMW 328xi
Adjusting camber:
Replace nut (2) and tighten to 5 Nm.
Turn eccentric bolt (1) to adjust camber to setpoint value.
Tighten nut (2).
For tightening torque refer to 33 32 9AZ in 33 32 CONTROL ARMS AND STRUTS .
Fig. 30: Identifying Camber Nut And Eccentric Bolt

Adjusting toe:
Replace nut (2) and tighten to 5 Nm.
Turn eccentric bolt (1) to adjust toe to specified value.
Tighten nut (2).
For tightening torque refer to 33 32 7AZ in 33 32 CONTROL ARMS AND STRUTS .
CARMANUALSUSA
2008 BMW 328xi
Fig. 31: Identifying Toe Nut And Eccentric Bolt

32 10 ... TEACHING IN END STOP SOFTWARE FOR ELECTRIC STEERING GEAR (EPS)
NOTE: The end stop software must be taught in:
 after the steering gear is replaced

 after programming/coding
Connect vehicle to BMW diagnosis system.
Select and perform end stop under Service functions.
32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING
NOTE: Adjustment of the active front steering must be carried out:
 after adjustment work on the front axle/steering

 after all mechanical work on the steering system
 after the battery has been disconnected or electrical plug connections on
the steering column switch cluster have been disconnected
 after replacement/programming or coding of the following components:
 Steering column switch cluster
 DSC control unit
 Active front steering control unit
 ARS control unit
CARMANUALSUSA
2008 BMW 328xi
Select and carry out initial operation/adjustment for active front steering
under Service functions.
33 00 ... REAR AXLE: WHEEL/CHASSIS ALIGNMENT CHECK MUST BE CARRIED OUT AFTER
THE FOLLOWING WORK
Fig. 32: Identifying Rear Axle Components

A Wheel/Chassis Alignment Check must be carried out after the following work:

 Camber arm to rear axle carrier / wheel carrier
 Trailing arm to rear axle carrier / wheel carrier
 Guide arm to rear axle carrier
 Toe arm to rear axle carrier / wheel carrier
 Control arm to rear axle carrier

1. Rear axle carrier
2. Camber arm / rubber mount / ball joint
CARMANUALSUSA
2008 BMW 328xi
3. Trailing arm / rubber mount

4. Guide arm
5. Wheel carrier / rubber mount / ball joint
6. Toe arm
7. Control arm
61 31 996 CARRY OUT STEERING ANGLE SENSOR ADJUSTMENT
IMPORTANT: In vehicles with active front steering, steering angle sensor adjustment is
integrated in the service function "Initial Operation/Adjustment For Active Front
Steering" and must not be carried out separately!
NOTE: Steering angle sensor adjustment must be carried out:

 E46 (AWD), E53, E83: after disconnection of battery
 after replacement / coding / programming of the following components:
 Fixture for switches of steering column / switch cluster / steering
angle sensor
 Dynamic Stability Control (DSC) control unit
 Active anti-roll stabilization (ARS)
Connect vehicle to BMW diagnosis system or Software Service Station.
Select and carry out steering angle sensor adjustment under Service
functions.
11 MECHANICAL STEERING GEAR

32 11 ... REPLACING GAITER FOR ELECTRIC STEERING GEAR (EPS) ON LEFT OR RIGHT
Spindle side:
IMPORTANT: The steering gear must be replaced If the corrosion on the spindle running
surface has advanced to such an extent that the steering is acoustically
conspicuous under load!
Adhere to the utmost cleanliness.
Do not regrease the spindle running surface. Sufficient special grease was
used during assembly for lifetime filling.
CARMANUALSUSA
2008 BMW 328xi
Fig. 33: Identifying Steering Gear Spindle Side

Rack side:
IMPORTANT: The steering gear must be replaced if the polished surface of the rack is
damaged (e.g. by corrosion)!
Clean rack and check surface for damage (e.g. by corrosion).
Grease rack (refer to BMW Service Operating Fluids ).
Fig. 34: Identifying Steering Gear Rack Side

 Remove Front Assembly Underside Protection
CARMANUALSUSA
2008 BMW 328xi
Clean tie rod.
Release band clamp (1).
Mark screw-in depth of tie rod (2) or count thread turns.
Unscrew bolt (3).
Twist tie rod (2) out of tie rod end (4).
Installation:
Replace microencapsulated screw.
Fig. 35: Identifying Band Clamp, Retaining Bolt, Tie Rod And Tie Rod End
Release Ear Clamp (1).
Detach gaiter (2) from tie rod (3).
Installation:
Read and follow notes/information on spindle and rack sides at the start of the document.
Clean tie rod and apply grease to taper. This ensures that the gaiter is not rotated when the tie rod is rotated.
CARMANUALSUSA
2008 BMW 328xi
Fig. 36: Identifying Ear Clamp, Gaiter And Tie Rod

Release water drain valve (1) (20 A/F) and replace.
Installation:
Fit O-ring (2).
For tightening torque refer to 32 00 3AZ in 32 00 STEERING .
Fig. 37: Identifying Water Drain Valve And O-Ring

After installation:
 Perform Chassis Alignment Check

 Carry out Steering Angle Sensor Adjustment
CARMANUALSUSA
2008 BMW 328xi
32 11 100 REPLACING GAITER FOR STEERING GEAR ON LEFT OR RIGHT
IMPORTANT: The power steering gear must be replaced if the polished surface of the rack is
damaged (e.g. by corrosion)!
Clean tie rod.
Release band clamp (1).
Mark screw-in depth of tie rod (2) or count thread turns.
Release screw (3).
Twist tie rod (2) out of tie rod end (4).
Installation:
Replace microencapsulated screw.
Fig. 38: Identifying Band Clamp, Tie Rod And Tie Rod End
Release Ear Clamp(1).
Detach gaiter (2) from tie rod (3).
Installation:
CARMANUALSUSA
2008 BMW 328xi
Clean rack and check surface for damage (e.g. by corrosion).
Grease rack (refer to BMW Service Operating Fluids ).
Clean tie rod and apply grease to taper. This ensures that the gaiter is not rotated when the tie rod is rotated.
Fig. 39: Identifying Ear Clamp, Gaiter And Tie Rod

After installation:

13 STEERING GEAR
32 13 006 BLEEDING POWER STEERING UNIT
WARNING: Danger Of Poisoning if oil is ingested/absorbed through the skin!
Risk Of Injury if oil comes into contact with eyes and skin!
IMPORTANT: Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
Using contaminated equipment to add fluid may introduce dirt particles into the
fluid reservoir and significantly reduce the service life of the power steering
system. Do not use any filler funnels or similar!
The fill level may only be checked or adjusted when the engine is stopped! The
fluid temperature should be approx. 20°C here.
CARMANUALSUSA
2008 BMW 328xi
Ensure that the cap is fully screwed in prior to the fill level check.
NOTE: To avoid mix-ups when filling with hydraulic fluid, mark the fluid reservoirs or
their caps with identification marks.
ATF Automatic transmission fluid
CHF Pentosin CHF11S
Fig. 40: Identifying Fluid Reservoir Caps With Identification Marks

