Honda Bmw 5 Service Manual
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Suspension, Steering and Brakes - General WHEELS AND TIRES Tire size is critical to the properoperation of the antilock brake system and traction control system. Several differentstyles of wheels in 15,16, and 17 inch diameters are available from an authorized BMW dealer. Rim and tire size applications are listed in the table below. Rim and tire sizes table ELECTRONIC BRAKE AND STABILITY CONTROL SYSTEMS Model 5251 5281 530i 540i (manual transmission) 540i (automatic transmission) All E39 vehicles are equipped with the Antilock Braking Sys- tem (ABS). Early production models featured ABS with Auto- matic Stability control (ABSIASC). Later models came equipped with ABS and Dynamic Stability Control (ABSIDSC). DSC builds upon the existing ABSIASC system to provide electronic control of drive and braking systems to insure vehicle stability. This manual will refer to these systems as ABS. ASC or DSC will be specified when necessary. ABS component replace- ment is covered in 340 Brakes. Standard ABS applications are shown in the accompanying table Rim size 16x7 15x7 16x7 17x8 16x7 Optional Tire size 225160R-15 235145-1 7 225155-1 6 Rim size 17x8 Front 17 x 8 Rear 17 x 9 17 x 8 Front 17x8 Rear 17x9 Front 17 x 8 Rear 17 x 9 Tire size 245145R-17 Front 235145-1 7 255140R-17 235145R-17 Front 235145-1 7 Rear 255140R-17 Front 235145-17 Rear 255140R-17
300-1 2 I Sus~ension, Steerincl and Brakes - General E39 electronic brake and stability control systems application table (528i, 54bi) Traction (ASC) I Hydraulic unit in right rear of engine compartment 1 Identifiers Year (model) I No precharge pump 1 Manuf. up to 911998 l~utomatic Stability Control plus I Electronic control module next to glove compartment System Precharge pump in lefl front of engine compartment, below steering fluid reservoir Separate rotational rate (yaw) and lateral acceleration sensors I I Combined rotational rate (yaw) and lateral acceleration sensors Electronic control module next to glove compartment Hydraulic unit in right rear of engine compartment Manuf. up to 911999 (540i optional) I I ABS system Dynamic Stability Control (Bosch DSC Ill v. 5.3) The electronically controlled ABS maintains vehicle stability and control during emergency braking by preventing wheel lock-up. ABS provides optimum deceleration and stability dur- ing adverse conditions. It automatically adjusts brake system hydraulic pressure at each wheel to prevent wheel lock-up. Control moduleihydraulic unit in right rear of engine compartment No precharge pump Manuf. from 911999 (all models) Automatic Stability Control (ASC) Dynamic Stability Control (Boscli DSC Ill v. 5.7) NOJE- ASC (Automatic Stability Control) may also be referred to as ASCiT (Automatic Stability ControkTraction). ASC works in conjunction with ABS and the engine manage- ment system to enhance vehicle control. The main function of the ASC system is to maintain the contact between the tires and the road surface under all driving conditions. This is achieved through exact application and management of brak- ing and drivetrain forces. The ASC system improves traction by electronically applying the rear brakes when the rear drive wheels are spinning at a faster rate than the front wheels. The combined ABSIASC control module, operating through the ABS hydraulic control unit, modulates braking force at the rear wheels. In addition, ASC overrides the throttle opening to reduce en- gine torque and maintain vehicle traction. Because the throt- tle is controlled electronically, the driver cannot increase engine power output during ASC intervention regardless of how far the accelerator pedal is pushed.
Suspension, Steering and Brakes - ~enerail The main components of the system are the wheel speed (pulse) sensors, the ABSIASC or ABSIDSC control module, and the hydraulic control unit. Traction control also comes into operation during decelera- tion. Decelerating on snowy or icy road surfaces can lead to rear wheel slip. If a rear wheel starts to drag or lock up, the ASC system can limit the problem by adjusting throttle, fuel injection and ignition timing. 4 A switch (arrow) on the center console is used to toggle the ASC on or off. NOJE- Even with the ASC system turned off, if the ASC control mod- ule senses a difference in wheel speed (one wheel spinning) the ASC system applies modulated braling force to the slip- ping wheel until traction is regained. There is no override of fuelinjection function. The ASC system is designed to be maintenance free. There are no adjustments that can be made. Repair and trouble- shooting of the ASC system requires special test equipment and knowledge and should be performed only by an autho- rized BMW dealer. ABSIASC traction I 1. control system Wheel speed sensor Wheel speed pulse wheel Brake disk Brake caliper ABSIASC hydraulic unit Brake master cylinder Pedal operated throttle valve ASC controlled throttle valve Engine control module (ECM) Accelerator pedal ABSlASC control module
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
