Idle BMW 528i 1999 E39 Repair Manual

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1 320 Steering and Wheel Alignment
General ........................... .32 0.2
Special tools
........................ .32 0.2
Steering system
..................... .32 0.4
Steering system variations
............. .32 0.5
Steering system warnings and cautions
... .32 0.6
Steering Wheel .................... .32 0.7
Steering wheel. removal and installation
.. .32 0.7
Steering Column ................. .32 0.1 0
Steering column components .......... .32 0.10
Steering column trim, removing
and replacing
...................... .32 0.10
lgnition switch ring antenna (EWS).
removing and installing
............... .32 0.1 1
lgnition lock cylinder.
removing and installing
............... .32 0-1 1
Steering column lock. removing
and installing
....................... .32 0.12
lgnition
interloclc cable. removing and installing
(models with automatic transmission)
... .32 0.13
Interlock cable. adjusting
(models with automatic transmission)
... .32 0.14
Steering column. removing and installing
. .32 0.14
Steering column adjustment motors.
removing and installing
............... .32 0.16
Power Steering Pump ............. .32 0.17
Power steering pump. removing
and installing
....................... .32 0.1 7
Power steering system.
bleeding and filling
.................. .32 0.18
Rack and Pinion Steering
(6-cylinder models)
............... 320-19
Rack and pinion steering components
(6-cylinder models)
.................. 320-1 9
Steering rack. removing and installing
.... 320-19
Steering
rack boot. replacing ........... 320-22
Tie rod (outer). replacing
.............. 320-22
Tie rod (inner). replacing
.............. 320-23
Steering Gearbox (V-8 models) .... 320-24
Steering gearbox system components
. .
(V-8 models) ....................... 320-24
Steering gearbox, removing and installing 320-25
Pitman arm. removing and installing ..... 320-28
Pitman arm. adjusting ................ 320-29
Steering idler arm. removing
and installing
....................... 320-30
Idler arm bushing. replacing ........... 320-31
Center tie rod. replacing
.............. 320-32
Wheel Alignment .................. 320-33
Camber
........................... 320-33
Caster
............................ 320-33
Front toe and toe difference angle
....... 320-34
Reartoe ........................... 320-34
Preparing for alignment
............... 320-35
Alignment specifications tables
......... 320-35

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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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I Steering and Wheel Alignment
I I 4 Gap A = 0.5 - 8.5 mm (0.02 - 0.33 in)
- Reinstall inner control arm bolts
Tightening torques
Control arm to
subframe 78 Nm (58 it-lb)
(tighten with wheel on ground)
Pitman arm pinch bolt (note direction of threads) 61 Nm (45 ft-lb)
Steering idler arm, removing and installing
The idler arm is bolted to the subframe through a bushing.
The bushing is subject to wear and is available as a replace-
ment part.
- Raise front of car. Remove splash shield from under engine.
WARNING -
Male sure the car is firmly supported on jaclc stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place jack stands under suspension
parts.
4 Remove center tie rod fastener and press tie rod out of idler
arm with
BMW special tool 32 1 190.
- Remove idler arm mounting bolt through opening in sub-
frame and remove idler arm from car.
- Installation is reverse of removal.
Make sure all thread bores, bolts, nuts and mating surfac-
es are clean.
Use new self
loclting nuts to mount idler arm to subframe
and center tie rod to idler arm.
If idler arm or idler arm bushing is replaced, adjust
pitman
arm as described earlier.
Have car professionally aligned.
Tightening torques
Center tie rod to idler arm 65 Nm (48 ft-ib)
(replace self-locking nut)
Idler arm to front subirame
(replace self-locking nut) 62
Nm (46 it-lb)

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320-31
Steering and Wheel ~li~nrnentl
ldler arm bushing, replacing
- Remove idler arm as described earlier.
< Press out bushing. Use BMW special tools 32 1 050 and 32
2 032 or equivalent press fittings.
4 Press in new bushing with BMW special tools 33 1 305 and
32 2 032 or equivalent press fittings.
4 Press new bushing in correct direction (arrow).
u ..... "A",
Press bushing in until lip makes firm contact (A) with idler
arm.
I
Installation is the reverse of removal
Use new self locking nuts to mount idler arm to
subframe
and traclc arm.
a Adjust pitman arm height as described earlier.
Have vehicle professionally aligned.
Tightening torques Center tie rod to idler arm
65 Nm (48 ft-lb)
;nl?mmn / (replace self-locking nut)
ldler arm to front
subframe
(replace sell-locking nut) 62
Nm (46 ft-lb)

