Air BMW 528i 1998 E39 Workshop Manual

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/~ront Susaension
Front suspension arms FRONT SUSPENSION ARMS
Scyllnder models (5251,5281,530i)
Control arms and tension struts are attached to the front sub-
Front suspension arms V-8 models (5401)
frame through rubber bushings and to the steering ltnuckles
by ball joints.
NOTE-
Tension struts are sometimes called thrust arms or thrust
rods.
Control arms or tension struts are sometimes called lower
front arms or lower rear arms.
Inspect ball joints for wear and looseness. lnspect bushings
for wear or fluid
lealts. The ball joint can only be replaced as
part of an entire suspension arm assembly. Some suspen-
sion arm
bushinas are available as re~lacement Darts. Al-
ways replace in pairs
NOTE-
Steering wheel vibration during braking (usually at road
speeds of
50 to 60 m.p.h.) are often causedby faulty suspen-
sion arm bushings, not out-of-true brake rotors.
Some special tools may be required to remove suspension
arms and to replace bushings. Read procedures through be-
fore beginning the job.
Control arm, removing and installing
(6-cylinder models)
- Raise car and remove wheel
Male sure
that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension
parfs.
Cars equipped with vertical headlight adjustment system:
Disconnect control arm from level sensor.
Remove control arm fasteners (arrows). Lightly tap inner
control arm mounting bolt out of subframe.

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I Steering and Wheel Alignment
This repair group covers steering wheel and column removal
and steering system service, including wheel alignment infor-
mation.
NOTE-
Ignition loclc cylinder replacement is covered in this sec-
tion.
a For information on steering column mounted switches, in-
cluding the ignition switch, see
612 Switches.
Special tools
Some special tools are necessary to carry out the repairs and
adjustments required for steering service and wheel align-
ment. Be sure to read the procedures through before starting
work on the vehicle.
4 Steering shafl retaining ring installation tool
(Tool No. BMW 32
1 090)
4 Bail joint removal tool
(Tool No. BMW 32
1 190)
4 Pitman arm removal tool
(Tool No. BMW 32 2
000)
4 Inner tie rod removal tool
(Tool No. BMW 32 2
110)

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I Steerina and Wheel Alianment
Steering
system
Two types of steering gear are used in the E39 series models.
6-cylinder
(5251, 528i and 530i) models are equipped with
rack and pinion steering. The steering rack is mounted to
an aluminum subframe.
V-8
(540i) models are equipped with a recirculating ball
and nut steering gearbox mounted to a steel subframe.
At low speeds, maximum power assist is provided to ease
parking and city driving. At high speeds, assist is reduced to
ensure stability. The power steering system varies assist
based on engine speed.
Power boost for the steering is provided by an engine-driven
hydraulic pump. A hydraulic control valve is used to control
boost pressure.
The steering wheel connects to the steering gear via an ad-
justable steering column which incorporates a rubber cou-
pling ("guibo") to dampen vibration and noise.
Power steering fluid is supplied from the fluid
reservoir to the
pump and to the steering gear via rubberlmetal hoses.
The return line from the steering gear to the
reservoir loops
into the airstream in front of the radiator and connects to the
steering fluid cooler. The fluid cooler is attached to a cassette
which also includes cooling coils for engine oil, transmission
fluid and AIC condenser.
The steering gear requires no maintenance other than align-
ment and periodic inspection for worn components. Inspect
rubber rack boots
(rack and pinion system) and tie-rod end
boots periodically for tears or damage. Replace
if necessary.
-
NOTE-
The airbag system is traditionally referred to as Supplemen-
tal Restraint System (SRS). The
BMW versfon of SRS used
m the E39 models is known as the Multiple Restraint System - (MRS). - -

