1999 BMW 540i Ride height

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330-27
Rear ~uspensionl
- If equipped, remove ride height sensor connectors.
Support final drive unit from below using transmission jack
(BMW special tools 00
2 030 and 33 4 390 or equivalent).
NOTE-
Special tool 33 4 390 will need modifications to cradle the ii-
nal drive properly.
4 Remove right and left suspension trim panels (arrow)
4 Remove right and left lower strut mount bolts (arrow)
Remove rear suspension
subframe by removing 4 mounting
bolts (arrows).
Carefully lower rear suspension
subframe away from body to
remove.

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Rear Suspension
- Remove exhaust system. See 180 Exhaust System.
- Detach driveshaft from differential. See 260 Driveshaft.
- Remove brake caliper and brake disc. Hang brake caliper
aside with stiff wire. Do not disconnect brake fluid hose. See
340 Brakes.
- Remove left and right ABS sensors from wheel bearing car-
riers.
Disconnect parking brake cable from brake shoe expander.
See 340 Brakes.
Remove heat shield from above driveshaft
If equipped, remove ride height sensor connectors
CAUTION-
Models with air springs: Disable air supply pump by discon-
necting electrical plug before performing any repairs. Pump is
locatedbeneath a coverunder
thespare tire in the floorof the
carqo compartment.
Models with air springs: Loosen compressed air pipes (ar-
rows) at air distribution assembly to release system pres-
sure.
WARNING -
Vehicle will lower when the air pipes are opened. 1
- Working underneath rear suspension, lift wheel bearing car-
rier to relieve rear spring tension. Then unbolt air spring
mounting bolt from seat on wheel bearing carrier.
4 Support final drive unit from below using transmission jack
(BMW special tools 00 2 030 and 33 4 390 or equivalent).
NOTE-
Special tool 33 4 390 will need modifications to cradle the fi-
nal drive properly
4 Remove right and left suspension trim panels (arrow),

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---
Rear Suspension
ELECTRONIC HEIGHT CONTROL
(EHC) COMPONENT REPLACEMENT
Sport Premium rear suspension is an option on Sport Wagon
models and standard on
1999 and later V-8 Sport Wagons.
This suspension incorporates electronic height control
(EHC)
using air springs.
With vehicle lifted off the ground,
if the rear air springs can be
compressed by hand, either the spring is defective or the sys-
tem is depressurized.
Locate
EHC faults using BMW scan tools DIS or MoDiC. EHC
description and some troubleshooting is covered in 300 Sus-
pension, Steering and Brakes-General.
Air spring replacement is covered earlier in this chapter. See
Air spring, removing and installing.
CAUTION-
Maintain high levels of cleanliness around air line connec-
tions when disassembling and assembling air suspension
components. Even
small dirt particles can cause leakage in
the pressurized system.
Electronic height control
(EHC) components
1. Air spring
2. 1 liter air reservoir
3. EHC control module
4. Air supply distributor
5. Airsupply pump
(under spare tire)
6. Air spring mounting bolt
(at wheel bearing carrier)
7. Rear ride height sensors
(Hall effect)
8. Air supply pump relay

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-- I
I: ... . -. Rear Suspension! -- .- -
Air compressor pump relay, removing and
installing
- Working in cargo compartment, remove spare wheel.
4 Remove air supply pump fasteners (arrows). Turn pump
over.
- Turn relay plug 45" and remove relay.
EHC control module, removing and
installing
The EHC control module is mounted on the right side of the
spare tire
well in the cargo compartment.
- Remove spare tire.
4 Remove electrical components cover (A).
- Release control module wiring harness plug loclting clip (B)
and remove module.
- Installation is reverse of removal.
- After assembly, reset ride height using BMW diagnostic scan
tool DIS.
Air supply unit, removing and installing
CAUTION-
Maintain high levels of cleanliness around air line connec-
tions when disassembling and assembling air suspension
components. Even small dirt particles can cause
leakage in
the pressurized system.
When the airsupply unit is removed for any reason, reset ride
height using BMW scan tools DIS or
MoDiC.
- Remove spare tire.
i~B,!n,,ayPubi.l,c~u.c~"~-A~~ R

