120 BMW 540i 1997 E39 Repair Manual

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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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--- .-
Rear ~us~ensionl
Remove fasteners A, B and C while supporting swing arm
from below.
Carefully pry swing arm away from mounting points, while
continuing to support from below.
Remainder of installation is reverse of removal, noting the fol-
lowing:
Use new self-locking nuts.
lnstall bolt
(C) through bracket and arm. Install and tighten
nut finger tight.
Install bolts
(A) and (6). Install and tighten nuts finger tight.
Line up eccentric camber adjusting bolt with marlts made
previously.
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
ABS pulse sensor to wheel bearing carrier 8 Nm (6 ft-lb)
Road wheel to hub
120+10 Nm
(89
i-7 ft-lb)
Stabilizer link to swing arm 65
Nm (48 ft-lb)
Swing arm to rear
subframe
(camber bolt M12) (A)
115 Nm (85 ft-lb)
Swing arm to rear
subframe (B) 58 Nm (43 ft-lb)
Swing arm
to wheel bearing carrier (C) 256 Nm (189 ft-lb)

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--. -
Rear Suspension
Remove fasteners A. B and C while supporting swing arm
from below.
Carefully pry swing arm away from mounting points, while
continuing to support from below.
Remainder of installation is reverse of removal, noting the fol-
lowing:
Use new self-locking nuts.
Install bolt
(C) through bracket and arm. Install and tighten
nut finger tight.
lnstall bolts (A) and
(6). Install and tighten nuts finger tight.
Line up eccentric camber adjusting bolt with rnarlts made
previously.
Make sure long lower shock absorber bushing fits in hole
in swing arm.
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
ABS pulse sensor to wheel bearing 8 Nm (6 It-lb)
carrier
Quiclc coupling screw to air shock 2 Nm (18 in-lb)
absorber
Road wheel to hub 120
210 Nm (89i-7 It-ib)
Shocic absorber
to lower control arm 127 Nm (94
ft-lb)
Stabilizer link to swing arm
65 Nm (48 ft-ib)
Swing arm to rear
subframe (camber 11 5 Nm (85 It-lb)
bolt M12) (A)
Swing arm to rear subframe (6) 58 Nm (43 It-lb)
Swing arm to wheel bearing carrier 256
Nm (189 It-lb)
(C)

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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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330-26
/ 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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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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330-30
I Rear Suspension
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.
To install, jack
subframe into position. Install and t~ghten sub-
frame mounting bolts. Note that on each bolt, rubber-coat-
ed detent plate
(arrow) must be installed at rear in driving
direction.
Models
w~th coil springs: Fit springs correctly in lower
spring seats.
Models with air suspension: Fit eccentric lug at bottom of
air
sprlng in recess of wheel carrier spring seat.
Tightening torques
-
Air spring to wheel bearing carrier 20 Nm (1 5 ft-lb)
Rear subframe to body (M12) 163 Nm (120 ft-lb)
-

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Rear Suspension
- Remainder of installation is reverse of removal, noting the fol-
lowing.
Tighten suspension arm and shock absorber fasteners to
final torque only afler vehicle has been lowered and sus-
pension has settled.
Tightening torques
ABS pulse sensor to wheel bearing carrier 8
Nrn (6 ft-lb)
Air line connection 2 Nrn (18 in-lb)
Brake rotor to hub 16
Nrn (12 ft-lb)
Driveshaft
CV joint to final drive flange
- MI0 (Torx bolts) 70
Nrn (51 ft-lb)
- MB (compression nut) 32 Nrn (24 ft-lb)
Rear
brake pad carrier (caliper) to wheel 65
Nrn (48 ft-lb)
bearing carrier
Road wheel to hub
120ilO Nrn
(89 i-7 ft-lb)
Rear subframe mounting bushings,
removing and installing
- Remove rear subframe mounting bolts as described earlier.
Lower
subframe approximately 40 - 45 mm (1 -2 in).
4 Install BMW special tools 33 4 140,33 4 151,33 4 154,33 4
155,33 4 156 as shown.
Use hot air gun with a maximum output temperature of
600°C (1100" F) to heat bushing area of subframe for no
more than
2 minutes. Remove rubber mount from sub-
frame.
CAUTION-
Aluminum suspension parts may be severely damaged
witli intense heat
* Heating for 2 minutes with the recommended heat
source is intended to
keep the temperature of the alu-
minum
parts below the safety threshold of 80°C
(1 76°F). .

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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-