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Steering and Wheel Alignment
Steering system warnings and cautions
WARNING -
The BMW airbag system is complex. Special precautions
must be observed when servicing the system. Serious in-
jury may result if system service is attempted by persons
unfamiliar with the BMW
airbag system and its approved
service procedures. BMW specifies that all inspection and
service should be
peiformed by an authorized BMW deal-
e,:
The BMW E39 is equipped with an airbag mounted in
the steering wheel. The
airbag is an explosive device
and should be treated with extreme caution. Always fol-
low the
airbag removal procedure as outlined in 721
Airbag System (SRS).
BMW airbags are equipped with a bacli-up power sup-
ply inside the
airbag control module. A 5 second wait-
ing period should be observed after the battery cable
has been disconnected. This will allow the reserve
power supply to discharge.
Do not reuse self-locking nuts. They are designed to
be used only once and may fail if reused. Always re-
place them with new locliing nuts.
* Do not install bolts and nuts coated with undercoating
wax, as correct tightening torque cannot be assured.
Always clean the threads with solvent before installa-
tion, or install new parts.
Do not attempt to weld or straighten any steering com-
ponents. Always replace damagedparts.
CAUTION--
- Some E39 models are equipped with aluminum suspen.
sion components. The following cautions apply:
Due to the chemical and corrosion characteristics of
aluminum, do not bring into contact with battery acid.
Do not clean with wire brushes with brass or iron bris-
tles. Only use brushes with stainless steel bristles.
Do
not expose to flying sparks from grindinghutting op-
erations.
Do not subject to steel welding splashes.
* Do not expose to temperatures over 80% (176°F).
even for short periods. Temperatures in painting iacili-
ties are not a problem.

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320-7
Steering and Wheel ~liqnmentl
STEERING WHEEL
Steering wheel, removal and installation
WARNING -
The BMWairbag system (Supplemental Restraint System or
SRS) is complex. Special precautions must be observed
when servicing. Serious injury may result if
SRS system serv-
ice is
attempted by persons unfamiliar with the BMW SRS
and its approved service procedures. BMW specifies that all
inspection andservice should be preformed by an authorized
BMW dealer.
E39 cars may come with either one of two different styles of
steering wheel:
Multifunction (MFL) steering wheel
* Sport steering wheel
4 Multifunction (MFL) steering wheel components:
1. Cruise control 1 radio 1 telephone electrical harness
2. Horn button electrical harness
3. Airbag electrical harness
4. Radio / telephone control switch set
5. Air bag
6. Cruise control switch set
Sport steering wheel
3
5 0021413
4 Sport steering wheel components:
1. Switch carrier
2 Steering wheel switch set electrical harness
3. Airbag
4. Lower cover
5. Horn button and airbag electrical harness
- Center steering wheel. Make sure front wheels are pointed
straight ahead.
- Disconnect negative (-) cable from battery.
CA UTIOP&
Prior to disconnecting the battern read the battew discon-
nection cautions given in
001 General Cautions and
Warnings.
-

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320-8
Steering and Wheel Alignment
4 MFL steering wheel: Loosen 2 airbag mounting fasteners
(Torx T27 or T30) located at rear of steering wheel (arrow).
4 Sport steering wheel:
Insert screwdriver through opening in rear of steering
wheel and push against spring tension to release
airbag.
Repeat procedure on other side of steering wheel.
- Carefully lift airbag from steering wheel and disconnect elec-
trical harnesses from
back side of unit. Refer to component
illustrations above. Also see
721 Airbag System (SRS).
Improper handling of the airbag could cause serious injury.
Store the
airbag with the horn pad facing up. If stored facing
down, accidental deployment couldpropel it violently into the
Avoid damaging the variety of convenience switches, such
as radio and cruise controls, installed in the steering wheel of
4 Remove steering wheel center bolt (arrow).

