steering wheel BMW 540i 2001 E39 Repair Manual

Downloaded from www.Manualslib.com manuals search engine
/steering and Wheel Alignment
Raise engine approximately 40 mm (1.6 in). See 110 Engine
Removal and installation.
Remove right and left engine mounts and remove mount
brackets from subframe.
Empty power steering fluid reservoir using a clean syringe.
Do not reuse power steering fluid.
Remove right tie rod fastener (arrow) from right steering
Itnuckle. Repeat for left.
4 Press right tie rod out of right steering knucltle using BMW
special tool 31
2 240. Repeat for left.
/ ~ock nut Loclting ring
0012143
4 Malte reference measurement (A) of right tie rod end to tie
rod. Record measurement. Repeat for left.
NOJE-
0 Accurate measurement of tie rod end with reference to tie
rod will help approximate correct wheel alignment during
reassembly.
Note correct placement of inner taper on
locling ring
Remove fluid line
banjo bolts (arrows)
from steering rack.

Downloaded from www.Manualslib.com manuals search engine
Steering and Wheel ~lignmentl
Remove lower steering column flexible joint pinch bolt (ar-
row). Pull flexible joint off steering rack shaft.
Remove steering rack mounting bolts. Remove steering
raclc
from subframe by pulling it to left.
Installation is reverse of removal, noting the following:
Make sure all thread bores, bolts, nuts, splines and mating
surfaces are clean.
Use new steering rack mounting bolts. Tighten in two stag-
es. Note tightening instructions in torque table below.
Use anti-seize paste on inner tie rod threads.
Use new self-loclting nuts wherever applicable.
Use keved
comDonents to reassemble steerino column
flexible\oint to ;teering raclt shaft. u
Use new bolt at steering shaft coupling.
Use new sealing O-rings on banjo fittings.
Do not over-torque banjo bolts.
Fill and bleed power steering system as described earlier.
Use tie rod measurement previously made (measurement
A) to temporarily set toe.
Have car professionally aligned.
Tightening torques Hydraulic lines to steering rack (use new O-ring
seals)
M14 banjo bolt 35 Nrn (26 ft-lb)
. M16 banjo bolt 40 Nm (30 ft-lb)
Steering shaft coupling
to rack (use new bolt) 19 Nm (14 it-lb)
Steering rack to subframe (use new bolts)
- initial torque 50 Nm (37 ft-lb)
Torque angle 90"
Tie rod
to Steering knuckle (replace self-locking
65 Nm (48 ft-lb)
nut)
- to Steering rack 71 Nm (52 ft-ib)
Outer tie rod end lock nut
51 Nm (38 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
--. --
Steering and Wheel Alignment
Steering rack boot, replacing
- Remove outer tie rod end. See Tie rod (outer), replacing
- Cut rack boot band clamps and remove boot.
- Cut rack boot band clamp and slide bellows back. Inspect
boot for any sign of damage. Replace
if necessary.
NOTE-
New rack boot lit comes with new band clamp.
- Grease tie rod taper so that small end of rack boot slides on
tie rod when tie rod is tightened, preventing raclc boot from
twisting.
- Slide new boot into position and replace band clamps
Tie rod (outer), replacing
LOCI( nut Locking ring
- Raise front of car. Remove road wheel
WARNING-
Male sure caris firmly suppoiiedon jackstands designed for
the purpose. Place jack stands beneath structural chassis
ooints. Do not olace iack stands under
susoension oaiis.
4 Make reference measurement (A) of outer tie rod end to tie
rod. Record measurement.
NOTE-
Accurate measurement of the tie rod end with reference to
the tie rod will help approximate correct
wheel alignment
when new parts are installed.
Note correct placement of inner taper on
loclcing ring.
Loosen outer tie rod end
loclc nut (arrow).
Remove tie rod lock nut from steering
ltnuclcle.
Press tie rod out of steering knuckle using BMW
31 2 240 or equivalent. special tool
Unscrew tie rod end from tie rod shaft.

Downloaded from www.Manualslib.com manuals search engine
Steering and Wheel Alignment
- lnstallation is reverse of removal.
Make sure all threaded parts are clean.
Use anti-seize paste on inner tie rod threads.
Use new self-locking nuts, where applicable.
Use tie rod measurement
(A) to set toe temporarily.
Have car professionally aligned.
Tightening torque
Tie rod
to steering itnuckle (replace seii-loclting nut) 65 Nm ( 46 ft-lb)
Outer tie rod end ioclt nut 51 Nm (38 ft-ib)
Tie rod (inner), replacing
- To replace inner tie rod, first remove outer tie rod end. See
Tie rod (outer), replacing.
- Cut rack boot clamps and slide bellows back
4 Loosen and remove inner tie rod shafl from steering rack with
special tool
32 2 110.
NOTE-
To avoid damage to steering rack while removing tie rod, turn
steering until end of rack is as far as possible inside rack
housing.
- When reassembling, grease tie rod taper so that rack boot
support buffer or small end of rack boot slides on tie rod when
tie rod is tightened, preventing rack boot from twisting.
- Inspect boot for any signs of damage. Replace boot if neces-
sary, using new clamps.
NOTE-
New rack boot comes with new band clamps
- Installation is reverse of removal, noting the following:
Make sure all threaded parts are clean
Replace self-locking nuts.
Install outer tie rod end to new tie rod. Use tie rod measure-
ment
(A) to set toe temporarily.
Have car professionally aligned.

