DISA BMW 528i 1998 E39 Owner's Guide

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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.

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Rear Suspension
Air spring, removing and installing
CAUTION-
If vehicle is driven with airspring depressurized, the airspring
will be permanently damaged and must be replaced.
An air spring is made from a flexible rubber material which
forms an airtight cavity. It is pressurized by an air supply
pump activated by an electronic control unit to provide a
vari- . . able spring rate depending on vehicle load
CAUTIOIG
Disable air supply pump by disconnecting electrical plug
before performing any repairs. Pump is located beneath a
cover under the spare tire in the floor of
the cargo compart-
ment.
When removing and installing air connections, extreme
cleanliness must be followed. Small dirt particles can
cause leakage in the system.
Remove luggage compartment floor mat.
- Working above air spring, loosen quick coupling screw con-
nection to allow
air pressure to escape.
- Once pressure has been reduced, retighten screw.
Tightening torque Quick coupling screw
to air pump 2 Nm (18 in-lb)
- Remove quick coupler. Plug openings to keep dirt out,
- Remove air spring mounting clips.
- Raise car and remove rear wheels.
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
jaclc stands under
suspension parts.
- 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. Remove air
spring.
NOTE-
Left and right air springs are different. The left air spring is
marked with a red identification
marl. The right air spring is
marked with a blue identification mark.

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[Rear Suspension Swing arm, removing and installing
(sedan models)
CAUTION-
If working on a vehicle with compressed airshock absorbers,
disable air supply pump by disconnecting electrical plug be-
fore performing any repairs.
- 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
sus~ension Darts.
- Disconnect control rod for ride height sensor if applicable.
Remove
ABS pulse sensor (arrow) from wheel bearing car-
rier.
Remove stabilizer bar link mounting nut
(arrow). Press link
out of swing arm.
4 Mark location (arrow) of rear camber adjustment washer and
bolt.
NOTE-
Rear camber is adjusted at the inner swing arm eccentric
rear mounting bolt
- Support wheel bearing carrier from below.

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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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330-22
I Rear Suspension
s
4 If necessary, machine special tool 33 4 191 as shown.
NOTE-
Slotted end of special tool 33 4 191 points toward wheel
bearing carrier.
Press new bushing into wheel bearing carrier using BMW
special tools
33 4 191,33 4 192,33 4 194 and 33 3 333 until
bushing collar is flush with carrier (arrows).
- Install new snap ring
- Reassembly is reverse of disassembly
Use new self-locking nuts.
Tighten fasteners to final torque only after vehicle has
been lowered and suspension has settled.
Tightening torques Integral link to wheel bearing carrier 105
Nm (77
ft-lb)
Quick coupling screw to air shock 2
Nm (18 in-ib)
absorber
Road wheel to hub
120+lO Nm (89c7ft-ib)
Shock absorber to lower control arm 127 Nm (94 ft-lb)
Stabilizer link to swing arm 65
Nm (48
fl-lb)
Swing arm to wheel bearing carrier (C) 256 Nrn (189 ft-lb)
Upper rear control arm, removing and
installing (sedan 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
jaclc stands under
suspension parts.

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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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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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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-