Suspension, Steering and Brakes - General Front ride height specifications (measurement A) E39 6-cylinder (5251,5281,530i) models E39 V8 (540i) models Wheel size 15 inch 16 inch 17 inch 18 inch Maximum variation between sides: 10 mm (0.4 in) Maximum deviation from specifications: 10 mm (0.4 in) Standard suspension 579 mm (22.8 in) 592 mm (23.3 in) 607 mm (23.9 in) 620 mm (24.4 in) Wheel size 15 inch 16 inch 17 inch 18 inch Sports suspension 559 mm (22.0 in) 572 mm (22.5 in) 587 mm (23.1 in) 600 mm (23.6 in) Maximum variation between sides: 10 mm (0.4 in) Maximum deviation from specifications: 10 mm (0.4 in) Standard suspension 579 mm (22.8 in) 592 mm (23.3 in) 607 mm (23.9 in) 620 mm (24.4 in) Rough road suspension 599 mm (23.6 in) 612 mm (24.1 in) 627 mm (24.7 in) 640 mm (25.2 in) Sports suspension 559 mm (22.0 in) 572 mm (22.5 in) 587 mm (23.1 in) 600 mm (23.6 in) M sports package 559 mm (22.0 in) 572 mm (22.5 in) 587 mm (23.1 in) 600 mm (23.6 in) Rough road suspension 599 mm (23.6 in) 612 mm (24.1 in) 627 mm (24.7 in) 640 mm (25.2 in) M sports package 562 mm (22.1 in) 575 mm (22.6 in) 590 mm (23.2 in) 603 mm (23.7 in)
300-1 6 I Suspension, Steering and Brakes - General Rear ride height specifications (measurement A) E39 6-cylinder (5251,5281,530i) models E39 VB (540i) models Wheel size 15 inch 16 inch 17 inch 18 inch Maximum variation between sides: 10 mm (.04 in) Maximum deviation from specifications: 10 mm (.04 in) Standard suspension 547 mm (21.5 in) 560 mm (22.0 in) 575 mm (22.6 in) 588 mm (23.1 in) I I I I I Maximum variation between sides: 10 mm (.04 in) Wheel size 15 inch 16 inch 575 mm (22.6 in) Maximum deviation from specifications: 10 mm (.04 in) Sports suspension 532 mm (20.9 in) 545 mm (21.5 in) 560 mm (22.0 in) 573 mm (22.6 in) Rough road suspension 567 mm (22.3 in) 580 mm ( in) E39 Sport Wagon models M sports package 536 mm (21.1 in) 549 mm (21.6 in) Standard suspension 547 mm (21.5 in) 560 mm (22.0 in) 588 mm (23.1 in)l 573 mm (22.6 in)/ 603 mm (23.7 in)l 608 mm (23.9 in)l 577 mm (22.7 in) 560 mm (22.0 in) Ride level control 562 mm (22.1 in) 575 mm (22.6 in) 590 mm (23.2 in) 603 mm (23.7 in) Sports suspension 532 mm (20.9 in) 545 mm (21.5 in) 590 mm (23.2 in) Rough road suspension 567 mm (22.3 in) 580 mm (22.8 in) 595 mm (23.4 in) 608 mm (23.9 in) Ride level control 562 mm (22.1 in) 575 mm (22.6 in) Wheel size 15 inch M sports package 532 mm (20.9 in) 545 mm (21.5 in) 560 mm (22.0 in) 573 mm (22.6 in) 595 mm (23.4 in) Sports suspension with air spring 548 mm (21.5 in) Standard suspension 548 mm (21.5 in) 16 inch 17 inch 18 inch 564 mm (22.2 in) Maximum variation between sides: 10 mm (.04 in) Maximum deviation from specifications: 10 mm (.04 in) 561 mm (22.0 in) 576 mm (22.6 in) 589 mrn (23.1 in) 561 mm (22.0 in) 576 mm (22.6 in) 589 mm (23.1 in) Ride level control 563 mm (22.1 in) Rough road suspension 568 mm (22.4 in) 576 mm (21.6 in) 591 mm (23.2 in) 604 mm (23.7 in) 581 mm (22.9 in) 596 mm (23.5 in) 609 mm (24.0 in)
31 0 Front Suspension General . . . . . . . . . . . . . . . . . . . . . . . . . . . .310-2 Front Suspension Arms . . . . . . . . . . . 310-1 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . ,310-2 Control arm, removing and installing Front suspension variations . . . . . . . . . . . . ,310-4 (6-cylinder models) . . . . . . . . . . . . . . . . . . 31 0-1 2 Control arm, removing and installing Front Strut 310-4 (-8 models) , , , , , , , , , , , , , , , , , , , , , , , 310-13 Front strut assembly, removing Tension strut, removing and installing . . . . 310-16 and installing . . . . . . . . . . . . . . . . . . . . . . . . ,310-5 Tension strut bushing, replacing . . . . . . . . 310-18 Front strut assembly components (6-cylinder models) . . . . . . . . . . . . . . . . . . ,310-9 Wheel Bearings, Front . . . . . . . . . . . . . 310-18 iron; strut assembly, disassembling Front Stabilizer Bar . . . . . . . . . . . . . . . 310-22 and assembling . . . . . . . . . . . . . . . . . . . . . ,310-9 Stabilizer bar, removing and installing . . . . 310-22
31 0-2 I Front Suspension This repair group covers the repair and replacement of com- ponents that make up the front suspension of E39 cars. Two different types of steering systems are used in the E39 series. 6-cylinder (5251,5281 and 530i) models are equipped with a rack and pinion type steering system mounted to an aluminum subframe. V-8 (540i) models use a steering gear- box type system mounted to a steel subframe. See 300 Suspension, Steering and Brakes-General for a description of the front suspension and components, as well as specifications for setting ride height. CAUTION- Some E39 models are equipped with aluminum suspen- sion components. The foiiowing 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- ties. Only use brushes with stainless steei bristles. Do not expose to flying sparks from grinding/cutting op- erations. * Do not subject to steei welding splashes. Do not expose to temperatures over 80°C (176°F). even for short periods. Temperatures in painting faciii- ties are not a problem. Special tools Special service tools are required for most of the work de- scribed in this repair group. In addition to the tools depicted in the illustrations, avariety of press tools are necessaryfor con- trol arm bushing replacement. Read the procedures through before beginning any job. 31 2 210 I < Strut nut socket (Tool No. 31 2 210)
Front Suspension < Ball joint press (Tool No. BMW 31 2 240) < Bushing press tools (Tool No. BMW 31 2 2611263) 4 Spring compressor and spring holder arms 31 3 350 (Tool No. BMW 31 3 340 131 3 350)
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