BMW 540i 1998 E39 Workshop Manual

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320-3
Steering and Wheel ~li~nmentl
4 Pitman arm height measurement gauge
/I (Tool NO. BMW 32 2 140)
-
4 Ball joint removal tool
(Tool No. BMW 31 2 240)
4 Ignition lock releasing tool
(Tool No. BMW 32 3
11 0)
4 Steering column shear bolt Toot socket (E8)
(Tool No. BMW 32 3 120)
4 Camber setting tool set
(Tool No. BMW 32 3 140)
4 Ring antenna removal tool
(Tool No. BMW
61 3 300)

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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
I Rack and r in ion steering 1 Steering system variations
I 6-~~linder'rnodels (525i,>28i, 530i) / 1. Left tie rod
2. Right tie rod
3. Steering rack
4. Steering gearbox
5. idler arm
6. Center tie rod
7. Steering knuckle
Recirculating ball and nut steering
r V-8 models 154Oib

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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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320-1 0
Steering and Wheel Alignment
Steering column
components
1. Steering lock
2. Lower steering shafl
3. Horizontal drive motor
4. Longitudinal adjusting drive
shafl
5. Steering column support
6. Vertical adjusting drive shafl
7. Vertical drive motor
8. Lower support ring for steering
angle sensor
9. Upper support ring for steering
angle sensor
10. Steering angle sensor
11. Upper steering shafl
12. Steering shafl bearing
13. Bearing inner sleeve
14. Circlip
15. Collar
16. Steering wheel mounting bolt
Steering column trim, removing and
replacing
- Tilt steering column down and extend fully.
- Remove plastic retaining screw from upper trim cover,
4 Push in sides of upper trim cover (arrow) to release from
lower trim. Pull back and up on upper trim.

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Steering and Wheel ~li~nrnentl
q Pry gently to detach flexible cover from upper trim. Lift off
trim.
< Remove lower dash trim panel fasteners (A) and (B).
Lower trim panel and disconnect wiring harnesses on back
side of panel.
Remove trim panel.
- Installation is reverse of removal.
Ignition switch ring antenna (EWS),
removing and installing
- Remove upper and lower steering column trim as described
earlier.
- Disconnect electrical harness plug from ring antenna.
- Use flat side of BMW special tool 61 3 300 to pry ring antenna
off ignition lock cylinder.
- Installation is reverse of removal.
lgnition lock cylinder, removing and
installing
- Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Cautions and
Warnings.
- Remove upper and lower steering column trim as described
earlier.

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I Steering and Wheel Alignment
With ignition key in ON position (60" from LOCKED):
- Disconnect ring antenna harness connector.
Insert
BMW special tool 32 3 110 or a thin piece of stiff wire
into opening (arrow) in lock cylinder.
Turn tool forward (clockwise) approximately 90" and re-
move lock cylinder.
* Reinstallation is reverse of removal.
NOTE-
Using the valet ley during this procedure will provide better
access to lock opening.
Steering column lock, removing and
installing
- Disconnect negative (-) cable from battery.
CAUTIO&
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Cautions and
Warnings.
- Remove steering wheel as described earlier.
- Remove steering column trim panels as described earlier.
- Remove collar and circlip from steering shaft. Refer to illus-
tration of steering column components.
4 Pry steering shaft bearing with inner sleeve out of lock hous-
ing.
- Remove ring antenna as described earlier.
- Remove column switches. See 612 Switches.
< Automatic transmission models: Loosen and disconnect in-
terloclc shift cable (arrow) from ignition lock assembly.