2000 BMW 540i brake

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/~ront Susaension
Front suspension arms FRONT SUSPENSION ARMS
Scyllnder models (5251,5281,530i)
Control arms and tension struts are attached to the front sub-
Front suspension arms V-8 models (5401)
frame through rubber bushings and to the steering ltnuckles
by ball joints.
NOTE-
Tension struts are sometimes called thrust arms or thrust
rods.
Control arms or tension struts are sometimes called lower
front arms or lower rear arms.
Inspect ball joints for wear and looseness. lnspect bushings
for wear or fluid
lealts. The ball joint can only be replaced as
part of an entire suspension arm assembly. Some suspen-
sion arm
bushinas are available as re~lacement Darts. Al-
ways replace in pairs
NOTE-
Steering wheel vibration during braking (usually at road
speeds of
50 to 60 m.p.h.) are often causedby faulty suspen-
sion arm bushings, not out-of-true brake rotors.
Some special tools may be required to remove suspension
arms and to replace bushings. Read procedures through be-
fore beginning the job.
Control arm, removing and installing
(6-cylinder models)
- Raise car and remove wheel
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 jack stands under
suspension
parfs.
Cars equipped with vertical headlight adjustment system:
Disconnect control arm from level sensor.
Remove control arm fasteners (arrows). Lightly tap inner
control arm mounting bolt out of subframe.

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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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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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Steering and Wheel Alignment
- Tighten nut while counterholding adjusting bolt,
- Tighten nut only after car has been lowered to ground and
suspension has settled.
Preparing for alignment
- The following conditions are necessary prior to wheel align-
ment:
Correct wheels and tires are installed, in good condition,
and are at the correct inflation pressures.
All steering and suspension parts and bushings are un-
damaged and show no signs of abnormal wear. Wheel
bearings are in good condition.
Ride height is in accordance with specifications. See
300
Suspension, Steering and Brakes-General.
Car is in normal loaded position. See below.
* Cars with air suspension: Remove air suspension power
fuse.
Normal loaded position
Each front seat
68 Kg (I50 lb)
Center of rear seat
Trunlc
Fuel tank
68 Kg (150 lb)
21 Kg (46 lb)
Full
Alignment specifications tables
In the alignment specification tables that follow, reference is
made to the various types of suspension used in
E39 cars.
The type of suspension can be identified by loolting at the la-
bel on the front strut tube.
Identifying symbol
None
Solid circle
Solid triangle
M5
Circle
Triangle Version
Standard suspension
Sports
suspension
Sports suspension
M sport package
Standard suspension
Sports suspension Model
Sedan
6-cylinder sedan
V-8 sedan
V-8 sedan
Touring (Sport Wagon)
Touring (Sport Wagon)

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330-2
I Rear Suspension
This repair group covers removal and replacement of E39
rear suspension components. A general description of sus-
pension systems and ride height specifications can be found
in 300 Suspension, Steering and Brakes - General.
CAUTIOI\C
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 bris-
tles. Only use brushes with stainless steel bristles.
Do not expose to flying
sparl~s from grinding/cutting op-
erations.
* Do not subject to steel welding splashes.
0 Do not expose to temperatures over 80°C (176°F).
even for shortperlods. Temperatures in painting facili-
ties are not a problem.
Special tools
Special service tools are required for some of the work de-
scribed in this repair group. Most of these tools are special-
ized press jigs and pullers that might be replaced by standard
pullers of various sizes.
Read the procedures through before beginning any job.
< Strut upper mounting nut socket
(Tool No. BMW
31 2 21 0)
I Axle shaft removal and installation set
Spring compressor (Tool No. BMW
31 3 340.31 3 350)