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320-32
Steering and Wheel Alignment
Center tie
rod, replacing
- Raise front of car. Remove splash shield from under engine.
WARNING-
Make sure tlie car is firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
cliassis points. Do not place jack stands under suspension
parts.
- Measure length of left and right (outer) tie rods. Write down
measurements.
NOTE-
Accurate measurement of the tie rod end with reference to
the center tie rod will help approximate correct wheel align-
ment when new parts are installed.
4 Remove self-loclting nuts connecting center tie rod to pitman
and idler arms. Press tie rod off pitman and idler arms using
BMW special tool
32 1 190 or equivalent.
4 Loosen left tie rod clamping bolt (arrow). Unscrew left tie rod
from center tie rod. Repeat for right.
- Installation is reverse of removal.
Malte sure all threaded parts are clean.
. Coat threads with antiseize compound.
Replace self-loclting nuts.
Check tie rod end ball joints and idler arm bushing for wear.
Use tie rod measurements previously made to temporarily
set toe.
- Have car professionally aligned.
Tightening torques
Center tie rod to
pitman and idler arms 65 Nm (48 ft-lb)
(replace self-locking nuts)
Left or right outer
tie rod clamping bolt 27 Nm (20 it-lb)

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OBD-8
I On-Board Diagnostics
DTC digit interpretation
1st digit
P powertrain
B body
C chassis
2nd digit
0 SAE
1 BMW
3rd digit
0
1
2
3
4
5
6
7
4th - 5th digits total
system
airlfuei induction
fuel injection
ignition system or misfire
auxiliary emission control
vehicle speed
& idle control
ECM
inputs/outputs
transmission
individual circuits or
components
DTC example: P 0 3 0 6
P: A powertrain problem
0: SAE sanctioned or 'generic'
a 3: Related to an ignition system / misfire
06 Misfire detected at cylinder #6
DTCs provide a freeze frame or snap-shot of a vehicle
performance or emissions fault at the moment that the fault
first occurs. This information is accessible through generic
OED I1 scan tools.
Freeze frame data contains, but is not limited to, the following
information:
Engine load (calculated)
Engine rpm
Short and
long term fuel trim
Vehicle speed
Coolant temperature Intake manifold pressure
Open/closed loop operation
Fuel pressure (if available)
DTC

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OBD-15
On-Board ~iagnosticsl
Engine diagnostic trouble codes: M52 engine (continued)
P-code
PO340
PO412
PO420
PO430
PO440
PO441
PO442
PO443
PO500
PO505
PO600
PO601
PO601
I PO601
~1132
~1133
BMW-FC
65
62
233
234
250 144
-
145
68
214
i I
DTC Definition
Camshalt Position Sensor 'A' Circuit (Bank 1 or Single Sensor)
Secondary Air Injection System Switching Valve A Circuit
Catalyst System Efficiency Below Threshold
(Bank 1)
Catalyst System Efficiency Below Threshold (Bank 2)
Evaporative Emission System
Eva~orative Emission Svstem Incorrect Purge Flow .
Evaporative Emission System Leak Detected (small leak)
Evaporative Emission System Purge Control Valve Circuit
Vehicle Speed Sensor 'A'
204
21 7
100
170
171
188
189
PI161
PI180
PI181
PI184
PI185
PI178
02 Sensor Heater Control Circuit (Bank 2 Sensor 2) I
idle Air Control System
Serial Communication
Link
Internal Control Module Memory Check Sum Error
Internal Control Module Memory
Check Sum Error
Internal Control Module Memory
Check Sum Error
02 Sensor Heater Control Circuit (Bank 1 Sensor
1)
02 Sensor Heater Control Circuit (Bank 2 Sensor 1)
Mass or Volume Air Flow Circuit RangeIPerlormance Problem PI140
I
I I
P1188 1227 I Fuel Control (Bank 1 Sensor 1)
PI145 150 /Solenoid Valve Running Losses Control Circuit Electrical
149
122
223
224
220 221
231
I I
P1189 1228 I Fuel Control (Banlc 2 Sensor 1)
Fuel Trim Adaptation Additive High (Bank 2) (M52: Engine Oil Temperature Sensor Circuit)
02 Sensor Signal Circuit Slow Switching from Rich to Lean
(Bank 1 Sensor 2)
02 Sensor Signal Circuit Slow Switching from Rich to Lean
(Bank 2 Sensor 2)
H02S Sensor Voltage Excursion Electrical (Banlc 1 Sensor 1)
HO2S Sensor Voltage Excursion Electrical (Banlc 2 Sensor 1)
02 Sensor Sianai Circuit Slow Switchina from Rich to Lean (Bank 1 Sensor 1)
02 Sensor Signal Circuit Slow Switching from Rich to Lean (Bank 2 Sensor 1) PI179
I I
PI190 1235 I Pre Catalyst Fuel Trim System (Banlc 1)
PI186 1190 102 Sensor Heater Control Circuit (Banlc 1 Sensor 2)
232
I I
PI191 1236 I Pre
Catalyst Fuel Trim System (Banlc 2)
PI192
. . -- - i Pi193 1226 I Post Catalvst Fuel Trim Svstem (Bank 2)
225
PI397
I I
Post Catalyst Fuel Trim System (Bank 1)
PI421 1246 /Secondarv Air System (Bank 2)
18
Secondary Air System (Bank
1) PI423
Camshaft Position Sensor '0' Circuit (Bank 1)
I 245