1. Thoroughly clean fluid reservoir and its immediate surroundings

2. Check and correct fill level
NOTE: The fill level can come to rest above the "MAX" mark when the engine is at
normal operating temperature. This is dictated by the design in that the
marking on the dipstick is referred to a fluid temperature of 20°C. With the
engine at normal operating temperature (approx. 50-60°C fluid
temperature) adjust a fill height 10 mm above the "MAX" mark. Do not
under any circumstances draw off the fluid to the "MAX" mark when the
engine is at normal operating temperature.
Hydraulic fluid: BMW Service Operating Fluids
3. Start engine
4. Turn steering wheel left and right twice in each case up to full lock; if necessary, top up hydraulic fluid
(e.g. if hydraulic system is completely drained)
5. Move steering wheel to straight-ahead position and turn off engine
6. Check and correct fill level with engine stopped
7. Check hydraulic system for leaks
CARMANUALSUSA
2008 BMW 328xi
32 13 060 REMOVING AND INSTALLING/REPLACING POWER STEERING GEAR (2WD)
system.
Seal off pipe connections with plugs.
 Draw off and dispose of hydraulic fluid from fluid reservoir

 E93: Remove V-strut
 Remove both Tie Rod Ends From Swivel Bearing
 Replacement only: Remove both Tie Rod Ends From Tie Rod
 Remove Lower Steering Spindle From Power Steering Gear
If necessary, remove heat shield from power steering gear.
Release banjo bolts (1, 4).
Disconnect pressure line (2) and return line (3) from power steering gear.
If necessary, remove hydraulic lines with bracket from power steering gear.
Fig. 41: Identifying Banjo Bolts, Pressure Line And Return Line
Installation:
Replace all sealing rings.
CARMANUALSUSA
2008 BMW 328xi
Make sure hydraulic lines are laid without tension and with sufficient spacing to adjoining components.
For tightening torque refer to 32 41 9AZ (pressure line) in 32 41 PUMP AND OIL SUPPLY .
For tightening torque refer to 32 41 10AZ (return line) in 32 41 PUMP AND OIL SUPPLY .
Remove power steering gear (2) towards front.
Installation:
Fig. 42: Identifying Power Steering Gear And Mounting Nuts

After installation:
 Fill and Bleed Hydraulic System

 Check pipe connections for leaks
32 13 060 REMOVING AND INSTALLING/REPLACING POWER STEERING GEAR (AWD)
WARNING: Danger to life. Ensure engine is secured in installation position to prevent

it from falling down.
CARMANUALSUSA
2008 BMW 328xi
system.

 Secure engine in installation position.
 Lower front axle support.
Remove cooler return line from front axle carrier.
Fig. 43: Identifying Banjo Bolts, Pressure Line And Return Line
Installation:
Replace sealing rings.
CARMANUALSUSA
2008 BMW 328xi
NOTE: Heat shield is only fitted on right side.
If necessary, release screws (1) and remove heat shield (2).
Fig. 44: Removing Heat Shield

Tightening torque 5.9 ft. lbs. (8 Nm).
Remove power steering gear (2) to one side.
Installation:
CARMANUALSUSA
2008 BMW 328xi
Fig. 45: Identifying Power Steering Gear And Mounting Nuts

After installation:

32 13 065 REMOVING AND INSTALLING/REPLACING ACTIVE FRONT STEERING POWER

STEERING GEAR
system.

 Remove diesel enclosure on driver's side
 Disconnect plug connection from power steering pump and expose connecting cable up to power steering
gear
CARMANUALSUSA
2008 BMW 328xi
Fig. 46: Identifying Pressure Line, Return Line And Banjo Bolts
Installation:
Replace all sealing rings.
Release screws (1) and remove brackets.
Release screws (2), remove pressure line and tie back.
For tightening torque refer to 41 11AZ in 32 41 PUMP AND OIL SUPPLY .
CARMANUALSUSA
2008 BMW 328xi
Fig. 47: Identifying Pressure Line Mounting Brackets Screws

Disconnect plug connections (1) and lay connecting cables to one side.
Fig. 48: Identifying Plug Connections

Tie up power steering gear to prevent it from falling down when

disconnecting plug connections.
IMPORTANT: Risk of damage
Do not expose connecting cables to tensile load.
CARMANUALSUSA
2008 BMW 328xi
Move power steering gear forwards and tie up.
Installation:
Fig. 49: Identifying Power Steering Screws

Disconnect plug connections (1) and lay connecting cables to one side.
Remove power steering gear.
Fig. 50: Identifying Power Steering Plug Connections

After installation:
CARMANUALSUSA
2008 BMW 328xi

32 13 070 REMOVING AND INSTALLING (REPLACING) ELECTRIC STEERING GEAR (EPS)
IMPORTANT: Steering gear:
Check connection of steering gear for corrosion, clean contacts if necessary.

The steering gear must be replaced if the corrosion is too far advanced.
Connecting cable:
In the event of moisture/corrosion inside the two plug connections, check the
insulation of the connecting cable. If the insulation reveals any
noticeable/striking features, it will be necessary to replace the part. Otherwise
it will be sufficient to replace the contacts or plug housing.
NOTE: In a warranty case you must always provide a fault memory printout, even
where there is no fault memory entry, with the defective part.
 Disconnect Battery Negative Lead
NOTE: High-current-carrying lead laid with permanent positive connection (80 A

fuse protection).

Cut open cable tie (1).
Disconnect plug connections (2).
Installation:
Check plug connections for moisture and corrosion. To do so, read and follow notes/information at the start of
the document.
CARMANUALSUSA
2008 BMW 328xi
Plug connections must audibly snap into place.
Make sure connecting lead is correctly laid.
Fig. 51: Identifying Electric Steering Cable Tie And Plug Connections
Remove steering gear (2) towards front.
Installation:
Fig. 52: Identifying Steering Gear And Mounting Screws

CARMANUALSUSA
2008 BMW 328xi
After installation:
 Replacement: Carry out programming/coding

 Teach in end stop software
21 STEERING ARMS, TIE ROD

32 21 151 REPLACING LEFT OR RIGHT TIE ROD
NOTE: If the tie rod end to tie rod screw/bolt connection is released, it is necessary
 Remove Front Wheel
IMPORTANT: Do not release tie rod end from swivel bearing with impact tool.
Rubber gaiter of tie rod end must not be damaged!
Release nut (1); if necessary, grip at Torx socket.
Remove tie rod end (2) from swivel bearing.
Installation:
Keep tie rod end to swivel bearing connection clean and free from oil and grease.
CARMANUALSUSA
2008 BMW 328xi
Fig. 53: Identifying Tie Rod End And Retaining Nut

Determine measurement (A) to simplify following adjustment of front axle.
Release screw (1).
Screw off tie rod end; if necessary, grip tie rod with open-end wrench.
Installation:
Check Gaiter for damage, replace if necessary.
Screw in tie rod end to measurement (A).
Fig. 54: Identifying Tie Rod End Measurement

CARMANUALSUSA
2008 BMW 328xi
After installation:

32 21 231 REPLACING LEFT OR RIGHT TIE ROD
 Remove Tie Rod End From Swivel Bearing

 Remove Gaiter From Steering Gear and slide back
IMPORTANT: To avoid damage to rack and to suspension mounting, move rack in as far as
possible.
Release joint (1) with standard tool (38 WAF) from steering gear rack.
Fig. 55: Identifying Steering Gear Rack Joint

Installation:
Clean rack.
Check surface of rack for damage (e.g. corrosion).
Power steering gear only: Grease rack (refer to BMW Service Operating Fluids ).
On replacement, assemble new part with gaiter:
CARMANUALSUSA
2008 BMW 328xi
 Determine measurement (A) to simplify following adjustment of front axle.
Installation:
Slacken clamping screw (1) and screw off tie rod end.
Push clamp and gaiter onto tie rod.
Screw in tie rod end to measurement (A).
Fig. 56: Measuring Tie Rod End

After installation:

32 41 ... INSTRUCTIONS FOR REMOVING AND INSTALLING EAR CLIPS
 32 1 260
NOTE: The work steps are show on assorted components.
Ear clip must always be replaced.
To remove an ear clip, place special tool 32 1 260 at right angles to ear and cut ear open.
CARMANUALSUSA
2008 BMW 328xi
Fig. 57: Using Special Tool (32 1 260) On Ear Clip

The ear clip can be fitted not only axially but also radially after the hook fastener has been opened.
Fig. 58: Identifying Ear Clip

Attach hook fastener and press ear together with special tool 32 1 260.
CARMANUALSUSA
2008 BMW 328xi
Fig. 59: Identifying Special Tool (32 1 260) And Hook Fastener
Side cutter of special tool 32 1 260 can be used in areas which are difficult to access.
Fig. 60: Identifying Side Cutter On Special Tool (32 1 260)

IMPORTANT: Gap (A) max. 1 mm!
CARMANUALSUSA
2008 BMW 328xi
Fig. 61: Identifying Ear Clip Gap

31 STEERING COLUMN
32 31 003 REMOVING AND INSTALLING/REPLACING UPPER SECTION OF STEERING
COLUMN TRIM
 00 9 323
IMPORTANT: Disconnecting the plug connection for the handsfree microphone or

emergency SOS call button results in fault memory entries in the telephone
control unit (limitation in the emergency SOS call system).
After installation:
 Read out fault memory and delete entries
Move steering column in "bottom" and "extended" position.
IMPORTANT: Risk of damage
Unclip steering column trim (1) at side with special tool 00 9 323.
CARMANUALSUSA
2008 BMW 328xi
Fig. 62: Identifying Steering Column Trim And Special Tool (00 9 323)
Tilt steering column trim (1) towards front.
Unclip steering column gap cover (2) from steering column trim.
Installation:
Tilt steering column trim towards rear, align by way of locks to lower section (of steering column trim) and
press down.
Fig. 63: Identifying Mounting Screws, Steering Column Trim And Steering Column Gap Cover
Replacement:
E93: Remove hands-free microphone from steering column trim.
32 31 020 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING

CARMANUALSUSA
2008 BMW 328xi
COLUMN TRIM
 Remove Upper Section Of Steering Column Trim

 Move steering column into "top" and "extended" position and do not secure with adjusting lever
Press detent lugs outwards a little and unclip steering column trim downwards.
Installation:
Align steering column trim by means of detent lugs to steering column and press up as far as it will go.
Press steering column trim on both sides together a little and then press upwards completely until detent lugs
snap into place.
Check installation position, correct if necessary.
Fig. 64: Removing Steering Column Trim

32 31 070 REMOVING AND INSTALLING / REPLACING LOWER SECTION OF STEERING

SPINDLE
IMPORTANT: If the lower section of the steering spindle is separated from the steering
gear/steering column, this can result in damage to the steering column switch
cluster when the steering wheel is turned!
 Move steering column in "top" and "extended" position

 Remove trim panel for pedal assembly.
CARMANUALSUSA
2008 BMW 328xi
 Secure upper section of steering spindle in footwell (can be pushed into steering column)
 N51, N52, N53: Remove Intake Filter Housing with intake hose to intake manifold/system
 N54: Remove intake filter housing with left charge-air duct
Release clamping screw.
Installation:
Recut thread.
Replace clamping screw.
Clamping screw must rest in groove of steering column.
No kinking permitted!
For tightening torque refer to 32 31 1AZ in 32 31 STEERING COLUMN .
Fig. 65: Identifying Steering Column Clamping Screw - Side View

Release clamping screw.
Move steering wheel to straight-ahead position and remove ignition key.
Detach lower section of steering spindle from steering gear.
Installation:
Recut thread.

CARMANUALSUSA
2008 BMW 328xi
Clamping screw must rest in groove of steering gear.
Fig. 66: Identifying Steering Gear Clamping Screw - Top View

Detach lower section of steering spindle from steering column.
Installation:
Lower section of steering spindle can only be attached in one position to the steering column.
Fig. 67: Identifying Lower Section Of Steering Spindle

After installation:
CARMANUALSUSA
2008 BMW 328xi

 Check directional stability of car
32 31 082 REMOVING AND INSTALLING/REPLACING STEERING ANGLE SENSOR
NOTE: Steering angle sensor is integrated in the steering column stalk fixture.Steering
Angle Sensor Adjustment
After installation:
 Replacement only: Carry out programming/coding

 Only when replacing / programming / coding: Carry out front steeringSteering Angle Sensor
Adjustment/Adjustment For Active
 Version with active front steering: Teach in centre position for power steering gear
32 31 090 REMOVING AND INSTALLING/REPLACING STEERING COLUMN
NOTE: Cars produced up to 12/2004 have a steering column with a 3-pin plug
connection for electric steering column locking. Cars produced after this date
have a 4-pin plug connection. Spare parts are offered for both variants.
 Remove Lower Section Of Steering Spindle

 Remove footwell heating duct
 RemoveSteering Column Trims
 Disconnect all plug connections at fixture for steering column stalk
 Disconnect plug connection on electric steering column lock
 Remove wiring harnesses from steering column
Release screws (1).
Secure steering column against falling out.
Remove steering column towards rear.
Installation:
CARMANUALSUSA
2008 BMW 328xi
When inserting the steering column into the sleeve, make sure the sleeve is not pressed out of the
bulkhead. Check installation position of sleeve, correct if necessary.
Fig. 68: Identifying Steering Column Mounting Screws

Replacement:
ModifyFixture For Steering Column Switch.
After installation:
 Carry out Steering Angle Sensor Adjustment for active front steering
 Replacement only: Turn steering wheel in both directions to full lock. The airbag warning lamp must not
light up in the process.
32 31 102 REPLACING STEERING SPINDLE SLEEVE
 Remove Lower Section Of Steering Spindle
After installation:
Pop sleeve (1) out of bulkhead and press together.
Push steering spindle into steering column.
Remove sleeve (1) from steering column.
CARMANUALSUSA
2008 BMW 328xi
Fig. 69: Identifying Steering Spindle Pop Sleeve

Installation:
Detach pull-in lug from sleeve and lubricate gap with silicone grease.
Press sleeve together, slide onto steering column, align to opening in bulkhead and insert in bulkhead.
NOTE: To prevent the sleeve from slipping out and to avoid complaints by the
customer about noise, make sure that sealing lip (1) on engine compartment
side rests against bulkhead all round and sealing lip (2) in inside the car rests
against the damping.
Fig. 70: Identifying Sealing Lip Between Engine Compartment And Damping
32 31 215 REMOVING AND INSTALLING/REPLACING DOUBLE JOINT FOR STEERING

SPINDLE LOWER SECTION (AWD)
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: If the double joint is separated from the power steering gear/lower section of
the steering spindle, the steering column switch cluster may be damaged when
the steering wheel is turned.
 Remove TRIM PANEL FOR PEDAL ASSEMBLY

 Secure upper section of steering spindle in footwell (can be pushed into steering column)
 N51, N52, N53, N54: Remove INTAKE FILTER HOUSING
Release clamping screw (1).
Installation:
Clean thread to remove all remnants of screw securing adhesive.
Clamping screw must rest in groove of power steering gear.
Tightening torque: 32 31 3AZ . See STEERING COLUMN for specs.
Fig. 71: Identifying Clamping Screw

Release clamping screw (1).
Return steering to straight-ahead drive setting and remove ignition key.
Pull steering spindle lower section (3) from double joint (4).
CARMANUALSUSA
2008 BMW 328xi
Installation:
Clean thread to remove all remnants of screw securing adhesive.
Clamping screw must rest in groove (2) of steering spindle lower section (3).
Tightening torque: 32 31 4AZ . See STEERING COLUMN for specs.
Fig. 72: Removing Steering Spindle Lower Section From Double Joint
Detach double joint (1) from power steering gear.
Installation:
Double joint (1) can only be attached in one position to the power steering gear.
CARMANUALSUSA
2008 BMW 328xi
Fig. 73: Identifying Double Joint