Downloaded from www.Manualslib.com manuals search engine
Steering and Wheel Alignment
Tightening torques
Tie rod
to Steering knuckle (replace self-locking nut) 65 Nm (48 it-lb)
to Steering rack 71 Nrn (52 ft-lb)
Outer tie rod end lock nut 51 Nrn (38 ft-lb)
Refer to the steering components illustration when perform-
ing the procedures below.
Steering gearbox system
components
(V-8 models
up to
911 999)
1. Tie rod end nut
2. Washer
3. Tie rod end
4. Steering fluid cooler
5. Tie rod end clamp bolt
6. Nut
7. ldler arm
8. ldler arm bushing
9. ldler arm bolt
10. Steering fluid reservoir
11. Hose clamp
12. Fluid supply line
13. Power steering pump
14. Fluid return line
15. O-ring seal
16. Banjo bolt
17. High pressure line
18. Center tie rod
19. Nut
20. Pitman arm
21.
Pitman arm pinch bolt
22. Nut
23. Fluid cooler supply line
24. Steering gearbox

Downloaded from www.Manualslib.com manuals search engine
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).

Downloaded from www.Manualslib.com manuals search engine
Steering and Wheel Alignment
Press center tie rod off pitman arm.
Remove lower steering column universal joint clamping bolt
(arrow) and slide universal joint up off steering gearbox
shaft.
Disconnect harness connector for electro-hydraulic regulator
at bottom of steering gearbox
if necessary.
Remove steering gearbox mounting bolts
Remove steering gearbox by sliding it forward and down.
Malte sure all thread bores, bolts, nuts, splines and mating
surfaces are clean.
4 To install steering gearbox, center steering column to gear-
box by aligning universal joint split with tab on steering gear-
box
(arrow). Install new clamping bolt and self-locking nut.
NOTE-
Make sure the clamping bolt fits into the machinedgroove in
the steering gearbox shaft when mating the universaljoint to
the shaft.
4 Draw steering gearbox into place using bolt A. Hand tighten
only. Tighten bolts
(B and C) to torque specification.
- Install pitman arm on steering gearbox shaft. Do not tighten
pinch bolt at this point.

Downloaded from www.Manualslib.com manuals search engine
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.

Downloaded from www.Manualslib.com manuals search engine
320-28
[steering and Wheel Alignment
Pitman arm, removing and installing
- Raise front of car. Remove splash shield from under engine.
Male sure the car is
firmly supported on jack stands de-
signed for the purpose. Place jack stands beneath structural
chassis points. Do not place
jaclc stands under suspension
parts.
4 Set steering wheel in straight ahead position with tab (arrow)
aligned with mark on steering gearbox.
Remove center tie rod fastener and press tie rod out of pit.
man arm with BMW special
too1 32 1 190.
- Loosen and remove pitman arm pinch bolt
4 Mark A on steering gearbox shalt must be located in center
of
pitman arm slot.
- Reinstall center tie rod and tighten nut.
- Adjust pitman arm height as described later.
- Have vehicle professionally aligned.
Tightening torques
50:s,n5m Center tie rod to pitman arm 65
Nm (48 ft-lb)
(use new self-locking nut)
Pitman arm pinch bolt (note direction of threads) 61 Nrn (45 ft-lb)

Downloaded from www.Manualslib.com manuals search engine
Steering and Wheel Alignment
Pitman arm, adjusting
As the vehicle suspension settles down, the toe on the left
and right wheels must remain identical for proper handling.
By adjusting the height of the
pitman arm, the left and right tie
rods are moved to the same ride level setting. This will opti-
mize straight-ahead travel on uneven road surfaces.
- Raise front of car. Remove splash shield from under engine.
WARNING-
Male sure the car is iirmly supported on jack stands de-
signed ior the purpose. Place jack stands beneath structural
chassis points. Do not place
jaclc stands under suspension
parts.
- Remove bolts from left and right inner control arm mounts.
Place
BMW special tool 32 2 140 through right side control
arm mounting bolt hole.
Loosen fastener
A and push pin El up so that it is firmly
against tie rod
(arrow). Tighten fastener A.
- Remove tool without disturbing position of pin El.
- Loosen pitman arm clamping bolt and slide arm up.
4 Place special tool 32 2 140 through left side control arm
mounting bolt hole.
Slide
pitman arm up or down until tie rod makes contact
with pin
(El).
Tighten pitman arm clamping bolt.
Tie rod height differences
Deviation between
left and right tie rod height -?-I .5 rnrn (LO6 in)