BMW 5 Series (E39) Service Manual: 1997-2002

Service Manua 5251, 5281, 530i, 540i Sedan, Sport Wagon 1997,1998,1999,2000,2001,2002

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-Benllcy Publishers, a division ol Robcrt Bcnlley, In=. 1734 M ~ S B ~ C I I U P Avenue ~IIS Cumbitdge. MA02138 USA Informationlhat makes 800-423-4885/ 617.547.4170 the diiierence"

BentleyPublishe~

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http://~~~.BentleyPublishere.com

Errata information We will evaluate submissions and post appropriate editorial changes online as text errata or tech discussion. Appropriate errata will be incorporated with the boolc text in future printings. Read errata information for this book before beginning work on your vehicle. See the following web address tor additional information: http://unw.BentleyPublishers.com/errata/

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WARNING-important safety notice Do not use this manual unless vou are familiar with basic automotive reoair orocedures and safe workshoo oracfices. This manual illustrates the workshop proceduresrequked formoslservice work. It is not a subsiituti for full and up-to-dateinformationfrom thevehiclemanufaciurer or for proper training as an automotive technician. Note that it is not possible for us to anticipate all of the ways or conditions under which vehicles may be serviced or to provide cautions as to all of the possible hazards that may result. The vehicle manufacturer will continue to issue service information updates and parls retrofits after the editorial closing of this manual. Some of lhese updates and retrofits will apply lo procedures and specifications in this manual. We regret that we cannot supply updates to purchasers of this manual. We have endeavored to ensure the accuracy of the information in this manual. Please note, however, that considering the vast quantity and the complexity of the service information involved, we cannot warrant the accuracy or completeness of the information contained in this manual. FORTHESE REASONS, NEITHER THE PUBLISHER NOR THE AUTHOR MAICES ANY WARRANTIES, EXPRESS OR IMPLIED, THATTHE INFORMATION IN THIS BOOK IS FREE OF ERRORS OR OMISSIONS. AND WE EXPRESSLY DISCLAIM THE IMPLIED WARRANTIES OF MERCHANTABILTTYAN0 OF FITNESS FOR A PARTICULAR PURPOSE,EVENIFTHE PUBLISHER OR AUTHOR HAVE BEEN ADVISED OFA PARTICULAR PURPOSE,AND EVEN IF A PARTICULAR PURPOSE IS INDICATED IN THE MANUAL. THE PUBLISHER AND AUTHOR ALSO DISCLAIM ALL LlABlLrrY FOR DIRECT. INDIRECT. INCIDENTAL OR CONSEQUENTIAL DAMAGESTHAT RESULT FROM ANY USE OFTHE EXAMPLES,INSTRUCTIONSOR OTHER INFORMATIONINTHIS BOOK. INNO EVENT

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Your common sense are crucial to safe and successful service work. Read orocedures throuoh before startino them. . -- -~ and oood - - - iudoment ~. Think about whether the condition of your car, &r level o f mechanical skill, or your level of reading compreh&sion might resill in or contribute in some way to an occurrence which might cause you injuly, damage your car, or result in an unsafe repair. If you have doubts for these or other reasons about your ability to pelform safe repair work on your car, have the work done at an authorized BMW dealer or other qualified shop. Part numbers listed in this manual are for identificationpurposes only, not for ordering. Always check wilh your authorized BMW dealer to verify part numbers and availability before beginning service work lhat may require new park. Before anempting any work on your BMW, read the 001 General Warnings and Cautions, and any WARNING or CAUTION that accompanies a procedure in the service manual. Review the WARNINGS and CAUTIONS each time you prepare to work on your BMW. Spec a too s req.1 red to perlorm cena n service operations arc oenl fed n the manLa an0 arc recomrnenoeo lor JSC Jse ol loo s olner than those recommended In lh s serv ce manual may be oelnmcnlal lo lrlc car's sale open1on as rvec as lne salely 01 lne person servcng the car. ~

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Copies of this manual may be purchased from most automotive accessories and parts dealers specializing in BMW automobiles, from selected booksellers, or directly from the publisher. This manual was published by Robert Bentley, Inc., Publishers. BMW has not reviewed and does not vouch for the accuracy of the technical specifications and procedures described in this manuai. Libratv of Conaress Cataloaino-in-Publication Data " " BMW 5 Series (E39) : service manual : 523. 528i, 530i. 540i, sedan, sport wagon, 1997, 1998, 1999,2000,2001,2002

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~Acludesindex. ISBN 0-8376-0317-X (obi28i, 530i)

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Steering system variations

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1.

Left tie rod

2.

Right tie rod

3.

Steering rack

4.

Steering gearbox

5. idler arm 6.