After installation:
 Turn steering wheel in both directions to full lock. The airbag warning lamp must not light up in the
process.
32 31 241 REPLACING ADJUSTING LEVER FOR STEERING COLUMN
 Remove Steering Column
If necessary, remove cable duct from steering column.
Unclip adjusting lever.
Installation:
Align adjusting lever to steering column and attach straight to prevent the locks from being damaged.
Check locks after attachment, replace adjusting lever if necessary.
CARMANUALSUSA
2008 BMW 328xi
Fig. 74: Identifying Steering Column Adjusting Lever Locks

33 STEERING WHEEL
32 33 ... REPLACING COVER FOR SPORT STEERING WHEEL
NOTE: Version with multifunction:
The procedure is described in the document "... Both Sport Steering Wheel
Switches ".
 Remove Airbag Unit
NOTE: Sport steering wheel (4) was only removed to generated the picture.
Release screws (1).
Release cover (3) from holders (2); if necessary, disconnect associated plug connection.
Version with multifunction: remove sport steering wheel switches
Installation:
Replace damaged cover.
CARMANUALSUSA
2008 BMW 328xi
Fig. 75: Identifying Steering Cover, Retaining Screws, Sport Steering Wheel And Holders
32 33 ... REPLACING DECORATIVE TRIMS FOR STEERING WHEEL

Unclip decorative trims (1).
Fig. 76: Identifying Steering Wheel Decorative Trims

32 33 000 REMOVING AND INSTALLING / REPLACING STEERING WHEEL
CARMANUALSUSA
2008 BMW 328xi

Move wheels/steering wheel into straight-ahead position.
Release screw.
Remove steering wheel.
Installation:
Align steering wheel using marking (1) to steering column and attach.
For tightening torque refer to 32 33 1AZ.
Fig. 77: Identifying Marking On Steering Column

Replacement:
Modify Multifunction Steering Wheel Decorative Trims/Switches.
32 33 010 REMOVING AND INSTALLING/REPLACING SPORT STEERING WHEEL
Move wheels/steering wheel into straight-ahead position.
Release screw (1).
For tightening torque refer to 32 33 1AZ in 32 33 STEERING WHEEL .

CARMANUALSUSA
2008 BMW 328xi
Disconnect plug connections (2) and remove sport steering wheel.
Fig. 78: Identifying Steering Wheel Plug Connections

Installation:
Align sport steering wheel using marking (1) to steering column and attach.
Fig. 79: Identifying Alignment Marking On Steering Column

Replacement:
Modify sport steering wheel cover/switches.
34 STEERING WHEEL FOR AIRBAG

32 34 020 REMOVING AND INSTALLING/REPLACING AIRBAG UNIT
CARMANUALSUSA
2008 BMW 328xi
WARNING: Observe the following instructions to avoid any risk of injury by the
airbag unit.
 Comply with Safety Regulations For Handling Components Gas

Generators .
 Do not exert any force on the airbag unit.
 Use only specified tools for releasing the airbag unit.
NOTE: Incorrect handling may result in triggering of the airbag unit and thereby cause
serious injury.
IMPORTANT: Steering Wheel must be replaced if airbag unit has been triggered!
Follow Procedure After Airbag Triggering.
Insert Torx screwdriver (T20) roughly straight from below into opening on reverse side of steering wheel up to
stop (approx. 5.5 cm).
Swing Torx screwdriver (T20) with handle sideways until airbag unit is unlocked.
Repeat procedure on other side.
Installation:
Make sure electrical lead is correctly positioned.
Snap airbag unit with uniform pressing force plane parallel in direction of steering column shaft into steering
wheel.
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Fig. 80: Using Torx Screwdriver To Unlock Airbag Unit

Airbag unit may only be set down with the airbag itself facing upwards .
Tilt airbag unit towards rear.
Disconnect plug connection and remove airbag unit.
Fig. 81: Identifying Airbag Unit Plug Connection

32 34 030 REMOVING AND INSTALLING / REPLACING AIRBAG UNIT (SPORT STEERING

WHEEL)
WARNING: Observe the following instructions to avoid any risk of injury by the
airbag unit.
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 Comply with Safety Regulations For Handling Components Gas

Generators .
 Do not exert any force on the airbag unit.
 Use only specified tools for releasing the airbag unit.
NOTE: Incorrect handling may result in triggering of the airbag unit and thereby cause
serious injury.
IMPORTANT: Steering Wheel must be replaced if airbag unit has been triggered!
Follow Procedure After Airbag Triggering.
Insert Torx screwdriver (T25) at an angle into concealed opening on reverse side of steering wheel until a spring
resistance is felt (approx. 1.5 cm).
Increase pressure on spring leg (concealed) using Torx screwdriver (T25) until airbag unit is unlocked.
Repeat procedure on other side.
Installation:
Make sure electrical leads are correctly positioned.
Snap airbag unit with uniform pressing force plane-parallel in direction of steering column shaft into steering
wheel.
Fig. 82: Identifying Angle To Insert Torx Screwdriver Into Steering Wheel
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2008 BMW 328xi
Airbag unit may only be set down with the airbag itself facing upwards .
Tilt airbag unit forwards.
Disconnect plug connections and remove airbag unit.
Installation:
Connect plugs to connections of same colour on airbag unit.
Fig. 83: Identifying Airbag Unit Plug Connection

65 77 ... NOTES ON SCRAPPING BMW VEHICLES WITH GAS GENERATORS (CENTRAL

AIRBAG CONTROL UNIT, AIRBAG SYSTEM)
The gas generator is a pyrotechnic component of:
 Airbag module
 Driver's/passenger airbag
 Side airbags
 Head airbag
 Knee airbag
 Belt pretensioner
 Belt buckle tensioner
 Safety battery terminal
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1 Series: E81, E87
3 Series: E46, E90, E91, E92, E93
5 Series: E60, E61 from build date 09/2005
6 Series: E63, E64 from build date 09/2005
X3: E83
X5: E53, E70
Z4: E85, E86
Gas generators that have not fired constitute a hazard (also to the environment)!
In accordance with accident prevention regulations and specific national regulations, gas generators must be
rendered unusable before they are scrapped. This is necessary because pyrotechnical objects can cause injury if
improperly activated (e.g. scrapping with flame cutters).
With above-mentioned vehicles which are scheduled for scrapping, it is always essential prior to draining and
further stripping work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can
then be scrapped together with the vehicle.
Triggering failure
If correct triggering is not possible, the relevant components must (while observing the safety regulations for
handling airbag system components) be removed and disposed of by special disposal companies!
If a triggering operation has failed:
 Disconnect the triggering device from the battery and

 only approach the vehicle after a few minutes have elapsed
The components of an airbag system must always be disposed of. Such components must not be sold on as
used parts.
Triggering
Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
responsible person. Other standard accident prevention regulations (safety goggles, ear defenders etc.) must also
be observed.
The gas generators must be fired from the outside in the vehicle scheduled for scrapping with the doors closed
but with the tailgate, door windows and sunroof open. To fire the gas generators, use the BMW developed
triggering device with the corresponding cables.
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WARNING: Once gas generators have been fired, observe a ventilation period of 10
minutes with the doors opened. Only then is it permitted to continue work
inside the vehicle.
Wear protective goggles and protective gloves when handling a fired gas
generator!
The burning of solid fuel will heat up airbag unit - danger of burning
hands!
Wash skin with water after contact with fired gas generators!
1. Vehicles with central airbag control unit (all airbags, seat belt pretensioners, safety battery
terminal)
1.1 Expose Airbag Control Unit .
1.2 Connect "Airbag master".
72 00 ... SAFETY REGULATIONS FOR HANDLING COMPONENTS WITH GAS GENERATORS
It is essential to comply with the regulations as specified in the law relating to the use of explosives when
working on airbag units and seat belt tensioners.
Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different
danger classes on the basis of the quantity of propellant that they contain. The assignment can be ascertained
from the identification marking on the product:
IMPORTANT: Failure to comply with the warning notices and repair instructions for gas
generator components can cause accidental deployment and result in injury
and vehicle damage!
This applies in particular to the following components:
 Airbag modules (driver's/front passenger airbags, side airbags)

