engine BMW 525i 1998 E39 Workshop Manual

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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.

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320-34
I Steerins and Wheel Alignment
Front toe and toe difference angle
Toe is the difference in the distance between the front of the
front wheels and the rear of the front wheels. It is adjusted by
altering the length of the tie rods.
Toe difference angle determines the progressively different
paths taken by the front wheels as the car is turning. In
V-8
models, it is set by the pitman arm adjustment, but depends
on accurate setting of the toe.
Toe adjustments should only be made on specialized align-
ment equipment and only with the car in normal loaded posi-
tion, described below.
- Set front wheel toe at tie rod ends:
4 6-cylinder models: Loosen tie rod lock nut (A).
Adjust toe by turning inner tie rod (B) to change length
- V-8 models: Loosen left and right tie rod clamp bolts.
Adjust toe by turning inner tie rod to change length.
NOTE-
* Steering rack or steering gearbox can be centered by
aligning centering mark on steering shaft
with lug on steer-
ing rack.
To keep steering wheel centered, adjust both tie rods equal
amounts.
&cylinder models: Make sure the rubber boot on the rack
moves freely on the tie rod and does not become twisted.
Tightening torques
Tie rod clamp bolt
Tie rod collar
nut
27 Nm (20 ft-lb)
45 Nm (33 A-lb)
Rear toe
To adjust rear wheel toe, turn eccentric inner mounting bolt in
upper front control arm (traction strut).
NOTE-
Always adjust rear camber first.
- Before making toe adjustment, install new
mounting nut and tighten.
- Loosen nut one-half to one full turn.
4 Turn eccentric bolt (arrow) to adjust toe. rear
control arm

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Steering and Wheel Alignment
- Tighten nut while counterholding adjusting bolt,
- Tighten nut only after car has been lowered to ground and
suspension has settled.
Preparing for alignment
- The following conditions are necessary prior to wheel align-
ment:
Correct wheels and tires are installed, in good condition,
and are at the correct inflation pressures.
All steering and suspension parts and bushings are un-
damaged and show no signs of abnormal wear. Wheel
bearings are in good condition.
Ride height is in accordance with specifications. See
300
Suspension, Steering and Brakes-General.
Car is in normal loaded position. See below.
* Cars with air suspension: Remove air suspension power
fuse.
Normal loaded position
Each front seat
68 Kg (I50 lb)
Center of rear seat
Trunlc
Fuel tank
68 Kg (150 lb)
21 Kg (46 lb)
Full
Alignment specifications tables
In the alignment specification tables that follow, reference is
made to the various types of suspension used in
E39 cars.
The type of suspension can be identified by loolting at the la-
bel on the front strut tube.
Identifying symbol
None
Solid circle
Solid triangle
M5
Circle
Triangle Version
Standard suspension
Sports
suspension
Sports suspension
M sport package
Standard suspension
Sports suspension Model
Sedan
6-cylinder sedan
V-8 sedan
V-8 sedan
Touring (Sport Wagon)
Touring (Sport Wagon)