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Rear Suspension
4 Remove air line fittings (A) from bottom of air distribution con-
nectors.
Cut off wire ties.
WARNING-
Vehicle will lower when the air pipes are opened.
4 Rotate air line distribution connector (A) 45" in direction of
arrow to remove.
Rotate electrical connector
(B) 45" in direction of arrow to
remove.
Compress wiring connector locking clips
(arrows) and dis-
connect wiring harness.
< Remove air supply unit mounting fasteners (arrows) and re-
move unit.
- Installation is reverse of removal.
When installing air lines always match line colors.
a After assembly, reset ride height using BMW diagnostic
scan tool DIS.

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330-47
Rear suspension/
Ride height sensor, removing and installing
Hall effect sensors for vehicle height detection are mounted
on the
left and right sides of the rear suspension. A coupling
rod mounted between the rear suspension arm and the sen-
sor arm is used to send a varying voltage signal to the
EHC
control module.
Raise car and support safely.
WARNING-
Male sure the car is firmly supported on jaclc stands de-
signed
for the purpose. Place jaclc stands underneath struc-
tural chassis points. Do not place jaclc stands under
sus~ension Darts.
Working underneath rear of car, remove trim panel (arrow)
just ahead of suspension subframe.
Disconnect electrical harness connector from sensor.
4 Remove control rod mounting nut (arrow).Turn control rod to
access sensor mounting fastener.
- Remove sensor mounting fasteners.
- Remove ride height sensor.
- Installation is reverse of removal.
Make sure sensor lever points outward. After assembly, re-
set ride height using BMW diagnostic scan tool DIS.
Tightening torques
Ride
height sensor to bracket 5 Nrn (44 lb-in)
Lever to height sensor
9 Nrn (80 ib-in)

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INDEX 5
WARNING
Your common sense, good
judgement, and general alerlness are
crucial lo
safe and successful service ivork. Before attempling any work on
your
BMW be sure lo read 001
General Warnings and Cautions
and the copyright page at the
fronl of
Ihe manual. Review these warnings
and
cautions each lime you prepare
to work on your BMW Please also
read any warnings and cautions tliat
accompany Nie procedures in the
manual.
Exhaust manifold see Exhaust system
Exhaust system diagrams
180.1 1
exhaust manifolds, removinglinstalling
180-4 muifier, replacing 180-8
oxygen sensors 180-8
and catalytic converter 020-1 9
see also Fuel injection
removinglinstalling 180-2
see also Maintenance
Expansion tank
see Cooling system
Expansion valve
see
NC
Exterior lighting
see
Lights
Exterior trim
BMW emblem
(Roundel), removing1
installing
510-13 body side molding, replacing 510.13
grill, removinglinsialiing 510-14
headlight housing trim, removing1
installing 510-14
outside mirror
510-2
EWS (electronic immobilization)
515-21 ring antenna,
iemovinglinstaiting
320-1 1
Fan see Cooling system Fault
codes
OBD-2
storage
100-4. 600.10
Fender
front, rernovinglinstailing
410-2
Filters see Maintenance
Final drive
lubricant
speciiicatiorls 020-9
mounh, replacing 331-12
oil level 020-26. 331-6
removinglinslalling 331-5 seals 331-7
Firing order
see Ignition system
FtS
see Interior protectiorl
Flex disc
see Driveshaft
Fluids and lubricants see Maintenance
Flywheel removinglinstalling 210-13
Fogllght
see Lights
Front centering guide see Driveshatt
Front oil seal
see
Crankshaft oil seals
Front suspension control arm
310-12 description 300-2
ride height 300-14
stabilizer bar, removinglinstalling
310-21
strutslsprings 31
0-4
tension strut 310-16
thrust arm 310-12 variations 310-4
wheel bearing 310-18
see also Maintenance
Fuel filter
see Maintenance
Fuet injection applications 130-2
Bosch M5.2, M5.2.1 130-46
Bosch ME 7.2 130-66 fuel delivery
see 130 under appropriate iuel
injection system
see also Fuel pump
see also
Fuet tank
oxygen sensors
130-72, 180-8
Siemens MS 41.1 130-7 Siemens MS 42.0. MS 43.0 130-23
Fuel injector
see 130 under appropriate fuel
injection system
Fuel level sender
160-15
see also Fuei pump
Fuel pressure
160-10
see also Fuel pump
Fuel pump
160-3
electrical circuit, testino 160-7
1
removinglinstalling (includes right side
iuel levei sender) 160-15
siphon pump, removinglinstaliing
160-19
troubleshooting 160-6 see also Fuel tank
Fuel rail
see 130 under appropriate iuel
injection system
Fuei supply
130-6
see also Fuei pump
see also
Fuet lank
Fuel
tank
312-way valve (running losses.
removinglinstalling
160-24 carbon canister 160-24
draining 160-20
evaporative control system 160-3
expansion tank, removinglinstalling
160-23
I
leak detection unit (LDP or DM-TL),
rernovinoiinstallino 160-24
level senier 160-15
removinglinstalling 160-21
Fuse locations
610-29
RV (remote entry)
see Central
locl(ing
Fan clutch
see Cooling system, cooling fan