 Buckle/belt tensioner
 Head airbag (ITS, AHPS)
 Active knee protection
 Active head restraint
 Safety battery terminal (SBK)
1. Regulations
The regulations quoted in the following refer to the Federal Republic of Germany.
In all other countries, the relevant legislation and regulations must be observed in each case. Country
CARMANUALSUSA
2008 BMW 328xi
specific legal regulations that go beyond this information or court decisions based thereon must be
followed in each case or given precedence over these regulations.
The following components used by BMW:
 Pyrotechnical restraint systems are subject to danger class PT1

 Gas generators are pyrotechnical objects belonging to danger class T1.
Handling, transporting and storing non-fired gas generators are subject to the "Explosive Materials
Act" (law relating to the use of explosives dated 13/09/1976).
The relevant trade supervisory authority must be notified at least 2 weeks before pyrotechnical objects are
handled for the first time. Here the relevant authority must be notified in writing of the person responsible
(e.g. dealership owner, holder of general power of attorney or if necessary workshop supervisor). A
certificate of qualification, i.e. specific training, is not required for the person responsible.
2. Disassembly and assembly

 Inspection, testing and installation work may only be carried out by expert trained personnel in
BMW Service.
 Work on components of the airbag system should only ever be carried out with the battery
disconnected, the negative terminal post covered and the plug connection of the cable leading to the
gas generator disconnected. If only the battery is disconnected, the following prescribed waiting
period must be observed without fail:
 30 minutes for vehicles up to 9/93;
 1 minute for vehicles from 9/93
 In the event of breaks in work, a component with a gas generator that has been removed must be
secured against access by other persons.
 Individual components must never be repaired. Instead, always replace them.
 Do not treat airbag system components with cleaning agents or grease.
 Components of the airbag system must not be exposed to temperatures in excess of 75°C.
 Airbag system components, including electronic diagnostic components, which have been dropped
from heights in excess of 0.5 m must not be reinstalled in the vehicles.
 Before installing, subject airbag system components (including electronic diagnostic components)
to a visual inspection for damage and replace if necessary.
 Airbag system components may only be electrically tested while they are installed and only with
the BMW diagnostic system / DIS.
 Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.
Otherwise the generator will be thrown upwards if it is fired.
 Do not point the firing pellet of a gas generator at other persons.
 Components with gas generators must not be fired while they are removed. They must be disposed
of by special disposal companies or returned to BMW in the packaging of the new components.
 When carrying out straightening and welding work with an electric welder:
 Disconnect battery
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2008 BMW 328xi
Cover negative terminal (post)


 Avoid all contact with the skin when removing a fired airbag module - wear gloves. Wash with
water after contact with the skin.
3. Transport
 Components with gas generators must be sent off in the packaging of the new components.
4. Storage
 Observe the regulations of the relevant trade supervisory authority and the applicable national
regulations.
72 12 ... PROCEDURE AFTER AIRBAG TRIGGERING AS RESULT OF AN ACCIDENT
Check and/or replace following components after airbag triggering:
Satellites (control unit + sensor)
 Components
 Satellite, A-/B-pillar, left/right
 Satellite, front door
 Satellite, rear seat
 Satellite, driver's/front passenger seat
 Satellite, vehicle center
 Procedure
 Read out fault memory
 Disconnect battery and observe waiting period
 Rectify faults
 Reconnect battery and observe waiting period
 Clear fault memory
 Turn off ignition and wait at least 2 minutes (no consumers may be switched on during this period
such as e.g. inside lights, radio, etc.)
 Switch ignition on.
 Clear fault memory and if necessary rectify faults
Cables and plugs
 Components and procedure

 Check cables and plugs for damage, replace if necessary.
Belt system
 Components
 Automatic safety belt tensioner
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2008 BMW 328xi
 Belt buckle tensioner

 Seatbelt height adjustment
 Procedure
 Check components, replace if necessary
Seats
 Components
 Seat
 Airbag module
 Active head restraint
 Procedure
 Check seats (function check of seat mechanism), replace if necessary
 Check seat screw/bolt connections
 Replace gas generator of active head restraint system
If the severity of the impact has not caused any other damage to the seat, only the triggered gas
generator needs to be replaced.
External feature: The triggered head restraint is folded forwards and engaged.
The repair work can be carried out in the car with the rear panel removed. The entire system can be
pushed back into its original position and the new gas generator installed.
The gas generator can be replaced up to 5 times.
 Replace airbag module and seat cover with padding
Driver's airbag
 Components
 Airbag module
 Steering wheel
 Steering column (if damaged)
 Procedure
 Replace steering wheel
Passenger airbag
 Components
 Airbag module
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 Instrument panel trim

 Supporting tube (if damaged)
 Procedure
Side airbag, front/rear
 Components
 Airbag module
 Door trim panel
 Door in white
 Seat
 Procedure
Head airbag (AHPS)
 Components
 Airbag module
 Trim, A-pillar
 Roofliner
 Trim, B-pillar (if damaged)
 Trim, C-pillar (if damaged)
 Bodyshell
 Procedure
Knee airbag
 Components
 Panel (driver's side)
 Lower section of glovebox
 Active knee protector (driver's and passenger sides)
 Procedure
Passive knee protector
 Components
 Panel (driver's side)
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 Glovebox incl. knee protector (passenger side)

 Procedure
 Check components for damage, replace if necessary
 Check fastening elements
41 PUMP AND OIL SUPPLY

32 41 ... INSTRUCTIONS FOR REMOVING AND INSTALLING EAR CLIPS
 32 1 260
NOTE: The work steps are show on assorted components.
Ear clip must always be replaced.
To remove an ear clip, place special tool 32 1 260 at right angles to ear and cut ear open.

