Rear seat BMW 525i 2001 E39 User Guide

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260-1 0
/ Driveshaft
Driveshaft, installing
- Prepare CV joint for reinstallation:
Extend joint to limit.
Clean off old grease and fill with fresh grease
Install new seal.
- Bend driveshaft slightly at center universal joint to install
CAUTION-
Do not allow CVjoint seal to become displaced.
- Align matchmarlts on driveshaft to matchmarks on final drive
and transmission flanges.
- Fit constant velocity joint to final drive input flange. Alternate-
ly tighten two opposite nuts to draw constant velocity joint
evenly into the final drive input flange. Once seated, tighten
down remaining nuts.
I CAUTION-
I Do not reuse self-locking nuts. These nuts are designed to be /
I used onlv once. 1
- Insert bolts in front of driveshafl to transmission output
flange. Counterhold each bolt while tightening nut.
CAUTION-
. Do not reuse self-locking nuts. These nuts are designed to
be used only once.
Avoid stressing the flex-disc when torquing the bolts.
Do this by counterholding the bolts and turning the nuts
on the flange side.
- Position center support bearing and install mounting nuts.
Use new self-locking nuts.
- Install heat shields.
- Install rear transmission support crossmember.
- Install exhaust system. See 180 Exhaust System.
Reconnect oxygen sensor wiring harnesses and reattach
wiring harness retainers to rear transmission support
crossrnernber.

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300-1 4
I Susoension. Steerina and Brakes - General
DSC system I
Dynamic Stability Control (DSC)
Dynamic Stability Control (DSC) utilizes many principles and
components of the ASC traction control system. DSC is ac-
tive throughoutthe driving range, unlike ASC which is only ac-
tive during acceleration and braking. DSC helps stabilize the
vehicle in cornering and avoidance maneuvers by adjusting
engine controls such as throttle, ignition, fuel injection and the
application of
brake pressure individually to the wheels.
Inputs
fi- 0
2 4-* .. o
[11-' IJ
411m4
3?-
G
4 The DSC control module uses various inputs to determine
vehicle instability during braking, cornering, or reduced trac-
tion situations. Based upon these inputs the ABSIDSC con-
trol module sends outputs to the engine control module and
the ABSIDSC hydraulic unit to activate torque reduction pro-
tocols and braking intervention.
-
ABSIDSC control module
OUI~YIS
4
The DSC system can be toggled on and off by a switch
mounted on the center console. Turning off the DSC system
does not disable ABS or ASC functions.
+
Measure ride height (A) from center of fender arch to bottom
of wheel rim.
Car in normal loaded position on the ground. See Normal
loaded position.
Engine
control
module
Specified tires and wheels, correct tire pressure, even tire
wear
-'* 9-
.%A
Correct wheel bearing play
T'== ..t, 9 B
-.m
Model with air suspension (EHC): Disconnect electrical har-
ness connector to air supply pump to prevent automatic
height regulation.
When finished, reset ride height using BMW diagnostic
scan tools DIS or
MoDiC.
NOTE-
Airsupply pump is located beneath a cover under the spare
tire in the floor of the cargo compartment.
- If ride height is outside specification listed, install new
springs. Suspension spring removal and installation is cov-
ered in
310 Front Suspension and 330 Rear Suspension.
Normal loaded position
Each front seat 68 kg (150 Ib)
Center of rear seat 68 kg (150 lb)
Trunk 21 kg (46 lb)
Fuel tank full

