1997 BMW 540i engine removal

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Driveshaft
- Road test vehicle to check for noise or vibration
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.
Tightening torques
Alunlinum driveshaft to flex-disc
- MI2 (use coated washers)
90 Nm (66 ft-lb)
Driveshaft
CV joint to final drive flange
Mi0 (Tom bolt)
70 Nm (51 ft-lb)
M8 (compression nut) 32 Nm (24 ft-lb)
Flex-disc to transmission flange or driveshaft
MI0 (8.8 grade) 48 Nm (35 ft-lb)
MI 0 (1 0.9 grade) 60 Nm (44 ft-lb)
- Mi2 (8.8 grade)
81 Nm (60 ft-lb)
- MI2 (10.9 grade) I00 Nm (74 ft-lb)
MI4 140 Nm (103 ft-lb)
Transmission
crossmember
to transmission (ME) 21 Nm (15 ft-lb)
. to chassis (M10) 42 Nm (30 ft-lb)
NOTE-
Boltgrade is marked on the bolt head. When replacing bolts,
only use bolts of the same strength and hardness as the orig-
inals installed.
Flex-disc, replacing
- Checlc flex-disc between front section of driveshafl and trans-
mission output flange for craclts, tears, missing pieces, or
distortion. Check for worn bolt hole bores in flange.
- If flex-disc needs replacement, remove driveshafl as de-
scribed earlier.
- Unbolt flex-disc from driveshaft.
NOTE-
Removal andinstallation of the bolts may be made easier by
placing a large hose clamp around the flex-disc, and tighten-
ing the clamp slightly to compress the rubber.

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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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31 0-4
I Front Suspension
6-cylinder models
12 3 4 5
V-8 models
16 7 4
Front suspension
variations
1. Steering knuckle
2. Tension strut (thrust arm)
3. Steering rack
4. Front suspension
subframe
5. Outer tie rod
6. Control arm
7. Steering box
8. Idler arm
9. Center tie rod
The front suspension
shoclc absorbers on E39 cars are
MacPherson struts. The strut is a major component of the
front suspension and supports the spring. Most strut assem-
bly components are available as replacement parts. Always
replace struts and springs in pairs.
Front strut, upper strut mount or spring replacement is a two-
step procedure:
Removal of strut assembly from vehicle
Disassembly and replacement of component on
work
bench

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31 0-8
Front Suspension
Slide strut assembly out of steering lknucltle pinch collar. If
necessary use pry bar.
CA UTIOI\C
Do notpullstrut out of steering knuckle with twisting motion.
This can scratch and damage the strut.
Disassemble and reassemble strut assembly as described
later.
When installing new strut, be sure to align locator letter (A)
on strut body with slot in steering
lknuckle pinch collar (6).
Struts are marked with L for left and R for right.
Remainder of installation is reverse of removal.
Make sure strut shoulder (below locator letter) bottoms out
in steering knuckle pinch collar.
Use new self-locking nuts and bolts.
When attaching stabilizer
lrnk to strut, use a thin wrench to
counterhold
link ball joint while t~ghtening nut.
- Have car professionally al~gned when job IS complete.
Tightening torques
Brake caliper to steering knuckle
110 Nm (81 ft-ib)
Road wheel to hub 120 ti0 Nm (89 t7 ft-lb)
Stabilizer bar
link to strut 65 Nm (48 It-lb)
Steering knucltle pinch bolt at strut 81 Nm (60 It-lb) - mountlng collar
Steering tle rod to steerlng knuckle 65 Nm (48 it-lb)
Strut assembly top to strut tower 24 Nm (18 it-lb)
- - -

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31 0-21
Front Suspension
4 Remove four bearing hub mounting bolts (arrows) and tap
hub assembly out of steering knuckle.
4 Before installing new wheel bearing and hub assembly, be
sure hub and steering knuckle sealing surfaces are free of
dirt and grease.
- Installation is reverse of removal.
Replace hub mounting bolts.
Use new self-locking nuts at steering tie rod and stabilizer
link.
Tightening
torques
Road wheel lugs to hub 120i-10 Nm (89i-7ft-lb)
Stabilizer link to stabilizer bar
Steering tie rod to steering
ltnuckle
Tension strut to steering
knucltie
Wheel bearing hub to steering
Itnucltle (replace bolts)
65 Nm (48 ft-lb)
65
Nm (48 it-lb)
80 Nm (59 ft-lb)
1
lo Nm (81 ft-lb)

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31 0-22
I Front Suspension
Stabilizer bar, removing and installing
On E39 models the front stabilizer bar links attach to the strut
assemblies.
- Raise car and support safely.
Male sure that 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.
< Remove slaol zer bar connecring I nk rnounl ng nLts (A) from
r~glit and eft s~des of slaol lzer bar C~~nIerhol~ ball ]olnl (6)
with flat wrench
NOTE-
Use a thin wrench to counterhold shaft of stabilizer bar link
ball joint while removing mounting nut.
< Remove stabilizer bar anchor bushing nuts (arrows) on right
and left sides and remove bar.
- Installation is the reverse of removal, noting the following.
Use new self-locking nuts on stabilizer bar links.
Installation of stabilizer bar is easiest with car level (front
wheels at the same height).
Tightening torques Stabilizer bar to stabilizer link
59 Nm (44 ft-lb)
Stabilizer anchor to subframe 22 Nm (16 ft-lb)

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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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I Steering and Wheel Alignment
This repair group covers steering wheel and column removal
and steering system service, including wheel alignment infor-
mation.
NOTE-
Ignition loclc cylinder replacement is covered in this sec-
tion.
a For information on steering column mounted switches, in-
cluding the ignition switch, see
612 Switches.
Special tools
Some special tools are necessary to carry out the repairs and
adjustments required for steering service and wheel align-
ment. Be sure to read the procedures through before starting
work on the vehicle.
4 Steering shafl retaining ring installation tool
(Tool No. BMW 32
1 090)
4 Bail joint removal tool
(Tool No. BMW 32
1 190)
4 Pitman arm removal tool
(Tool No. BMW 32 2
000)
4 Inner tie rod removal tool
(Tool No. BMW 32 2
110)