The ear clip can be fitted not only axially but also radially after the hook fastener has been opened.
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Fig. 85: Identifying Ear Clip

Attach hook fastener and press ear together with special tool 32 1 260.
Fig. 86: Identifying Special Tool 32 1 260 (1 Of 2)

Side cutter of special tool 32 1 260 can be used in areas which are difficult to access.
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Fig. 87: Identifying Special Tool 32 1 260 (2 Of 2)

IMPORTANT: Gap (A) max. 1 mm!
Fig. 88: Identifying Ear Clip Gap

32 41 ... INSTRUCTIONS FOR USING SPECIAL TOOL 32 4 000
 32 4 000
 32 4 004
 32 4 005
 32 4 006
 32 4 011
 32 4 012
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Depending on the pressure hose connection on the pump, the special tool 32 4 000 must be assembled.
1 = Connection, pump
2 = Connection, steering gear
Fig. 89: Identifying Special Tool (32 4 000), Pump Connection And Steering Gear Connection
< EMPHASIZE >Pressure hose connection to pump with M14 x 1.5 banjo bolt:
Screw special tool 32 4 004 with M14 x 1.5 banjo bolt (1) and 2 sealing rings to special tool 32 4 000.
Screw special tool 32 4 011 onto pump and connect special tool 32 4 004.
Screw special tools 32 4 006 / 32 4 012 onto special tool 32 4 000 and connect pressure hose with M14 x 1.5
banjo bolts and 2 sealing rings.
Fig. 90: Identifying Special Tools (32 4 011), (32 4 004), (32 4 006) And (32 4 012)
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Pressure hose connection to pump with M16 x 1.5 banjo bolt:
Screw special tool 32 4 005 onto pump and connect special tool 32 4 004.
Screw special tool 32 4 006 onto special tool 32 4 000 and connect pressure hose with M16 x 1.5 banjo bolt and
2 sealing rings.
Fig. 91: Identifying Special Tools (32 4 006), (32 4 005), (32 4 004) And Banjo Bolt
Pressure hose connection to pump with M16 x 1.5 union screw:
Connect special tool 32 4 004 to pump.
Screw special tools 32 4 006 / 32 4 005 onto special tool 32 4 000 and connect pressure hose.
Fig. 92: Identifying Special Tools (32 4 006), (32 4 005), (32 4 004) And Banjo Bolt
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32 41 ... NOTES ON HYDRAULIC LINE WITH QUICK-CONNECT COUPLING
1. Quick-connect coupling with ID marking
Fig. 93: Identifying Quick-Connect Coupling, Piping, Spring And Coupling Marking
Removing:
Push quick-connect coupling (1) against pipe (4) (thereby relieving strain on spring (2)).
Press plastic ring (3) into quick-connect coupling (1) and remove coupling (1).
Assembly:
Markings (K) on coupling (1) and pipe (4) must be flush.
Push quick-connect coupling (1) onto pipe (4) until a "click" can clearly be heard.
To check that quick-connect coupling (1) has been installed correctly, pull it back forcefully.
2. Quick-connect coupling with indication pins
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Fig. 94: Identifying Quick-Connect Coupling, Transportation Lock, Pipe, And Indication Pins
Removing:
Press plastic ring (2) into quick-connect coupling (1) and remove coupling (1).
Assembly:
When replacing hydraulic line: remove transportation lock (T).
Push quick-connect coupling (1) onto pipe (3) until both indication pins (4) can be seen and felt to point
outwards at outside diameter of housing.
To check that quick-connect coupling (1) has been correctly fitted, feel indication pins (4) at outside
diameter of housing. When correctly seated, indication pins (4) cannot be pressed into housing.
IMPORTANT: Coupling is not correctly engaged if both indication pins (4) fail to
protrude from housing. Leakage is thus unavoidable.
32 41 009 CHECKING FUNCTION OF POWER STEERING VANE PUMP

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 32 4 000
IMPORTANT: Prior to this check, first check all hose connections, the vane pump and the
power steering gear for leaks.
Adhere to the utmost cleanliness. Do not allow any dirt to enter the hydraulic
system.
After installation:

 Draw off and dispose off hydraulic fluid from fluid reservoir
Observe country-specific waste-disposal regulations

 Disconnect Pressure Line From Vane Pump
Connecting special tool:
Connect special tool 32 4 000 (refer to Notes On Use) with new sealing rings to vane pump and pressure line.
1. Connection, vane pump

2. Connection, power steering gear
Fig. 95: Identifying Special Tool (32 4 000), Vane Pump Connection And Power Steering Gear
Connection
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Checking pump pressure:
1. Close valve (A).

2. Open valve (B).
3. Fill and Bleed Hydraulic System
4. Start engine.
5. Heat hydraulic fluid to approx. 50°C by moving steering wheel at increased engine speed.
6. Close valve (B) for max. 10 secs. and read off pressure.
7. Compare measured pressure with specified Nominal Pressure .
Replace Vane Pump if the nominal pressure is exceeded by more than 10 %.
Check belt tension if the nominal pressure is undershot by more than 10 %. Replace Vane Pump if belt
tension is OK.
Fig. 96: Identifying Special Tool (32 4 000), Open And Close Valves
32 41 033 REMOVING AND INSTALLING OR REPLACING POWER STEERING PUMP FOR

POWER STEERING GEAR WITH ACTIVE STEERING (N51, N52, N53)
IMPORTANT: Aluminium-magnesium materials.
No steel screws/bolts may be used due to the threat of electrochemical

corrosion.
A magnesium crankcase requires aluminium screws/bolts exclusively.
Aluminium screws/bolts must be replaced each time they are released .
The end faces of aluminium screws/bolts are painted blue for the purposes of
reliable identification.
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Jointing torque and angle of rotation must be observed without fail (risk of
damage) .
system.
Close off pipe connections with plugs.

 Remove Intake Filter Housing
 Replacement only: Slacken screws of Belt Pulley
 Relieve tension on Drive Belt and remove from belt pulley
Release hose clamp (2) and detach suction line from power steering pump.
Installation:
Align suction line by way of marking to connection on vane pump.
Release banjo bolt (3) and disconnect pressure line.
Installation:
Replace all sealing rings (D).
Make sure pressure line is laid without tension and with sufficient spacing to adjoining components.
For tightening torque refer to 32 41 8AZ in 32 41 PUMP AND OIL SUPPLY .
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Fig. 97: Identifying Steering Pump Plug Connection, Hose Clamp, Banjo Bolt And Sealing Rings
Release bolt (1) and remove bracket with refrigerant line.
Release screws (2).
Installation:
Replace aluminium screws.
Observe screwing sequence.
Fig. 98: Identifying Refrigerant Line Mounting Bracket Bolt And Screws
Remove Front Underbody Protection .
Remove radiator seal.
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Replacement only: Unfasten screws and remove Belt Pulley.
Release bolts (1) and remove power steering pump (2) towards top.
Installation:
Fig. 99: Identifying Power Steering Pump And Mounting Bolts

Screw-fastening sequence:
1. Secure power steering pump with screws

2. Tighten front screws to 2 Nm
3. Tighten side screws to 2 Nm
4. Tighten down front screws to jointing torque and angle of rotation
5. Tighten down side screws to jointing torque and angle of rotation
After installation:

32 41 060 REMOVING AND INSTALLING OR REPLACING POWER STEERING VANE PUMP

CARMANUALSUSA
2008 BMW 328xi
(N51, N52, N53)
IMPORTANT: Aluminium-magnesium materials.
No steel screws/bolts may be used due to the threat of electrochemical

corrosion.
A magnesium crankcase requires aluminium screws/bolts exclusively.
Aluminium screws/bolts must be replaced each time they are released .
The end faces of aluminium screws/bolts are painted blue for the purposes of
reliable identification.
Jointing torque and angle of rotation must be observed without fail (risk of
damage).
system.