Center tie rod

7. Steering knuckle

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Recirculating ball and nut steering V-8 models 154Oib

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 injury 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 deale,: 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 follow the airbag removal procedure as outlined in 721 Airbag System (SRS). BMW airbags are equipped with a bacli-up power supply inside the airbag control module. A 5 second waiting 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 replace 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 installation, or install new parts. Do not attempt to weld or straighten any steering components. Always replace damagedparts.

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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 bristles. Only use brushes with stainless steel bristles. Do not expose to flying sparks from grindinghutting operations. Do not subject to steel welding splashes. * Do not expose to temperatures over 80% (176°F).

even for short periods. Temperatures in painting iacilities are not a problem.

320-7 Steering and Wheel ~liqnmentl

STEERING WHEEL Steering wheel, removal and installation WARNINGThe BMWairbag system (Supplemental Restraint System or SRS) is complex. Special precautions must be observed when servicing. Serious injury may result if SRS system service 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

4 Sport steering wheel components:

Sport steering wheel

1. Switch carrier 2 Steering wheel switch set electrical harness 3. Airbag 4. Lower cover 5. Horn button and airbag electrical harness

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0021413

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Center steering wheel. Make sure front wheels are pointed straight ahead. Disconnect negative (-) cable from battery.

CAUTIOP& Prior to disconnecting the battern read the battew disconnection 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).

4Sport 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.

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Carefully lift airbag from steering wheel and disconnect electrical harnesses from back side of unit. Refer to component illustrations above. Also see 721 Airbag System (SRS).

Improperhandling 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, installedin the steering wheel of

4 Remove steering wheel center bolt (arrow).

Check for proper alignment of steering column marks (arrow) before removing steering wheel.

NOTEThe steering column and steering wheel are match marked at the factory Remove lower steering column trim panel. See Steering column 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) Airbag to steering wheel (MFL only)

63 Nm (47 ft-lb) 8 Nm (6 ft-lb)

320-10 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

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Tilt steering column down and extend fully.

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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.

Steering and Wheel ~li~nrnentl

q Pry gently to detach flexible cover from upper trim. Lift off trim.


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Automatic reel loose. Return spring brolten inside reel.

Tighten reel mounting bolt. Replace reel assembly.

Automatic belt soueaks when fastened or

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I~xcessivefriction in belt guides. Automatic reel loose. Return sorino broken inside reel. ~-~~ , ~

Seat belt pyrotechnic tensioner triggered.

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I Replace reel assembly. I

Tighten reel mounting bolt Replace reel assembly. '

Accident triggered pyrotechnic deployment. Replace complete automatic seat belt. Also check retaining bracket of belt

Seat Belts NOTEThe rear bench seat belt strap may not retract fully due to increased friction between strap and seat cover. A small remaining loop in belt strap when fully retracted is acceptable.

WARNING* For maximum protection from injury, seat bells should be

replaced as a set (including all hardware), if they are subject to occupant loading in a collision. Seat belts should not be modified or repaired. The seat belt mounting points should not be changed or modified. Do not bleach or dye seat belt webbing. Webbing that is severely faded or redyed will not meet the strength requirements of a collision and must be replaced. Clean belts with a luke-warm soap solution only: Seat belts should be periodically inspected for webbing defects such as cuts or pulled threads.

* Immediately after replacing a damaged or worn seat belt, destroy the old belt to prevent it from being used again.

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Seat Belts

Front seat belt tensioner, removing and installing The front seat belt loclts are equipped with pyrotechnic (explosive charge) automatic tensioners. These tensioners are designed to automatically retract and tension the seat belt by 55 mm (approximately 2 inches) in the event of an accident.

WARNINGPyrotechnic seat belt tensioners are powerful devices and should be handled with extreme care. Incorrect handling can trigger the tensioner and cause injury BMW recommends that all repair or replacement work on pyrotechnic devices must be carried out by a qualified BMW technician. Be sure to disconnect the battery and wait 5 seconds before attempting to work on pyrotechnic devices. Pyrotechnic devices cannot be repaired. Always replace them.

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Never treat pyrotechnic components with cleaning agents or grease. Do not expose pyrotechnic components to temperatures above 75% (167°F). Pyrotechnic components can only be tested electrically when installedusing the BMWService Tester (DISplus, G T I , or MoDiC). Do not fire a pyrotechnic gas generatorprior to disposal. It must be fired by a special disposal company or shipped back to BMW in the packaging of the new component. During body straightening and welding with an electric arc welder, always disconnect the battery and the connection to the pyrotechnic gas generators.

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Disconnect battery negative (-) cable in trunk.

CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given in 001 General Warnings and Cautions.

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Remove front seat as described in 520 Seats.

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Seat ~ e l t s l