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--- -
On-Board Diagnostics - - --- - -- - -
PI542
PI550
PI580
PI 580
PI 580
PI 593
PI622
PI623
PI623
PI 624 176
27 109
114
119
124
123
115
116
168 Pedal Position Sensor Electrical
Idle-Speed
Control Valve Closing Coil Electrical
Throttle Valve Mechanically Stuck
(M73: Throttle Valve 1 Spring Test)
Throttle Valve Mechanically Stuck
(M73: Throttle Valve 1 Spring Test)
Throttle Valve Mechanically Stuck
(M73: Throttle Valve 1 Spring Test)
DlSA (Differentiated lntalte Manifold) Control Circuit Electrical
Map Cooling Thermostat Control Circuit Electrical
Pedal Position Sensor Potentiometer Supply
Pedal Position Sensor Potentiometer Supply
Pedal Position Sensor Potentiometer Supply Channel
1 Electrical (M52: Coolant Thermostat (Coolant
Temperature Below Thermostat Regulating Temperature))

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I On-Board Diagnostics
Engine diagnostic trouble codes: M54 engine (continued)
P-code
BMW-FC Explanation
Catalyst System Efficiency Below Threshold (Bank 2)
PO430
PO443
PO444
PO445
PO455
PO456
PO491
PO492
PO500
PO441 1250 / Evaporative Emission System Incorrect Purge Flow
234
I I
68
68
68 143
143
245
246
214
PO604
PI083
PI084
PI085
PI086
Evaporative Emission System Purge Control Valve Circuit
Evaporative Emission System Purge Control Valve Circuit Open
Evaporative Emission System Purge Control Valve Circuit Shorted
Evaporative Emission System Leak Detected (large leak)
Evaporative Emission System Leak Detected (very
small leak)
Secondary Air injection System Insufficient Flow (Bani( 1)
Secondary Air Injection System insufficient Flow
(Banic 2)
Vehicle Speed Sensor
'A'
Idle Air Control System PO505
.
PI 087
PI 088
PI089
PI090
PO600 / 217 I Serial Communication Link
204
100
202
202
203
203
PI091
PI092
PI093
PI094
Pllll
PI112
PI120
Internal Control Module Random Access Memory (RAM) Error
Fuel Control Limit Mixture Too Lean (Bank 1 Sensor
1)
Fuel Control Limit Mixture Too Rich (Bank 1 Sensor 1)
Fuel Control Limit Mixture Too Lean (Bank 2 Sensor 1)
Fuel Control Limit Mixture Too Rich (Banic 2 Sensor 1) ~ ~
229
229
230 235
PI121
PI122
PI123
02 Sensor Circuit Slow Response in Lean Control Range (Bank 1 Sensor 1)
02 Sensor Circuit Slow Response in Rich Control Range (Bank 1 Sensor
1)
02 Sensor Circuit Slow Response in Lean Control Range (Banlc 1 Sensor 2)
Pre Catalyst Fuel Trim System Too Lean
(Bank 1)
236
235
236
230
11
11
114
PI134
PI135
PI136
PI137
PI138
Pre Catalyst Fuel Trim System Too Lean (Banic 2)
Pre Catalyst Fuel Trim System Too Rich
(Bank 1)
Pre Catalyst Fuel Trim System Too Rich (Bank 2)
02 Sensor Circuit Slow Response in Rich Control Range (Banic 2 Sensor 1)
Engine Coolant Temperature Sensor Radiator Outlet Low Input
Engine Coolant Temperature Sensor Radiator Outlet High Input
Pedal Position Sensor Circuit
117
110
110
25
25
25
79
79 Pedal Position Sensor 1
RangeIPerformance Problem
Pedal Position Sensor 1 Low Input
Pedal Position Sensor 1 High Input
02 Sensor Heater Circuit Signal Intermittent (Bank 1 Sensor 1)
02 Sensor Heater Circuit Low Voltage (Bank 1 Sensor
1)
02 Sensor Heater Circuit High Voltage (Bank 1 Sensor 1)
02 Sensor Heater Circuit Signal Intermittent (Bank 1 Sensor 2)
02 Sensor Heater Circuit Low Voltage
(Banic 1 Sensor 2)
-
-

