engine BMW 525i 1998 E39 Workshop Manual

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Trunk Lid, Tailgate
4 Pry out trunk light and disconnect electrical harness plug
connector.
- Gently pry trunk liner away from lid and remove.
4 Disconnect Wiring connectors A, B and C. Remove wiring
harness by pulling through opening in lid frame
D.
While supporting trunk lid, loosen left and right top hinge fas-
teners (arrow
A) and remove lower fasteners (arrow B).
NOTE-
Before loosening hinge bolts, mark hinge and hinge bolt lo-
cations for
reins~alla~on
Lift trunk lid straight up to remove.
Installation is reverse of removal. If necessary, align trunk lid
to body as described in
Trunk lid, adjusting.

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/~runk Lid, Tailgate
Trunk lid, adjusting
< Trunk lid must be parallel to both side panels and should be
mounted flush with body side panels
(arrows). Lid fit toler-
ance is
rt 1 mm (0.04 in).
- Raise trunlc lid and support in open position.
Turn trunk lid detent buffers in
4 Remove trunlc strut retaining clip (arrow) and disconnect
struts.
WARNING-
Make sure to suppori trunk lid before removing struts.

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Trunk Lid, ~ail~atel
Loosen bolts at lefl and right trunk
to point where lid can be moved. hinges
fasteners (arrows)
4 Remove plastic cover from lower trunlc lock. Loosen lock
bolts (arrows) until lock assembly can be moved.
CAUTION-
Before locking trunklid, check that trunk lid is not able to dam-
age the body or rear window.
4 Carefully close trunk lid and check side gaps (arrows). Min-
imum gap is 0.5 mm (0.02 in).
Adjust to fit side body panels.
Open trunlc lid.
Be careful not to alter adjustments.
Tighten lower trunlc lock fasteners.
Close trunk lid and check adjustments.
Repeat process if necessary.
- Close trunk lid. Measure gap between trunlc lid and lower
body panel.
Position lower section of rear trunlc lid
lock higher or lower
so that a
ciao of 5.0 mm (0.04 in) exists between trunlc lid
and
lowe;body panel. '
Check adjustment and repeat if necessary,
4 Screw out detent buffers (arrow) until left and right sides of
trunk lid rest against detent buffers with lid closed.

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. .- -
l~runk Lid, Tailgate
Trunk lid support strut, removing and
installing
/ Make sure to supporf trunk lid before removing struts. I
Open trunk lid and support in open position.
Remove trunk strut retaining clip
(arrow) and disconnect
struts.
4 Remove spring clip (arrow) from lower end of strut and re-
move strut.
- Installation is reverse of removal. Replace retaining clips
damaged during removal.
Tailgate, emergency release
The tailgate of the E39 Sport Wagon has no ltey cylinder. An
emergency release mechanism is incorporated into the tail-
gate latch. This allows mechanical opening of the latch in
case of an electrical failure. The release is located in the rear
cargo area, along the lower edge of the rear apron behind a
small access cover.
Working inside car, at base of tailgate:
Open tool compartment cover.
Pry out emergency release cable cover.
Pull plastic cable to release rear tailgate latch

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r Trunk Lid, Tailgate
Tailgate and window strut
diagram
1. Rear window frame
2. Gas struts for tailgate
3. Gas struts for rear window
4. Rear window frame

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41 2-8
l~runk Lid, Tailgate Window strut removal
diagram
1. Rear window
2. Rear window gas strut
3. Inner strut support
4. Tailgate gas strut
5. Area to install protective tape
6. BMW special tool 51 2 153
7. BMW special tool 51 2 152

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. .- -
Trunk Lid, Tailgate
Rear window gas strut, removing and
installing
- Tailgate and window struts are located in left and right sides
of roof.
- Open rear window.
WARNING-
The tailgate is very heavy and will close without both pressu-
rized lifting struts installed. Properly support tailgate prior to
removal of the lifting struts.
< Remove fasteners (A) from rear window hinge trim cover,
< While pressing detents (A) and (6) pull down (arrow) on trim
panel to remove.
- Close rear window and open tailgate and support.
- Remove weather stripping along rear of roof panel.
< Remove tailgate hinge trim panel fasteners (A).

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.-
l~runk Lid, Tailgate
Starting at top, pull down (arrow) on trim cover. Carefully re-
move wiring harness support clip from trim cover.
NOTE-
Tailgate window trim cover and weather stripping shown in
place.
Insert BMW special tool 51 2
153 into body cavity below
hinge.
WARNING-
Tlie tailgate is ve!y heavy and will close without both pressu-
rized liftinq struts installed. Properly support
tailgafe prior to r
1 removal of the lifting struts.
- Working at hinge end of strut, remove strut retaining clip and
remove strut from mounting pin.
Slide BMW special tool 51 2 152 over strut until end of tool is
aligned with strut pin
(arrow).
Press down on outer end of special tool to release inner
strut mount.
Remove special tool with strut.
When installing strut make sure ball cup is pointing straight
down.
Rema~nder of installation 1s reverse of removal.
Tailgate gas strut, removing and installing
- Open tailgate and support.
Remove tailgate hinge trim panel fasteners
(A).

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Trunk Lid, Tailgate
Starting at top, pull down (arrow) on trim cover. Carefully re-
move wiring harness support clip from trim cover.
Install protective plate
(BMW special tool 51 2 153) between
roof panel and hinges.
WARNING -
The tailgate is very heavy and will close without both pressu-
rized lifting
struts installed. Properly support tailgate prior to
removal of the lifting struts.
Worlting at left side:
Remove gas strut retaining clip and pin (arrow).
4 Insert BMW special tool 51 2 151 over strut.
NOTE-
BMW special tool 51 2 151 must be chamfered in area (A).
Press tool down to release inner end of gas strut.
Push strut forward and toward center of vehicle to remove.
- When installing strut make sure ball cup is pointing straight
down.
- Remainder of installation is reverse of removal.
Tailgate, removing and installing
- Remove radio antenna amplifier. See 650 Radio.
- Disconnect outer end of window and tailgate gas struts. See
Rear window gas strut, removing and installing and Tail-
gate gas strut, removing and installing.
WARNING-
The tailgate is very heaq and will close without both pressu-
rized lifling struts installed. Properly support tailgate prior to
removal of the lifling struts.
- Remove trim panel from tailgate.

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Trunk Lid, Tailgate I
4 Remove rubber grommet and applicable connectors. Discon-
nect rear window washer hose.
NOTE-
To facilitate installation, mark position of hinges for tailgate
and rear window frame on body
WARNING-
The tailgate is very heavy and will close without both pres-
surized lifting struts installed. Properly support tailgate pri-
or to removal of the lifting struts.
There is risk of fingers being trapped once tailgate fas-
teners are removed.
CAUTION-
Protect body opening for tailgate with fabric tape.
4 Remove hinge fasteners for tailgate and rear window frame.
Lower tailgate so that hinge for tailgate and rear window
can be tilted.
- Tilt hinge for tailgate and rear window frame so that tailgate
can be moved towards the rear with rear window frame.
- Remove tailgate with rear window frame towards rear.
- Installation is the reverse of removal
Rear window, removing and installing
- Disconnect electrical harnesses.
- Support window in open position.
Loosen fasteners on each window hinge.
NOTE-
Note positions of any spacers for reinstallation
CAUTION-
Rear window is heavy Use a second person to support win-
dow prior to releasing from hinges.
- Remove window hinge fasteners and lift off window.
- Installation is reverse of removal. Replace waterprooiing
sheeting where disturbed.
See Rear window and tailgate, alignment.