 Replacement only: Slacken screws of Belt Pulley
 Relieve tension on Drive Belt and remove from belt pulley
Release hose clamp (1) and detach suction line (2) from vane pump.
Installation:
Align suction line by way of marking to connection on vane pump.
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Fig. 100: Identifying Vane Pump Hose Clamp And Suction Line
Release bolt (1) and remove bracket with refrigerant line.
Release screws (2).
Installation:
Fig. 101: Identifying Refrigerant Line Mounting Bolt And Screws

Remove Front Underbody Protection .
Remove radiator seal.
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2008 BMW 328xi
Release banjo bolt (1) and disconnect pressure line.
Installation:
Replace all sealing rings (D).
Make sure pressure line is laid without tension and with sufficient spacing to adjoining components.
Replacement only: Unscrew bolts and remove belt pulley.
Release bolts (2) and remove vane pump towards bottom.
Installation:
Fig. 102: Identifying Vane Pump Bolts And Banjo Bolt

Screw-fastening sequence:
1. Secure vane pump with screws

2. Tighten front screws to 2 Nm
3. Tighten side screws to 2 Nm
4. Tighten down front screws to jointing torque and angle of rotation
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5. Release screws at side and check screw fastening points for gap freedom
6. Tighten down side screws to jointing torque and angle of rotation
After installation:

32 41 100 REMOVING AND INSTALLING/REPLACING BELT PULLEY ON VANE PUMP FOR

POWER STEERING
NOTE: Carry out preliminary work as described in the document "Replacing drive belt
".
Slacken bolts (1)
Relieve tension on Drive Belt and remove from belt pulley (2).
Unscrew bolts (1) and remove belt pulley (2).
Installation:
Lettering on belt pulley (2) must point forwards.
Fig. 103: Identifying Belt Pulley And Bolts

32 41 250 REMOVING AND INSTALLING / REPLACING FLUID RESERVOIR FOR POWER

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2008 BMW 328xi
STEERING
 32 1 260
system.
N45, N46, M47T2:
 Remove intake duct if necessary with gaiter
M57T2 335d:
 Unclip water hose from coolant expansion tank
Release screw (1).
NOTE: If necessary, raise and/or turn fluid reservoir in order to gain better access to
hose clamps.
Remove hose clamps if necessary with special tool 32 1 260.
Disconnect suction line and radiator return line from fluid reservoir.
Lift out fluid reservoir.
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Fig. 104: Identifying Fluid Reservoir Retaining Screw

After installation:

32 41 253 REMOVING AND INSTALLING / REPLACING FLUID RESERVOIR FOR POWER

STEERING WITH ACTIVE FRONT STEERING
 32 1 260
system.
M57T2 335d:
 Unclip water hose from coolant expansion tank
Release screw (1).
NOTE: If necessary, raise and/or turn fluid reservoir in order to gain better access to
CARMANUALSUSA
2008 BMW 328xi
hose clamps.
Remove hose clamps if necessary with special tool 32 1 260.
Disconnect suction line and radiator return line from fluid reservoir.
Lift out fluid reservoir.
Fig. 105: Identifying Fluid Reservoir Retaining Screw

After installation:

32 41 311 REPLACING INTAKE LINE FOR POWER STEERING (N51, N52, N53)
system.

Remove fluid reservoir from mounting bracket/body.
Release hose clamp (1) and detach suction line (2) from fluid reservoir.
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Installation:
Make sure hydraulic line is laid without tension and with sufficient spacing to adjoining components.
Fig. 106: Identifying Fluid Reservoir Hose Clamp And Suction Line
Expose suction line up to connection on vane pump.
Release hose clamp (1) and detach suction line (2) from vane pump.
Installation:
Markings (3) on suction line and vane pump must match up.
If a marking is missing, it is important to ensure when installing the hydraulic line that it is laid without tension
and with sufficient spacing to adjoining components.
Fig. 107: Identifying Suction Line Markings, Hose Clamp And Vane Pump Suction Line
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After installation:

32 41 332 REPLACING DELIVERY LINE FOR POWER STEERING (N51, N52, N53)
system.
Recycling:
Catch and dispose of hydraulic fluid in a suitable container.

 Remove Front Underbody Protection .
 Remove trim on radiator at bottom
Release banjo bolt and detach pressure line from vane pump.
Installation:
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Fig. 108: Identifying Hydraulic Line Banjo Bolt

Expose pressure line up to connection on power steering gear.
Release banjo bolt and disconnect pressure line.
Installation:
Fig. 109: Identifying Pressure Line Banjo Bolt

After installation:

32 41 341 REPLACING COOLER RETURN LINE FOR POWER STEERING
system.
Recycling:
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 N51, N52, N53, N54: Remove Intake Filter Housing
 M47T2, M57T2: Remove intake duct
Remove fluid reservoir from mounting bracket/body.
Release hose clamp (1) and detach cooler return line (2) from fluid reservoir.
Installation:
Fig. 110: Identifying Fluid Reservoir Hose Clamp And Cooler Return Line
Expose cooler return line up to connection on power steering coil.
Release Quick-Connect Coupling and seal power steering coil connection with a suitable plug.
Installation:
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Fig. 111: Identifying Quick-Connect Coupling

After installation:

32 41 351 REPLACING RETURN LINE FOR POWER STEERING (N51, N52, N53)
system.
Recycling:

Release Quick-Connect Coupling and seal cooling coil connection with a suitable plug.
Installation:
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Fig. 112: Identifying Hydraulic Line Quick-Connect Coupling

Expose return line up to connection on power steering gear.
Release banjo bolt and disconnect return line.
Installation:
Fig. 113: Identifying Return Line Banjo Bolts

After installation:
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43 ELECTRONIC POWER STEERING

32 10 005 ADJUSTMENT FOR ACTIVE FRONT STEERING
NOTE: Adjustment of the active front steering must be carried out:

 after the battery has been disconnected or electrical plug connections on
the steering column switch cluster have been disconnected
 after replacement/programming or coding of the following components:
 Steering column switch cluster
 DSC control unit
 Active front steering control unit
 ARS control unit
Select and carry out initial operation/adjustment for active front steering under Service functions.
32 43 010 REMOVING AND INSTALLING/REPLACING CONTROL UNIT FOR ACTIVE FRONT

STEERING
IMPORTANT: Read and comply with notes on protection against electrostatic damage (ESD
protection).

 Remove Front Left Wheel Arch Cover (Rear Section)
Release screw (1) and remove grounding cable.
Unlock plug (2) with a suitable tool and detach.
Open cable tie (arrowed).
Unclip cable holder (4).
Unlock plug (3) with a suitable tool and detach.

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Installation:
Replace faulty cable holder (4).
Fig. 114: Identifying Steering Control Plugs,Cable Ties, Cable Holder And Screws
Unscrew nut (1).
For tightening torque refer to 32 43 1AZ in 32 43 ELECTRONIC POWER STEERING .
Release screw (2).
For tightening torque refer to 32 43 1AZ in 32 43 ELECTRONIC POWER STEERING .
Remove active front steering control unit (3).
Fig. 115: Identifying Active Front Steering Control Unit

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After installation:
 Replacement only: Carry out programming/coding

 Carry out Adjustment For Active Front Steering
90 TROUBLESHOOTING
32 90 ... TROUBLESHOOTING ON ELECTRIC STEERING GEAR (EPS)
Read fault memory.
ELECTRIC STEERING GEAR TROUBLESHOOTING CHART

Fault Cause Remedy
Failure of power-assisted 1. Contacts corroded NOTE:
steering / clear reduction of Check insulation of connecting
power-assisted steering when cable for damage, replace part if
stationary necessary
Replace contacts and plug

housing
 Clean contacts on steering
gear, replace Steering Gear
if necessary
2. Insulation of connecting Check insulation of connecting
cable damaged cable for damage, replace part if
necessary
Refer to Troubleshooting On Front Axle
Excessive steering wheel Screws at lower section of Replace screws and tighten down
play/steering wheel shake steering spindle to steering (refer toRemoving And
gear/steering column loose Installing/Replacing Lower
Section Of Steering Spindle)
Journal of tie rod end deformed Replace Steering Gear And Tie
Rod Ends
Tie rod end worn Check steering gear rack; if
necessary, replace Steering Gear
Check tie rods, replace if necessary
Replace Tie Rod End
Steering gear rack damaged Replace Steering Gear
Steering wheel inclination Tie rod end worn Replace Tie Rod End
Front axle alignment incorrectly Carry out Chassis/Wheel
adjusted Alignment Check, adjust toe/track
if necessary
CARMANUALSUSA
2008 BMW 328xi
Vehicle pulls Steering angle sensor adjustmentCarry out Steering Angle Sensor
failed Adjustment
Steering column switch cluster Check Mounting For Steering
faulty Column Switch , replace if
necessary
Interference noise when steering Spindle surface dirty or corroded Replace Steering Gear
through (under load) (caused by damaged gaiter)
NOTE: In a warranty case you must always provide a fault memory printout, even
where there is no fault memory entry, with the defective part.
32 90 ... TROUBLESHOOTING ON STEERING
Observe troubleshooting on front axle and diagnosis help for steering (SI).
STEERING TROUBLESHOOTING CHART

