2001 BMW 528i sport mode

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Rear Suspension Swing arm, removing and installing
(Sport Wagon models)
- Raise rear end of car and remove wheel.
WARNING -
Make 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.
CAUJION-
Model with air springs: Disable air supply pump by discon-
necting electricalplug
beforeperforminganyrepairs. Pump is
located beneath a cover under the spare tire in the floor of the
cargo compartment.
< Model with air springs: Loosen compressed air pipes (ar-
rows) at air distribution assembly to release system pres-
sure.
NOJE-
Vehicle will stand quite low
- If applicable: Detach air supply line from shock absorber.
Plug ports and lines to
lkeep out dirt.
- Model with rear coil springs: Remove cargo compartment
floor carpet.
4 Working at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring from under car.
4 Working from underneath, position BMW special tool
33
2 301 between 2nd and 3rd spring coil from bottom.
Make sure tool recess faces upward.
Working in cargo compartment, guide BMW special tool
33
2 304 from above and thread into special tool 33 2 301.

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330-1 9
Rear suspension1
Swing arm ball joint, replacing
- Raise rear end of car and remove wheel.
Make 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.
- Sport Wagon model: Support wheel bearing carrier from be-
low.
CA
UTION-
The shock absorberprevents the drive axle and wheel bear-
ing carrier from dropping too far. Supporting the wheel bear-
ing carrier before disconnecting the
shoclc absorber
mounting fastenerprevents damage to the brake hose, park-
ing
brake cable and drive axle CVjoints.
- Model with air shock absorbers: Detach air supply line from
shoclc absorber. Plug ports and lines to keep out dirt.
- Sport Wagon model: Remove shock absorber lower mount-
ing bolt.
4 Remove stabilizer bar link mounting nut (arrow). Press link
out of swing arm.
Model with air springs: Disable air supply pump by discon-
necting electrical plug before performing any repairs. Pump is
located beneath a cover under
the spare tire in the floor of the
carao
comoartment.
4 Model 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.
- Models with rear coil springs: Remove cargo compartment
floor carpet.

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330-23
Rear Suspension
Remove rear control arm:
Remove inner control arm bolt
(A).
Detach plastic wiring harness support (B).
* Remove outer control arm ball joint nut (C). Press ball joint
out of rear wheel bearing carrier.
Installation is reverse of removal, noting the following:
Always use new self-locking nuts.
Malte sure all threaded bolts, nuts and mating surfaces are
clean.
Inner control arm mounting bolt must thread to rear (bolt
head at front).
Tighten fasteners to final torque only afler vehicle has
been lowered and suspension has settled.
Have car professionally aligned when job is complete.
Tightening
torques
Control arm to subframe (M12) 110 Nm (81 ft-ib)
Control arm
ball joint to wheel bearing 142 Nm (105 ft-lb)
carrier
(M14)
Quick coupling screw to air shock absorber
2 Nm (18 in-lb)
Road wheel
to hub 120-flONm
(89 i7 ft-lb)
Upper rear control arm, removing and
installing (Sport Wagon models)
CAUTIOG
Disable air supply pump by disconnecting electrical plug be-
fore
perlorming any repairs. Pump is located beneath a cover
under the spare tire in the floor of the
carqo compartment.
- Raise rear end of car and remove wheel.
WARNING -
Make 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 jack stands under
suspension parts.
Models with rear coil springs: Remove cargo compartment
floor carpet.
Worlting at top of coil spring, press center cap down or pry
upward to remove. If pushed down, remove from inside coil
spring from under car.

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330-28
Rear Suspension
4 To install, jack subframe into position. Install and tighten sub-
frame mounting bolts. Note that on each bolt, rubber-coat-
ed detent plate
(arrow) must be installed at rear in driving
direction.
Tightening torques
Rear
subframe to body (M12) 163 Nm (120 ft-lb)
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Make sure long lower strut bushing fits in hole in wheel
bearing carrier.
111 0 Tighten suspension arm and shoclc absorber fasteners to
502330036 final torque only afler vehicle has been lowered and sus-
pension has settled.
Have car professionally aligned when job is complete
Tightening torques
ABS pulse sensor to wheel bearing carrier 8 Nrn (6 ft-lb)
Brake rotor to hub
16 Nm (12 ft-lb)
Driveshaft
CV joint to final drive flange
- MI0 (Tow bolts) 70 Nm (51 ft-lb)
MB (compression nut) 32
Nm (24 ft-lb)
Rear brake pad
carrler (caliper) to wheel 65 Nm (48 ft-lb)
bear~ng carrler
Rear strut to
wheel bearlng carrler 127 Nm (94 ft-lb)
Road wheel to hub
120210Nrn
(89 57 ft-lb)
Rear axle assembly, removing and
installing (Sport Wagon models)
Incaseof damage to thesubframe, or if apressed-in bushing is
worn, remove
subframe by removing complete axle assembly.
In Sport Wagon models with conventional coil spring, lower
subframe slowly, making sure rear springs stay on spring
seats.
In models with air suspension
(EHC), disable the air supply
pump, deflate the air springs and disconnect them from the
wheel carriers before lowering the subframe.
- Raise car and remove rear wheels.
WARNING-