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On-Board ~ia~nosticsl
I I
PO340 1113 I Camshaft Position Sensor 'A' Circuit (Bank 1 or Single Sensor)
Engine
diagnostic trouble codes:
M62 engine (continued)
P-code
PO342
PO343
PO345
PO347
PO348
PO363
PO370
PO41 2
PO335 I111 I Crankshaft Position Sensor 'A' Circuit
BMW-FC
I I -
I I -
PO445 1 98 1 Evaporative Emission System Purge Control Valve Circuit Shorted
Explanation
113
113
114
114
114
62 112
85
PO41 3
PO41 8
PO420
PO430
PO440
PO442
PO442
PO443
PO444
Camshaft Position Sensor 'A' Circuit Low (Bank 1 or Single Sensor)
Camshaft Position Sensor
'A' Circuit High (Bank 1 or Single Sensor)
Camshaft Position Sensor
'A' Circuit (Bank 2)
Camshaft Position
Sensor'A' Circuit Low (Bank 2)
Camshaft Position Sensor 'A' Circuit High
(Banic 2)
Misfire Detected
- Fueling Disabled
Timing Reference High Resolution Signal
'A'
Secondary Air lniection System Switchinq Valve A Circuit
PO41 4 / 85 I Secondary Air Injection System Switching Valve A Circuit Shorted
85
84
40
45 93 183
188
98
98
PO450
PO452
PO453
PO455
PO456
PO491
PO492
PO500
PO506
I I
PI102 1163 I Idle Control System, Adaptation of Unmetered Air Mass Too Low
Secondary
Air Injection System Switching Valve A Circuit Open
Secondary Air Injection System Control
'A' Circuit
Catalyst System Efficiency Below Threshold (Bank 1)
Catalyst System Efficiency
Below Threshold (Bank 2)
Evaporative Emission System
Evaporative Emission System Leak Detected (small
leak)
Evaporative Emission System Leak Detected (small leak)
Evaporative Emission System Purge Control Valve Circuit
Evaporative Emission System Purqe Control Valve Circuit Open
I
I
185
185
185
183
187
80
81 120
32
PO507
Evaporative Emission System Pressure SensorISwitch
Evaporative Emission System Pressure SensorISwitch Low
Evaporative Emission System Pressure
SensorISwitch High
Evaporative Emission System
Leaic Detected (large leak)
Evaporative Emission System
Leal$ Detected (very small leak)
Secondary Air Injection System Insufficient Flow (Bank
1)
Secondary Air Injection System insufficient Flow (Bank 2)
Vehicle Speed Sensor
'A'
idle Air Control System RPM Lower Than Expected
PI103
PI130
PI131
PO600 1 220 I Serial Communication Link
32
idle Air
Control System RPM Higher Than Expected
163
17
23
Idle Control System, Adaptation of Unmetered Air Mass Too Large
02 Sensor Circuit Dynamic Test (Bank
1 Sensor 2)
02 Sensor Circuit Dynamic Test (Bank 2 Sensor 2)