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Check for proper alignment of steering column marks (ar-
row) before removing steering wheel.
NOTE-
The steering column and steering wheel are match marked
at the factory
Remove lower steering column trim panel. See Steering col-
umn trim, removing
and replacing.
Working underneath steering column, disconnect electrical
harnesses (A) and
(B).
Remove steering wheel.
When reinstalling steering wheel:
Align steering wheel and column match
marks.
Align steering wheel to alignment pins located on steering
column switch block.
Install steering column center bolt. Do not over-torque.
Carefully install
airbag. See 721 Airbag System (SRS).
Tightening torques
Steering wheel to steering
shaft (M14) 63 Nm (47 ft-lb)
Airbag to steering wheel (MFL only) 8 Nm (6 ft-lb)

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Steering and Wheel ~li~nrnentl
Steering gearbox, removing and installing
- Disconnect negative (-) battery cable. See 020 Mainte-
nance.
CAUTION-
Prior to disconnecting the battew read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove airbag unit from steering wheel. See 721 Airbag
System (SRS).
WARNING -
Improper handling of the airbag could cause serious injury
Store the
airbag with the horn pad facing up. If stored lacing
down, accidental deployment couldpropel it violently info the
air, causing
injuv
- Remove steering wheel as described earlier.
- Drain power steering system reservoir.
- Raise front of car.
WARNING -
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
Darts.
- Remove heat shield from left side of subframe.
- Remove fluid hoses from top of steering gearbox. Immedi-
ately plug all fluid openings.
Remove and discard
pitman arm self-loclting nut (arrow).

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L.. Steering and Wheel ~li~nrnentl ~
4 Mark A on steering gearbox shaft must be located in center
of
pitman arm slot.
- Adjust pitman arm as described later.
I 5"?~~5~"
I / < Gap A = 0.5 - 8.5 mm (0.02 - 0.33 in)
- Tighten pitman arm pinch bolt to specification.
' 1 Tightening torques
I u "steering Steering gearbox to subframe 62 Nm (46 ft-lb)
box Steering shaft universal joint to steering 19 Nm (14 It-lb)
gearbox (replace bolt)
- Install center tie rod to pitman arm using a new self locking
Pilrnan nut. arm
5nz3zn588 - Connect harness connector for Servotronic electro-hydraulic
regulator
if necessary.
- Connect fluid hoses to steering gearbox. Use new sealing
washers at couplings and make sure not to overtorque banjo
bolts.
Tightening torques Hydraulic lines to steering gearbox (banjo bolts)
MI0 12 Nm (9 ft-lb)
- M14 35 Nm (26 ft-lb)
. M16 40 Nm (30 ft-lb)
MI8 45 Nm (33 it-lb)
Center tie rod to pitrnan arm 65 Nm (48 it-lb)
(use new self-loclting nut)
- Reconnect negative (-) battery cable.
- lnstall airbag unit. See 721 Airbag System (SRS).
- Fill and bleed power steering system as described earlier.

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Steerina and Wheel ~lianmentl
Proper handling, stability and driving ease depend upon the
correct alignment of all four wheels. The front axle is aligned
in relation to the rear axle, then the front wheels are aligned in
relation to one another. This is known as a four-wheel or
thrust-axis alignment.
Front and rear alignment specification are given in tables at
the end of this repair group.
BMW E39 cars use a sophisticated multi-link suspension at
the front and rear of the car. Proper alignment requires com-
puterized alignment equipment.
Camber
Front wheel camber is set at the factory and cannot be adjust-
ed. Rear wheel camber is fully adjustable.
Always set rear camber before adjusting toe
Before making rear camber adjustment, install a new rear
control arm mounting nut
(arrow) and tighten.
- Loosen mounting nut one-half to one full turn.
Using eccentric bolt, adjust camber to factory settings.
Tighten nut only after car has been lowered to ground and
suspension has settled.
Tighten nut while counterholding adjustment bolt.
Tightening torque
Camber adjusting nut (rear)
MI2 (sedan)
- MI4 (Sport Wagon)
115 Nm (85 ft-lb)
174 Nm (128 ft-lb)
Caster
Front and rear caster are fixed by the design of the car and
deviations are usually the result of worn or damaged suspen-
sion or body parts.
- Check front suspension arms and bushings for wear, dam-
age and deformation if front caster problems are present.
- Check rear axle subfrarne and traction struts if rear caster
problems are present.