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Isteering and Wheel Alignment
6-cylinder sedan (5251,5281,530i)
Parameter
Front axle
. .. I I I
Outside wheel (approx. ") / 33.5 133 133
M Sport
suspension
Standard
suspension
With
i 20" wheel loclc
Front wheel displacement
Inside wheel
(approx. ")
Sport suspension
O0 5' i 10'
- 36' i 30'
-ID56'-t30'
N/A
6" 41' i 30'
Total toe
Camber (difference between lefffright maximum
40')
Track (differential angle with 20" lock on inside wheel)
Caster (difference between lefffright maximum
30')
With i 10" wheel locic
6" 42' i 30'
0°i15'
42
. .. I I I
Rear axle
6-cylinder Sport Wagon (5251,5281)
0"5'il0'
-13'+30'
-1" 56' -t 30'
N/A
6" 28' i 30'
OD5'i10'
- 36' i 30'
-1" 56' i 30'
N/A
6" 41' i 30'
6" 55'
i 30'
0'2 15'
41.5
0" 22'
-t 4'
0" i 12' Geometrical axis deviation
6' 55' i 30'
0"
i 15'
41.5
0°22'i4' Total toe 0" 22' i 4'
Camber (difference between leitlright maximum 15') 1-20 04' ?- 5' 1-2" 04' i 5'
O"i12'
Sport suspension
Parameter
- I I
. .. I I
Outside wheal (approx. ") 133.5 133
-2' 04' -t 5'
OO-t 12'
Standard suspension
Wlth i 10" wheel lock
I I
Front axle
With
i 20" wheel lock 16" 42' i 30' 16" 55'i30'
6" 28' i- 30'
0"
i 15' Front wheel displacement
. .. I I
Rear axle
D"5'iIO'
- 36' i 30'
-I056'i30'
NIA
Total toe
Camber (difference between
IeWright maximum 40')
Track (differential angle with 20" lock on inside wheel)
Caster (difference between
lefffrioht maximum 30') 6" 41'
+ 30'
Inside wheel (approx. ") 142 141.5
OOi 15'
0"5'i10'
- 13'i30'
-1" 56' i 30'
N/A
0" 16'i 10' Total toe
0" i 12' Geometrical axis deviation
Camber (difference
between iefffright maximum
15') /-lo 50' i 20' 1-1" 50'i20'
0" 16'f 10'
0" il2'

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Steering and Wheel Alignment
V-8 Sedan (540i)
I Front axle I
Parameter Standard
suspension
Total toe
.
Track (differential angle with 20" ioclc on inside wheel)
Caster (difference between
leftiright maximum 30')
With i 10° wheel loclc
With i 20" wheel lock
Front
wheel displacement
Inside
wheel (approx. ")
Outside wheel (approx. ")
M Sport suspension
Camber (difference between
leitiright maximum 40') 1- 13'i30' 1- 30' i 30' 1- 37' i 30'
0" 10'i 10' 0" 14'ilO'
Sport suspension
0" 14'i 10'
Rear axie
-1°35'i30'
N/A
6" 18'+30'
6' 36' i 30'
0"
i 15'
42
32.6
Total toe
Camber (difference between
IeWright maximum 15')
Geometrical axis deviation ~~
V-8 Sport Wagon (540i)
O"10'iW
-lo 49' i 5'
O"i12'
0" 22' i 4'
-2' 04' i 5'
0"
i 12'
Parameter
-1 " 43 'i 30'
NIA
6" 27'
i 30'
6"49'i30'
Pilo'
41.5
32
0°22'i4'
-2" 04' i 5'
O"i 12'
-ID 44' i 30'
N/A
6" 34' i 30'
6' 50' 130'
0" i 15'
42
31.8
Standard suspension Sport suspension
Front axie
0" 14'210'
-37i30'
-la44'+30'
N/A
6" 34' i 30'
6' 50' i 30'
O0i15'
42
31.8
0"
16'2 10'
-I050'i20'
0" i 12'
Total toe
Camber (difference between
ieftiright maximum 40')
Track (differential angle
with 20" loclc on inside wheel)
Caster (difference between
leftiright maximum 30')
With i 10" wheel lock
With i 20° wheel lock
Front wheel displacement
Inside wheel (approx.
")
Outside wheel (approx. ")
0" 14'i 10'
-13'i30'
-1" 35' i 30'
N/A
6' lS'i30'
6' 36' i 30'
On+ 15'
42 32.65
Rear axle
Total toe
Camber (difference between
lettiright maximum 15')
Geometrical axis deviation
0" 16'i 10'
-I050'i20'
0" i 12'