Fault Cause Remedy
Excessive steering wheel Screws at lower section of Replace screws and tighten down
play/steering wheel shake steering spindle to steering (refer to Removing And
gear/steering column loose Installing/Replacing Lower
Section Of Steering Spindle)
Bolt connection, universal Replace and tighten down bolts
joint/double joint, to lower section
of steering spindle/steering
gear/steering column loose
Journal of tie rod end deformed Replace Steering Gear And Tie
Rod Ends
Tie rod end worn Check steering gear rack; if
necessary, replace Steering Gear
Check Tie Rod End, replace if
necessary
Replace Tie Rod End
Steering gear rack damaged Replace Steering Gear
Steering wheel inclination Tie rod end worn ReplaceTie Rod End
Front axle alignment incorrectly Carry out Chassis/Wheel
adjusted Alignment Check, adjust toe/track
if necessary
CARMANUALSUSA
2008 BMW 328xi
SUSPENSION Integrated suspension systems - Repair Instructions
SUSPENSION
Integrated suspension systems - Repair Instructions
GENERAL
37.... OVERVIEW OF 2-AXLE RIDE-HEIGHT CONTROL
Fig. 1: Overview Of 2- Axle Ride-Height Control

37.... OVERVIEW OF ELECTRONIC DAMPER CONTROL (EDC)

CARMANUALSUSA
Sunday, August 30, 2015 5:33:16
2008 BMW 328xi
Fig. 2: Overview of Electronic Damper Control (EDC)

ELECTRICAL COMPONENTS
37 14 511 REPLACING FRONT RIDE-HEIGHT SENSOR
Protection).
Release nut (1) and disconnect jointed rod (2).
Installation:
For tightening torque refer to 37 14 3AZ in 37 14 ELECTRIC COMPONENTS .
Release screws (4).
Remove ride-height sensor and disconnect plug connection (3).
CARMANUALSUSA
2008 BMW 328xi
Installation:
Sensor lever (5) must point from ride-height sensor to left front wheel.
Fig. 3: Identifying Plug Connection, Screws, Lever, Jointed Rod And Nut
After installation:
 Check Headlight Adjustment , correct if necessary
37 14 512 REPLACING REAR RIDE-HEIGHT SENSOR
Protection). .
Installation:
Release bolt (4) and remove ride-height sensor with bracket.
Installation:
Align bracket to corresponding bore hole (arrow) in rear axle carrier.

CARMANUALSUSA
2008 BMW 328xi
Fig. 4: Identifying Nut, Jointed Rod, Plug Connection And Bolt

Replacement:
Release screws (1) and remove ride-height sensor from bracket (2).
Installation:
Sensor lever (3) must point from ride-height sensor in direction of screw fastening point (arrow) of bracket.
Fig. 5: Identifying Ride-Height Sensor Bracket And Screw

37 14 511 REPLACING RIDE HEIGHT SENSOR AT FRONT (AWD)
CARMANUALSUSA
2008 BMW 328xi
IMPORTANT: Read and comply with notes on NOTES ON PROTECTION AGAINST

ELECTROSTATIC DAMAGE (ESD PROTECTION) .
Tightening torque: see 3AZ in 37 14 ELECTRIC COMPONENTS .
Installation note:
Replace nut.
Release screws (3), remove ride height sensor and disconnect plug connection (4).
Tightening torque: see 1AZ in 37 14 ELECTRIC COMPONENTS .
Installation note:
Sensor lever (2) must point from ride height sensor to left front wheel.
Fig. 6: Identifying Jointed Rod, Sensor Lever, Nut, Screws, And Connector
After installation:
 Check HEADLIGHT ADJUSTMENT , correct if necessary
CARMANUALSUSA

00 Brake Testing and Bleeding: 2008 BMW 328xi 2008 BMW 328xi

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00 Brake Testing and Bleeding: 2008 BMW 328xi 2008 BMW 328xi

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2008 BMW 328xi

00 BRAKE TESTING AND BLEEDING

 Replace brake fluid at least every two years.

Brake pads must always be replaced on both sides of any axle.

 Always strip preservative off new parts before installation.

Brake lines, brake hoses:

Wheel-slip control system:

34 00 ... GENERAL INFORMATION ON BRAKING IN NEW BRAKE DISCS / BRAKE PADS

IMPORTANT: After completing work:

NOTE: Running AWD vehicles on dynamic brake analyzers is governed by different

IMPORTANT: Power measurements on single-axle roller dynamometers are generally not

6. E60 / E61 AWD

34 00 009 CHECKING BRAKES ON TEST STAND

Necessary preliminary tasks:

 Check tires for damage

IMPORTANT: The corresponding system must be deactivated on vehicles equipped with

Fig. 1: Identifying Brakes Test Stand

34 00 010 CHECKING THICKNESS OF BRAKE PAD

Special tools required:

NOTE: A. Brake disk

Safe Limit For Lining Wear, Front Brake.

Safe Limit For Lining Wear, Rear Brake.

Fig. 2: Identifying Special Tool (34 1 260)

34 00 025 REPLACING FLUID IN ABS/ASC+T BRAKE SYSTEM

NOTE: Read And Comply With General Information.

Unclip retaining tabs (1).

Pull cover (3) out of guide (2) and remove.

Fig. 3: Identifying Brake System Retaining Tabs, Cover And Guide

Connect brake fluid changer to expansion tank and switch on.

NOTE: Check relevant Operating Instructions for each device.

Charging pressure should not exceed 2 bar.

Fig. 4: Identifying Brake Fluid Changer

Flushing brake system completely

Close bleed valve.

Fig. 5: Identifying Rear Right Brake Caliper Bleeder Valve

Check brake fluid level.

Close expansion tank.

NOTE: Pay attention to rubber seal (1) in sealing cap.

34 00 050 BLEEDING BRAKE SYSTEM WITH DSC

NOTE: Read And Comply With General Information.

 Tandem brake master cylinder

Connect bleeder unit with max. 2 bar filling pressure.

A second person is needed to help carry out this work.

Unclip retaining tabs (1).

Pull cover (3) out of guide (2) and remove.

Fig. 7: Identifying Brake System Retaining Tabs, Cover And Guide

Connect brake fluid changer to expansion tank and switch on.

IMPORTANT: Check relevant Operating Instructions for each device.

Charging pressure should not exceed 2 bar.

Fig. 8: Identifying Brake Fluid Changer

Flushing brake system completely

Close bleed valve.

Fig. 9: Identifying Rear Right Brake Caliper Bleeder Valve

Bleeding rear-axle brake circuit

Close bleeder valve.

Run bleeding routine with DIS with bleeder valve open.

Close bleed valve.

Repeat procedure at rear left.

Fig. 10: Identifying Rear Right Brake Caliper Bleeder Valve

Bleeding front-axle brake circuit

Close bleeder valve.

Run bleeding routine with DIS with bleeder valve open.

Close bleed valve.