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330-35
Rear Suspension
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Always use new self-loclting nuts.
Make sure all threaded bolts, nuts and mating suriaces are
clean.
Make sure long lower strut bushing fits in hole in wheel
bearing carrier.
Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Stake axle collar nut after tightening.
Tightening torques
ABS pulse sensor to wheel bearing carrier
8 Nm (6 ft-lb)
Brake rotor to hub 16 Nm (12 ft-lb)
Rear brake pad carrier (caliper) to wheel 65
Nm (48
ft-lb)
bearing carrier
Rear axle shaft to hub
(M27) 300 Nm (221 ft-lb)
Rear strut to wheel bearing carrier 127
Nrn (94 ft-lb)
Road wheel to hub
120+10 Nm
(89
i7 ft-lb)
Swing arm to wheel bearing carrier 256
Nrn (189 ft-lb)
Upper front control arm (traction strut) to 65 Nrn
(48
ft-lb)
wheel carrier
Upper rear control arm to wheel carrier 142
Nrn (105
ft-lb)
Rear wheel bearing carrier, removing and
installing (Sport Wagon models)
- Raise rear end of car and remove wheel.
WARNING-
Make 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.
Models
with air springs: Disable air supply pump by discon-
necting electricalplug
beforepedormingany repairs. Pump is
located beneath a cover under the spare tire in the floor of the
cargo compartment.
-- 4 Models with air springs: Loosen compressed air pipes (ar-
rows) at air distribution assembly to release system pres-

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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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Final ~rivel
4 Remove staked collar nut and press output shafl out of wheel
hub with special
BMW tool 33 2 111/116/117.
- Remove drive axle.
- Installation is reverse of removal, noting the following:
Use a new collar nut.
a Apply a light coating of oil to contact face of collar nut and
install it loosely.
* Install road wheel and lower car to ground.
- With an assistant applying brakes, tighten drive axle collar
nut to its final torque.
Stake collar nut.
Tightening torques
-
Drive axle collar nut to drive flange M27 300 Nrn (221 ft-lb)
Drive axle to differential flange
* M10x20 rnm black Torx bolt
83 Nrn (61 ft-lb)
M10x20 rnrn silver Torx bolt
100 Nrn (74 ft-lb)
Road wheel to hub 120 Nrn f 10 (89 ft-lbf7)
Drive axle, removing and installing
(Sport Wagon)
4 With an assistant applying brakes, brealc free staked collar
nut (arrow) at center of rear wheel hub. Do not remove com-
pletely.
NOJE-
The drive flange collar nut is tightened to a torque of over 300
Nm (221 ft-lb). Make sure the car is firmly on the ground.
WARNING -
Disable airsupply pump (if applicable) by disconnecting elec-
tricalplug before performing any repairs. Pump is located be-
neath a cover under the spare tire
in the floor of the cargo
compartment.
- Raise rear of car. Remove rear wheel.
WARNING -
Malce sure that the car is firmly supported on jack stands de-
signed for the purpose. Place the jack stands beneath struc-
tural chassis points. Do not place jack stands under
suspension parts.
- Models with rear coil springs: Remove cargo compartment
floor carpet.

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400-4
I Bodv-General
Bumpers
The front and rear bumpers are clad in high quality
deform-
able plastic and, at solid barrier impact speeds of 4 kph (2.5
mph), provide protection with virtually no damage to the
bumper
orthe vehicle. In addition to hydraulic dampeners.
which absorb the initial impact energy, these bumpers are
backed by compressible tubes. These deform in a controlled
manner at impact speeds greaterthan that
forwhich bumpers
and hydraulic dampeners are designed. This helps avoid ex-
pensive damage to the body at impact speeds up to 14 kph (9
mph).
The E39 Sport Wagon was introduced to the US market in
911 998 (model year 1999). It shares many components with
the E39 sedan and is identical to it from the B-pillar forward.
US
marltet 5 Series Sport Wagons are available in two vari-
ants:
6-cylinder
(5251, 528i) powered by the 2.8 liter M52 TU en-
gine (1 999) or the 2.5 liter M54 engine (2000 and later)
* V-8 (540i) powered by the 4.4 liter M62 TU engine
The wheelbase of the Sport Wagon is the same as the sedan.
Howeverthe body is 30
mm (1.2 in) longer and 10 mm (0.4 in)
higher.
The Sport Wagon rear suspension was redesigned to elimi-
nates the upper rear spring strut mounting on the E39 sedan.
The use of separate coil springs and
shoclc absorbers results
in a flat, wide floor in the cargo area. See
300 Suspension,
Steering and Brakes-General.
The self-leveling air spring suspension system (electronic
height control or EHC) is standard on Sport Wagon V-8 mod-
els and optional on 6-cylinder models.
Sport Wagon cargo capacities are shown below.
Sport Wagon load capacities
Cargo capacity
Rear seat up 909 liters (32.1 cu ft)
Rear seat folded down I809 liters (63.9 cu ft)
Load limit
Cargo compartment
460 Kg (1014 lb)
Roof
I00 Kg (220 lb)