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330 Rear Suspension
General . . . . . . . . . . . . . . . . . . . . . . . . . . . ,330-2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . ,330-2
Rear suspension variations . . . . . . . . . . . . ,330-4
Rear Struts and Springs
(sedan models)
. . . . . . . . . . . . . . . . . . . . ,330-5
Rear strut assembly, removing
and installing
. . . . . . . . . . . . . . . . . . . . . . . ,330-5
Rear strut assembly, disassembling
and assembling
. . . . . . . . . . . . . . . . . . . . . ,330-7
Rear Shock Absorbers and
Springs (Sport Wagon models)
. . . . . ,330-9
Rear shock absorber, removing
and installing
. . . . . . . . . . . . . . . . . . . . . . . ,330-9
Coil spring, removing and installing . . . . . ,330-1 1
Air spring, removing and installing
. . . . . . ,330-12
Rear Suspension Arms,
Subframe and Bushings . . . . . . . . . . ,330-13
Rear suspension arm components . . . . . . ,330-1 3
Swing arm, removing and installing (sedan models)
. . . . . . . . . . . . . . . . . . . . . ,330-1 4
Swing arm, removing and installing (Sport Wagon models)
. . . . . . . . . . . . . . . ,330-16
Swing arm ball joint, replacing . . . . . . . . . ,330-1 9
Upper rear control arm, removing
and installing (sedan models)
. . . . . . . . . . .330-22
Upper rear control arm, removing
and installing (Sport Wagon models)
. . . . .330-23
Upper front control arm (traction strut),
removing and installing
. . . . . . . . . . . . . . . ,330-25
Rear axle assembly, removing and
installing (sedan models)
. . . . . . . . . . . . . ,330-26
Rear axle assembly, removing and
installing (Sport Wagon models)
. . . . . . . ,330-28
Rear subframe mounting bushings,
removing and installing
. . . . . . . . . . . . . . . .330-31
Rear Wheel Bearings . . . . . . . . . . .
Rear wheel bearing carrier, removing
and installing (sedan models)
. . . . . . .
Rear wheel bearing carrier, removing
and installing (Sport Wagon models)
. .
Rear wheel bearing, replacing . . . . . . .
Rear Stabilizer Bar
Stabilizer bar, removing and installing .
Stabilizer bar link, removing
and installing
. . . . . . . . . . . . . . . . . . . .
Electronic Height Control (EHC)
Component Replacement
. . . . . . .
Electronic height control (EHC)
components
.....................
Air compressor pump relay, removing
and installing
. . . . . . . . . . . . . . . . . . . .
EHC control module, removing
and installing
. . . . . . . . . . . . . . . . . . . .
Air supply unit, removing and installing
Ride height sensor, removing
and installing
. . . . . . . . . . . . . . . . . . . .

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330-2
I Rear Suspension
This repair group covers removal and replacement of E39
rear suspension components. A general description of sus-
pension systems and ride height specifications can be found
in 300 Suspension, Steering and Brakes - General.
CAUTIOI\C
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
sparl~s from grinding/cutting op-
erations.
* Do not subject to steel welding splashes.
0 Do not expose to temperatures over 80°C (176°F).
even for shortperlods. Temperatures in painting facili-
ties are not a problem.
Special tools
Special service tools are required for some of the work de-
scribed in this repair group. Most of these tools are special-
ized press jigs and pullers that might be replaced by standard
pullers of various sizes.
Read the procedures through before beginning any job.
< Strut upper mounting nut socket
(Tool No. BMW
31 2 21 0)
I Axle shaft removal and installation set
Spring compressor (Tool No. BMW
31 3 340.31 3 350)

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Rear suspension/
31 3 333 "I Rubber bushing removal tool set
(Tool No. BMW
33 3 331,33 3 332,33 3 333,33 3 334)
4 Subframe mount removal set
(ToolNo.BMW334 140,334148,334149,334151,334
155.33 4 156)
4 Subirame mount tool set
(Tool
No.BMW334151,34140,334155,334154)
4 Rear wheel bearing carrier mount tool set
(ToolNo.BMW334151,334152,334153,334154,334
156,334157)
4 Subframe mount installation set
(Tool No. BMW
33 4 153,33 4 155,33 4 156,33 4 157)
Slide hammer set
(Tool No. BMW
33 4 201,33 4 202,33 4 203)
13 4 201

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330-4
Rear Suspension Rear suspension variations
1. Coil spring
2. Strut
3. Final drive (differential)
4. Rear subframe
5. Upper rear control arm
(wishbone)
6. Subframe mounting bushing
7. Drive axle
8. Upper front control arm
(traction strut)
9. Swing arm (lower control arm)
10. Integral link
12. Air spring
I
Waaon
11. Shockabsorber
a m3 withair s~riias