1999 BMW 525i Workshop Manual

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Front Suspension
< Use BMW special tool 31 2 240 or equivalent to separate
control arm ball joint from steering ltnuckle.
- When installing control arm, make sure all thread bores.
bolts, nuts and mating surfaces are clean.
- Install bushing end of control arm to subframe, using wash-
ers on both sides of bolt and a new self-locking nut. Do not
tighten nut at this time.
- Install control arm ball joint to steering lknucltle using a new
self-locking nut. Tighten fully.
- Install wheel and lower car.
- Load car to normal loaded position as described under Ride
height. See
300 Suspension, Steering and Brakes-Gen-
eral. Bounce suspension a few times.
- With car on ground and loaded, tighten control arm bushing
through-bolt.
Tightening torques
Control arm to steering ltnuckle
80 Nm (59 ft-lb)
Control arm to subframe 110 Nm (81 It-lb)
Road wheel to hub 120ilO Nm (8957 it-lb)
Control arm, removing and installing
(V-8 models)
- Raise car and remove wheel
WARNING-
Make sure that the car is firmly supported on jack stands de-
signed for the purpose. Place jack stands underneath struc-
tural
cliassis points. Do not place jack stands under
suspension parts.
Loosen and remove stabilizer bar link mounting nut
(A) while
counterholding ball joint
(B). Disconnect stabilizer link from
stabilizer bar.
- Cars equipped with vertical headlight adjustment system:
Disconnect control arm from level sensor.

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31 0-1 4
Front Suspension
4 Mark installation position of strut tube (arrow) at steering
knuckle pinch collar.
NOJE-
The strut tube installation position is marked on factory
strut tubes:
L for leff and R for right.
Marking the strut tube is not necessary if factory marks
(L
or R) are still visible.
CAUTION-
Use paint, not a scribe tool, to mark location of strut tube.
Counterhold strut tube nut. bolt
(arrow) while
loosening
4 Spread steering ltnucltle pinch collar with BMW special tool
31 2 200 to release strut tube.
- Pull steering knuckle down so that strut tube slides up far
enough to gain better access to control arm nut.

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310-1 5
Front ~us~ension/
4 Remove control arm fasteners (arrows). Lightly tap inner
control arm mounting bolt out of subframe.
Use
BMW special tool 31 2 240 or equivalent to separate ball
joint from steering knuckle.
When installing control arm, make sure all thread bores,
bolts, nuts and mating surfaces are clean.
lnstall bushing end of control arm to subframe, using wash-
ers on both sides of bolt and a new self-loclting nut. Do not
tighten nut at this time.
lnstall control arm ball joint to steering knuckle, using new
self-locking nut. Tighten fully.
- Slide strut back into position and tighten strut pinch bolt fully.
- Install wheel and lower car.
- Load car to normal loaded position as described under Ride
height. See
300 Suspension, Steering and Brakes-Gen-
eral. Bounce suspension a few times.
- With car on ground and loaded, tighten control arm bushing
through-bolt.
Tightening torques
Control arm to steering knuckle 80 Nm
(59 ft-lb)
Control arm to
subframe 78 Nm (58 ft-lb)
Road wheel to hub
120
f 10 Nm (89 +7 ft-lb)
Stabilizer bar
link to stabilizer bar
59 Nm (44 fl-lb)
Strut pinch bolt
81 Nm (60 it-lb)

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I Front Suspension
Tension strut, removing
and installing
- Raise car and remove wheel.
WARNING-
Make 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
jack stands under
suspension parts.
- Remove engine splash shield
6-cylinder models: Remove
brake cooling duct.
V-8 models: Detach stabilizer bar from front subframe.
Mark installation position of strut tube (arrow) at steering
ltnuckle pinch collar.
NOJE-
* The strut tube installation position is marlted on factory
strut tubes:
L for left and R for right.
* Marlting the strut tube is not necessary if factory marks (L
or R) are still visible.
CAUJION-
Use paint, not a scribe tool, to mark location of strut tube. 1
4 Counterhold strut tube pinch bolt (arrow) while loosening
nut.