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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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330-5
Rear Suspension
REAR STRUTS AND SPRINGS
(SEDAN MODELS)
Rear strut assembly, removing and
installing
Replace struts and coil springs in pairs only.
- Raise car and remove rear wheels.
WARNING -
Male sure 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 parts.
- Remove rear parcel shelf:
Remove rear seat headrests by pulling straight up.
Remove both rear roof pillar (C-pillar) trim panels.
Unbolt rear seat
belt anchors. See 720 Seat Belts.
Models with fixed rear seat: Remove rear seat backrest.
See 520 Seats.
* Models with fold-down rear seat: Remove rear seat back-
rest side sections. See 520 Seats. Fold down backrest.
* Working inside trunk, remove roller blind mounting nuts
and bolts, if applicable. Also disconnect roller blind har-
ness connector at right edge of rear seat backrest.
Gently pry rear speaker cover grilles and rear window defog-
ger grilles
(A) out of parcel shelf.
Carefully remove seat belt and headrest mount finisher
strips (B).
Remove
middle seat headrest anchor bolts (C). Remove
headrest anchor.
Remove expansion rivets (arrows) and lift out parcel shelf.
- Remove rear speakers.
- Remove rear wheels. Remove wheel arch trim
- Support rear wheel bearing carrier.
CAUTION-
The strutassembly prevents the drive axle and wheel bearing
carrier
from dropping too far. Supporting the wheel bearing
carrierbefore disconnecting the strut mounting fasteners pre-
vents damage to the brake hose, parking brake cable and
drive axle
CV joints.

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330-8
Rear Suspension
4 Compress spring and install it and related components to
shock absorber. Use new self-locking upper strut mounting
nut.
1. Upper strut mount self-locking nut
2. Washer
3. Poor road surface adapter
4. Upper spring seat
5. Upper strut mount
6. Upper rubber bumper seat
7. Rubber bumper
8. Coil spring
9. Dust boot
10. Lower spring seat
I I. Strut
WARNING-
Male sure the upperself-locking nut is fully tightened before
releasing the spring compressor.
Tightening torque
Upper strut mount to strut shaft
27 Nm (20 ft-lb)
(M14, replace self-locking nut)
4 Before releasing spring tension, position upper strut mount
so that one threaded stud is on a plane with flat end of strut
bushing at other end of strut.
- Release spring compressorslowly, positioning spring ends in
shoulders of spring seats.
- Reinstall strut assembly in vehicle, as described above in
Rear strut assembly, removing and installing.

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330-1 0
/Rear Suspension
- Remove rubber protective cap from shock absorber upper
mount.
- Remove shock absorber upper mounting nuts.
- Remove shock absorber lower mounting bolt. Lower shock
absorber out of wheel housing.
< Transfer shock top mounting plate, dust cover (if applicable)
and related components to new shoclc absorber.
1. Self-locking nut
2. Washer
3. Upper siioclc absorber mount
4. Rubber bumper seat
5. Rubber bumper
6. Dust boot
7. Shock absorber
8. Long lower bushing
Tightening torques
Shock absorber to upper mount
27 Nm (20 it-lb)
(M14, replace self-locking nut)
- Installation on car is reverse of removal, noting the following:
Make sure all threaded bolts, nuts and mating surfaces are
clean.
Install shock absorber upper mount to
subframe using new
self-locking nuts.
. Make sure long lower shock absorber bushing fits in hole
in suspension swing arm.
Tighten lower shoclc absorber bolt to its final torque once
car is on ground.
Tightening torques
Quick coupling screw to air 2 Nm (18 in-lb)
shock absorber
Road wheel to
hub 120 &I0 Nm (89 -f7 ft-lb)
Shock absorber to swing arm 127 Nm (94 ft-lb)
Strut mount to body
Gray fasteners
Yellow fasteners
24 Nm ( 18 it-lb)

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330-1 1
Rear Suspension
Coil spring, removing and installing
Raise car and remove rear wheels.
WARNING-
Make sure 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 parts.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect
bralte fluid hose. See
340 Brakes.
- Remove exhaust system. See 180 Exhaust System.
- Disconnect driveshafl from final drive. See 260 Driveshaft.
- Detach parking bralte cables from mounting bracltets on sub-
frame.
< Support final drive unit from below using transmission jack
and
BMW special tool 33 4 390 or equivalent.
Remove rear suspension
subframe mounting bolts (arrows).
Lower rear
subframe until coil springs can be removed.
When reinstalling springs, replace upper and lower spring
pads if necessary.
Slowly lift suspension
back into position, making sure coil
springs are correctly seated in upper and lower spring seats.
Install and tighten
subframe mounting bolts. Note that on
each bolt, rubber-coated detent plate (arrow) must be in-
stalled at rear in driving direction
- Remainder of installation is reverse of removal
Tightening torques Road wheel
to hub 12OilO Nm (89i-7 ft-lb)
Subframe to body 163 Nm (120 ft-lb)

