front strut BMW 540i 1998 E39 Owner's Guide

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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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330-1 3
Rear Suspension
1 1 4 Check roll fold of air spring (arrows). Reinstall only if roll fold
is undamaged and formed correctly.
- To install air spring:
Check sealing O-rings at air spring inlet. Replace
if dam-
aged. Do not grease O-rings. Reinstall protective plug.
* Install spring above suspension subframe. Make sure ec-
centric lug at bottom of air spring fits in recess of
subframe
spring seat.
Reattach top spring mounting clips.
- Reattach air line connections.
- Remainder of installation is reverse of removal.
Tightening torques
Air line connection
2 Nm (1 8 in-lb)
Air spring
to wheel bearing carrier 20 Nm (1 5 ft-lb)
Road
wheel to hub 120 510 Nm (89-F-7 ft-lb)
REAR SUSPENSION ARMS,
SUBFRAME AND BUSHINGS
A damaged suspension arm orworn bushings will change the
rear wheel alignment and may adversely affect handling and
stability.
WARNING-
Do not attempt to straighten a damaged suspension arm.
Bending or heating may
weaken the original part. Always re-
olace a damaoed susoension arm.
Rear suspension arm
components
1. Eccentric washer
(for rear toe adjustment)
2. Upper front control arm
(guide link or traction strut)
3. Outer swing arm bushing and
integral link
4. Swing arm (lower control arm)
5. Upper rear control arm
(wishbone)
6. Wheel bearing carrier
7. Circlip
8. Swing arm ball joint
9. Eccentric washer
(rear camber adjustment)

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330-25
Rear Suspension
Remove rear control arm:
Remove inner control arm bolt
(A). Push shock absorber
out of the way to slide bolt out.
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.
Maite sure
ail threaded bolts, nuts and mating surfaces are
clean.
Inner control arm mounting bolt must thread to front
(bolt . head at rear).
Make sure long lower shock absorber bushing fits in hole
in suspension swing arm.
* Tighten fasteners to final torque only after 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 shocit absorber
2 Nm (18 in-lb)
Road wheel to hub
Shoclc absorber to lower control arm 127 Nm (94 it-lb)
Upper front control arm (traction strut),
removing and installing
- Raise rear end of car and remove wheel.
WARNING-
Maice 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
< Mark location of inner control arm eccentric washer (rear toe

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330-26
/ Rear Suspension
Remove inner control arm eccentric nut and bolt (A)
Remove control arm ball joint nut (6). Press ball joint out
of wheel bearing carrier.
Lifl out control arm.
Installation is reverse of removal, noting the following:
Use previously made
marks to install eccentric bolt and
nut.
Always use new self-locking nuts.
Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
0 Have car professionally aligned when job is complete.
Tightening
torques
Road wheel to hub 120klONm
(89 i7 ft-lb)
Upper front control arm (traction strut) to 60
Nm (44
ft-lb)
subframe (rear toe adjusting bolt)
Upper front control arm (traction strut) to wheel
65 Nm (48 ft-lb)
carrier
Rear axle assembly, removing and
installing (sedan models)
In case of damage to the subframe, or if a pressed-in bushing
is worn, remove
subframe by removing complete axle assem-
bly.
- Raise car and remove rear wheels.
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.
- 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 lefl 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.

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(Rear Suspension
< Remove upper front control arm (traction strut) ball joint
mounting nut
(arrow). Press control arm ball joint out of
wheel bearing carrier.
- Repeat above process on upper rear control arm.
- Remove wheel bearing carrier assembly.
4 When reinstalling, pull axle shaft through wheel bearing car-
rier using
BMW special tools 33 2 115, 33 2 116 and 33 2
118.
- Lightly oil bearing surface of axle collar nut and install. T~ght-
en collar nut firmly, but do not fully tighten it at this time.
WARNING-
For safety reasons, the ale collar nut should only be tight-
ened to its final torque with the wheel installed and the car
lowered to
the ground. However, loading the bearing without
the nut tightened sufficiently may damage tlie bearing.

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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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I Rear Suspension
4 Press out axle shaft using BMW special tools 33 2 117. 33 2
116and332111.
4 Remove upper front control arm (traction strut) ball joint
mounting nut (arrow). Press control arm ball joint out of
wheel bearing carrier.
- Repeat above process on upper rear control arm.
- Remove wheel bearing carrier assembly.
4 When reinstalling, pull axle shafl through wheel bearing car-
rier using BMW special tools 33
2 115, 33 2 116 and 33 2
118.
- Lightly oil bearing surface of axle collar nut and install. Tight-
en collar nut firmly, but do not fully tighten it at this time.
WARNING-
For safety reasons, the axle collar nut should only be tight-
ened to its final torque with the wheel installed and the car
lowered to the ground. However, loading the bearing without
the nut tiqhtened
suificiently may darnaqe the bearina.

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330-39
I Rear suspension1
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Models with coil springs: Fit spring correctly in lower spring
seat.
* Models with air suspension: Fit eccentric lug at bottom of
air spring in recess of wheel carrier spring seat.
Always use new self-locking nuts.
- Make sure all threaded bolts, nuts and mating surfaces are
clean.
a Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Stake axle collar nut afler tightening.
Tightening torques
ABS pulse sensor to wheel bearing 8 Nm (6
ft-lb)
carrier
Air spring to wheel bearing carrier 20 Nm (15 ft-lb)
Brake rotor to hub 16 Nm (12
it-lb)
Rear axle shaft to hub (M27) 300 Nm (221 ft-lb)
Rear brake pad carrier (caliper) to wheel 65 Nm (48 ft-lb)
bearing carrier
Road wheel to hub
120ilONm
(89 k7 ft-lb)
Swing arm to wheel bearing carrier 256 Nm (189 it-lb)
Upperfrontcontrol arm (traction strut) to 65 Nm (48 ft-lb)
wheel carrier
Upper rear control arm to wheel carrier 142 Nm (105 ft-lb)
Rear wheel bearing, replacing
< The rear wheel bearing is integrated with its mounting flange.
1. Torx bolt
2. Wheel bearing and mounting flange
3. Wheel hub
4. Collar nut
- 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 jack stands underneath struc-
tural chassis points. Do not place jack stands under
suspension parts.

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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)

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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