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31 0-1 7
Front ~uspensionl
< Spread steering knuckle pinch collar with BMW special tool
31 2 200 to release strut tube.
- Pull steering knuckle down so strut tube slides up farenough
to gain better access to tension strut or tension strut nut.
4 Unscrew ball joint nut (arrow) from steering knuckle. Use
BMW special tool
31 2 240 to remove ball joint from steering
Iknucltle.
CAUTION--
Tale care not to damage the balljoint threads if the tension
strut
is to be reused.
- Remove through-bolt attaching tension strut to subframe.
- When installing tension strut, make sure all thread bores,
bolts, nuts and mating
suriaces are clean.
- Install bushing end of tension strut to subframe using wash-
ers on both sides of bolt and a new self-locking nut. Do not
tighten nut at this time.
- Install tension strut ball joint to steering knuckle using new
self-locking nut. Tighten fully.
- Slide strut back into position and tighten strut pinch bolt fully.
- Install wheel and lower car.
- Load car to normal loaded position as described under Ride
height. See
300 Suspension, Steering and Brakes-Gen-
eral. Bounce suspension a few times.
- With car on ground and loaded, tighten tension strut bushing
through-bolt.
Tightening torques Road
wheel to hub 120-i-10 Nm (89+7ft-lb)
Stabilizer bar to subframe 24 Nm (1 8 ft-lb)
Tension strut to steering
knucltle
80 Nm (59 ft-lb)
Tension strut
to subframe 110 Nm (81 ft-lb)
81 Nm (60 it-lb)
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31 0-1 8
I~ront Suspension Tension strut bushing, replacing
- Raise car and remove wheel.
WARNING-
Make sure that the caris 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 tension strut from car as described earlier.
- Using a service press and appropriate press tools (BMW
special tools 31 2 26112621263 or equivalent), press bushing
out of tension strut.
4 Clean bushing bore and press in new bushing while aligning
mark on bushing with
rnarlt on tension strut (arrows).
CAUTION-
To avoid damaging the new bushing, press only on the outer
steel sleeve during installation.
- Press bushing in so it protrudes equally from both sides of
tension strut.
- Install tension strut as described earlier.
CAUTION-
Tighten the tension strut bushing through-bolt to its final
torque only with car on the ground and the suspension nor-
mally loaded as described earlier.
The front wheel bearings are permanently sealed and require
no maintenance. The bearing is integral with the wheel hub.
The wheel bearing and hub assembly is bolted to the steering
knuckle.
- Raise car and remove front wheel
WARNING-
Make 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
jack stands under
susoension Darts.
- Unbolt brake caliper and hang to side with stiff wire. Do not
disconnect bralte hose. Remove bralte disc. See
340
Brakes.

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Front Suspension
4 Remove ABS pulse sensor mounting bolts (arrows) and pull
sensor from housing.
- Detach stabilizer bar link from stabilizer bar.
4 6-cylinder models: Remove tie rod outer end nut. Use BMW
special tool
31 2 240 or equivalent to press tie rod end off
steering arm.
4 Mark installalion position of strut tube (arrow) at steering
knuckle pinch collar.
NOTE-
The strut tube installation position is marked on factory strut
tubes:
L for left and R for right.
CAUTION-
Use paint, not a scribe tool, to mark location of strut tube.

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31 0-20
Front Suspension
Counterhold strut tube
nut. pinch
bolt (arrow) while loosening
4 Spread steering ltnuckle pinch collar with BMW special tool
31 2 200 to release strut tube.
- Pull steering knuckle down so that strut tube slides up far
enough to gain access to wheel bearing hub mounting bolts.
Carefully pry out dust cover on back side of bearing while
noting location
(arrow) of cover.