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Rear Suspension
Air spring, removing and installing
CAUTION-
If vehicle is driven with airspring depressurized, the airspring
will be permanently damaged and must be replaced.
An air spring is made from a flexible rubber material which
forms an airtight cavity. It is pressurized by an air supply
pump activated by an electronic control unit to provide a
vari- . . able spring rate depending on vehicle load
CAUTIOIG
Disable air supply pump by disconnecting electrical plug
before performing any repairs. Pump is located beneath a
cover under the spare tire in the floor of
the cargo compart-
ment.
When removing and installing air connections, extreme
cleanliness must be followed. Small dirt particles can
cause leakage in the system.
Remove luggage compartment floor mat.
- Working above air spring, loosen quick coupling screw con-
nection to allow
air pressure to escape.
- Once pressure has been reduced, retighten screw.
Tightening torque Quick coupling screw
to air pump 2 Nm (18 in-lb)
- Remove quick coupler. Plug openings to keep dirt out,
- Remove air spring mounting clips.
- Raise car and remove rear wheels.
Make sure the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural chassis points. Do not place
jaclc stands under
suspension parts.
- Working underneath rear suspension, lift wheel bearing car-
rier to relieve rear spring tension. Then unbolt air spring
mounting bolt from seat on wheel bearing carrier. Remove air
spring.
NOTE-
Left and right air springs are different. The left air spring is
marked with a red identification
marl. The right air spring is
marked with a blue identification mark.

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330-1 3
Rear Suspension
1 1 4 Check roll fold of air spring (arrows). Reinstall only if roll fold
is undamaged and formed correctly.
- To install air spring:
Check sealing O-rings at air spring inlet. Replace
if dam-
aged. Do not grease O-rings. Reinstall protective plug.
* Install spring above suspension subframe. Make sure ec-
centric lug at bottom of air spring fits in recess of
subframe
spring seat.
Reattach top spring mounting clips.
- Reattach air line connections.
- Remainder of installation is reverse of removal.
Tightening torques
Air line connection
2 Nm (1 8 in-lb)
Air spring
to wheel bearing carrier 20 Nm (1 5 ft-lb)
Road
wheel to hub 120 510 Nm (89-F-7 ft-lb)
REAR SUSPENSION ARMS,
SUBFRAME AND BUSHINGS
A damaged suspension arm orworn bushings will change the
rear wheel alignment and may adversely affect handling and
stability.
WARNING-
Do not attempt to straighten a damaged suspension arm.
Bending or heating may
weaken the original part. Always re-
olace a damaoed susoension arm.
Rear suspension arm
components
1. Eccentric washer
(for rear toe adjustment)
2. Upper front control arm
(guide link or traction strut)
3. Outer swing arm bushing and
integral link
4. Swing arm (lower control arm)
5. Upper rear control arm
(wishbone)
6. Wheel bearing carrier
7. Circlip
8. Swing arm ball joint
9. Eccentric washer
(rear camber adjustment)

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Rear ~us~ensionl
Working in cargo compartment, attach BMW special tools
33 2 302,33 2 303 and 33 2 305 to special tool 33 2 304.
Use special tool 33 2 306 to compress spring.
Tighten until lower spring coil lifts off spring seat on wheel
bearing carrier.
- Disconnect control rod for ride height sensor if applicable.
4 Remove ABS pulse sensor (arrow) from wheel bearing car-
rier.
- Support wheel bearing carrier from below.
CAUTION-
The shock absorberprevents the drive axle and wheel bear-
ing carrier from dropping too far. Supporting the wheel bear-
ing carrier before disconnecting the shock absorber
mounting fastenerprevents damage to the
brake hose, park-
ing brake cable and drive axle
CVjoints.
- Remove shock absorber lower mounting bolt
4 Remove stabilizer bar link mounting nut (arrow). Press link
out of swing arm.
4 Mark location (arrow) of rear camber adjustment washer and
bolt.
NOTE -
Rear camber is adjusted at the inner swing arm eccentric
rear mounting bolt.