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INDEX 9
WARNING
Your common sense, good judgemenl, and general alerlness are
crucial lo seie end successful service
ivork. Beiore attempting any work on
your
BMW be sure to read 001
General Warnings and Cautions and llle copyright page at lhe iron1 of
the manual. Review Niese warnings
and caulions each lime you prepare
lo work on your BMW Please also
read any warnings and caulions lllal accompany the procedures in the
manual.
Rear suspension
ball joints
330-19
bushings 330-13
control arms
seesuspension arms, below
description
300-5
electronic height control (EHC)
330-44
ride height 300-14 ride height sensor 330-46
shoclr absorbers end springs 330-9
stabilizer bar 330-42
struts and springs 330-5 subframe 330.13
suspension arms 330-13
variations 330-4 wheel bearing, replacing 330-32
see also Maintenance
see also Drive axles
see also Final drive
Rear window (Sport Wagon)
see
Tailgate
Rear window defroster 610-17
Receiverldrter
see NC
Relay positions
see Electrical component tocations
table 610-3
Remote entry (FZV)
see Central locking
Reversing light switch
see
Baclc-up light switch
Ride height
300-14
Ride height sensor
see Rear suspension
Ring antenna
see EWS (electronic immobilizalion)
Rotor
see Brakes
Roundel see Exterior trim
Running tosses
(312-way) valve
see Fuel
tenlr
SCA (soft close)
seeTailgate, soft close
see also Trunk lid. soft close
Scan tools
OED-3
Seals gaskets and 010-9
see also Crankshaft seals
Seat front,
removing/instelling 520-10
memory system 520-4 rear 520-13
see also Seat belt
Seat beit front 720-4
rear 720-8
troubleshooting 7202
see also Maintenance
Secondary air injection
see 130 under appropriate
iuel
injection system
Selector shaft seat
see Manual transmission, oil
Seals
Self-adjusting ctulch (SAC)
see Clutch, variations
Service indicator see Maintenance
Shift interlock see Gearshift
Shift lever
see
Gearshift
Shift linkage see Gearshift
Shiftlock see Gearshilt
Shack absorber see Rear suspension
/ Side turn signal assembly
see Lights
Sill trim panel
411-10
Slave cylinder
see Clutch, lhydraulic
Steep mode
600-1 1
Soft close
(SCA) see Tailgate
see also
Trunk lid
Solenoid 121-23
Sound system
650-2
Spare parts kit
010-21
Spark plugs
see Maintenance
Speakers
650-4
Specifications, fluid
020-4
Sport wagon
400-4
Springs
see Front suspension
see also Rear suspension
SRS (supplemental restraint system)
see
Airbag system (SRS)
Stabilizer bar see Front suspension
see also Rear suspension
Starter see Battery, starter, alternator