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Installion of front & rear shocks/springs..Details (archive)

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Posted by ITSDAVID on August 20, 2001 at 21:26:44:

How this is NOT a job for the timid! 2000 540I Sport

Rears: Start on the inside of car before you get REAL dirty.

1. Remove lower seat cushion. Pull straight up.
2. Remove all head rest. Pull straight up..with force.
2. Remove upper seat cushion. 2 screws on each side. 10mm
4. Remove center head rest bracket. 4 screws 4mm hex wrench.
5. Remove rear deck side panel lights. Start at the top and pull down, how remove panel. Place your hand in the light hole and pull, there are 2 clips that will disengage,
slide panel toward front of car.
6. Remove rear deck panel. This is held on by 4 black
expanding fasteners. Pull on center pin and remove, then remove fastener. Slide rear deck panel out,this may take a little force.
7. Remove speaker boxes. 2 screws phillips head.

Low and beholded we are close to that upper shock nut!

8. Lift the insulation material, you will find a black
rubber cover. Remove and here is the nut. 18mm
(DO NOT REMOVE AT THIS TIME!!!!!!!!!!!)

How we are ready to start on the outside!!

9. Place rear of car on jack stands. Remove rear wheels.
10. Remove rear sway bar. 13mm & 16mm socket & wrench.
( This will make it easy.)
11. Remove inter wheel liner. 3 8mm screws & 3 expanding
fasteners.( Now you are going to get dirty.)
12. Compress spring. This will require a spring compression tool. Can be rented at most auto part stores.
13. Remove lower shock bolt. 18mm
14. Remove upper shock nut.....Remember that nut???
15. Push on lower end of shock and remove from spindle. Here comes the challenge....Hope you compressed the spring enough. Push down on the lower a-arm and jockey the shock & spring out of the car.
If you are brave and smart enough to do this, Installion of the NEW shock and spring is now up to you. (reverse order)

Front:

1. Place front of car on jack strands.
2. Remove wheels.
3. Unbolt lower A-Arm near motor. ( Not the trailing A-Arm)
18 & 16 mm
4. Remove lower sway bar bolt.
5. Remove lower shock bolt. 18 & 16mm (1 bolt) It is a pinch collar design. Spray WD40 around shock and alum bracket.
6. Place 2x4's under rotor. Remove 3 nuts at upper shock
mount. 13mm. Assembly will now rest on 2x4;s.Remove black rubber dust cover. (DO NOT REMOVE NUT AT THIS TIME)
7. Remove 2x4's while holding shock assembly. Rotor will
fall to the ground,( be carefull not to put to must
tension on brake line) twist shock assembly out of the
lower pinch scocket.

WOW!!!! We are almost home!!!!

8. Remove 18mm nut from shock assembly with an impac gun.
( be careful of spring compression!!!!! )
9. Compress new spring (spring compression tool) and install new spring, bump stop and hat assembly unto new shock. Orient lower spring base per shock instructions.
10. Reverse order time.

Hope I didn't leave anything out. It was an all day job for me so be perpared. You can email me if you have questions.

I installed Koni adjustable shocks in the front and Koni in the rear. H & R springs all 4 corners. Thanks To BRAD my 540 is now the way it should be.





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