2000 BMW 540i Suspension

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330 Rear Suspension
General . . . . . . . . . . . . . . . . . . . . . . . . . . . ,330-2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . ,330-2
Rear suspension variations . . . . . . . . . . . . ,330-4
Rear Struts and Springs
(sedan models)
. . . . . . . . . . . . . . . . . . . . ,330-5
Rear strut assembly, removing
and installing
. . . . . . . . . . . . . . . . . . . . . . . ,330-5
Rear strut assembly, disassembling
and assembling
. . . . . . . . . . . . . . . . . . . . . ,330-7
Rear Shock Absorbers and
Springs (Sport Wagon models)
. . . . . ,330-9
Rear shock absorber, removing
and installing
. . . . . . . . . . . . . . . . . . . . . . . ,330-9
Coil spring, removing and installing . . . . . ,330-1 1
Air spring, removing and installing
. . . . . . ,330-12
Rear Suspension Arms,
Subframe and Bushings . . . . . . . . . . ,330-13
Rear suspension arm components . . . . . . ,330-1 3
Swing arm, removing and installing (sedan models)
. . . . . . . . . . . . . . . . . . . . . ,330-1 4
Swing arm, removing and installing (Sport Wagon models)
. . . . . . . . . . . . . . . ,330-16
Swing arm ball joint, replacing . . . . . . . . . ,330-1 9
Upper rear control arm, removing
and installing (sedan models)
. . . . . . . . . . .330-22
Upper rear control arm, removing
and installing (Sport Wagon models)
. . . . .330-23
Upper front control arm (traction strut),
removing and installing
. . . . . . . . . . . . . . . ,330-25
Rear axle assembly, removing and
installing (sedan models)
. . . . . . . . . . . . . ,330-26
Rear axle assembly, removing and
installing (Sport Wagon models)
. . . . . . . ,330-28
Rear subframe mounting bushings,
removing and installing
. . . . . . . . . . . . . . . .330-31
Rear Wheel Bearings . . . . . . . . . . .
Rear wheel bearing carrier, removing
and installing (sedan models)
. . . . . . .
Rear wheel bearing carrier, removing
and installing (Sport Wagon models)
. .
Rear wheel bearing, replacing . . . . . . .
Rear Stabilizer Bar
Stabilizer bar, removing and installing .
Stabilizer bar link, removing
and installing
. . . . . . . . . . . . . . . . . . . .
Electronic Height Control (EHC)
Component Replacement
. . . . . . .
Electronic height control (EHC)
components
.....................
Air compressor pump relay, removing
and installing
. . . . . . . . . . . . . . . . . . . .
EHC control module, removing
and installing
. . . . . . . . . . . . . . . . . . . .
Air supply unit, removing and installing
Ride height sensor, removing
and installing
. . . . . . . . . . . . . . . . . . . .

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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)

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Rear suspension/
31 3 333 "I Rubber bushing removal tool set
(Tool No. BMW
33 3 331,33 3 332,33 3 333,33 3 334)
4 Subframe mount removal set
(ToolNo.BMW334 140,334148,334149,334151,334
155.33 4 156)
4 Subirame mount tool set
(Tool
No.BMW334151,34140,334155,334154)
4 Rear wheel bearing carrier mount tool set
(ToolNo.BMW334151,334152,334153,334154,334
156,334157)
4 Subframe mount installation set
(Tool No. BMW
33 4 153,33 4 155,33 4 156,33 4 157)
Slide hammer set
(Tool No. BMW
33 4 201,33 4 202,33 4 203)
13 4 201

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330-4
Rear Suspension Rear suspension variations
1. Coil spring
2. Strut
3. Final drive (differential)
4. Rear subframe
5. Upper rear control arm
(wishbone)
6. Subframe mounting bushing
7. Drive axle
8. Upper front control arm
(traction strut)
9. Swing arm (lower control arm)
10. Integral link
12. Air spring
I
Waaon
11. Shockabsorber
a m3 withair s~riias

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330-5
Rear Suspension
REAR STRUTS AND SPRINGS
(SEDAN MODELS)
Rear strut assembly, removing and
installing
Replace struts and coil springs in pairs only.
- Raise car and remove rear wheels.
WARNING -
Male sure 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 rear parcel shelf:
Remove rear seat headrests by pulling straight up.
Remove both rear roof pillar (C-pillar) trim panels.
Unbolt rear seat
belt anchors. See 720 Seat Belts.
Models with fixed rear seat: Remove rear seat backrest.
See 520 Seats.
* Models with fold-down rear seat: Remove rear seat back-
rest side sections. See 520 Seats. Fold down backrest.
* Working inside trunk, remove roller blind mounting nuts
and bolts, if applicable. Also disconnect roller blind har-
ness connector at right edge of rear seat backrest.
Gently pry rear speaker cover grilles and rear window defog-
ger grilles
(A) out of parcel shelf.
Carefully remove seat belt and headrest mount finisher
strips (B).
Remove
middle seat headrest anchor bolts (C). Remove
headrest anchor.
Remove expansion rivets (arrows) and lift out parcel shelf.
- Remove rear speakers.
- Remove rear wheels. Remove wheel arch trim
- Support rear wheel bearing carrier.
CAUTION-
The strutassembly prevents the drive axle and wheel bearing
carrier
from dropping too far. Supporting the wheel bearing
carrierbefore disconnecting the strut mounting fasteners pre-
vents damage to the brake hose, parking brake cable and
drive axle
CV joints.

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330-6
Rear Suspension
4 Remove rear strut top cover. Remove upper strut mounting
nuts (arrows).
Remove strut assembly lower mounting bolt (arrow).
Disassemble strut and spring assembly as described below
in Rear strut assembly, disassembling and reassem-
bling.
Installation of assembly to car is reverse of removal, noting
the following:
Make sure all threaded bolts, nuts and mating surfaces are
clean.
Install strut assembly top mount using new self-loclting
nuts.
Malte sure long lower strut bushing fits in
hole in wheel
bearing carrier.
Tightening torques Strut to wheel bearing carrier 127 Nm (94
it-lb)
Strut mount to body
Gray fasteners 28 Nm (21 ft-lb)
Yellow fasteners 24 Nm
( 18 it-lb) -
Road wheel to hub 120ilO Nm (89i7ft-lb)

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330-8
Rear Suspension
4 Compress spring and install it and related components to
shock absorber. Use new self-locking upper strut mounting
nut.
1. Upper strut mount self-locking nut
2. Washer
3. Poor road surface adapter
4. Upper spring seat
5. Upper strut mount
6. Upper rubber bumper seat
7. Rubber bumper
8. Coil spring
9. Dust boot
10. Lower spring seat
I I. Strut
WARNING-
Male sure the upperself-locking nut is fully tightened before
releasing the spring compressor.
Tightening torque
Upper strut mount to strut shaft
27 Nm (20 ft-lb)
(M14, replace self-locking nut)
4 Before releasing spring tension, position upper strut mount
so that one threaded stud is on a plane with flat end of strut
bushing at other end of strut.
- Release spring compressorslowly, positioning spring ends in
shoulders of spring seats.
- Reinstall strut assembly in vehicle, as described above in
Rear strut assembly, removing and installing.

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--
C. -- -- - -- Rear ~us~ensionl
Depending on year and model applications, the Sport Wagon
rear suspension may be equipped with:
Conventional shock absorbers and coil springs
Electronic height control (EHC) system which incorporates
air springs
NOTE-
. Suspension and EHC troubleshooting is covered in 300
Suspension, Steering and Brakes-General.
EHC system repairs, other than air spring replacement,
are covered in Electronic height control
(EHC) compo-
nent replacement.
Replace shock absorbers and springs in pairs only.
Rear shock absorber, removing and
installing
- Raise car and remove rear wheels,
WARNING-
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 parts.
CAUTION-
If working on a vehicle with compressedairshock absorbers,
disable air supply pump by disconnecting electrical plug be-
fore performing any repairs. Pump is located beneath a cover
under the spare tire in the floor of the cargo compartment.
- Support swing arm from below
CAUTIOG
The shock absorber prevents the drive axle and wlieel bear-
ing carrier from dropping too far. Supporting the wheel bear-
ing carrier before disconnecting the shock absorber
mounting fasteners prevents damage to the
brake hose,
parking
brake cable and drive axle CVjoints.
- Working in cargo compartment, remove carpet. Remove tri-
angular upper shock mount covers located beside spare tire
well.
- If applicable: Detach air supply line from shock absorber.
Plug ports and lines to keep out dirt.