Car engin BMW 528i 1997 E39 Workshop Manual

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Fenders, Engine ~ood/
Hood, removing and installing
With hood open:
Remove hood wiring harness mounting clip
(A)
Disconnect electrical harness connector (B).
Unplug windshield washer hose (C).
WARNING-
The hood is heavy Before removing the hoodsupports, be
sure to have an assistant help
support the hood.
Mark position of hinge plates.
With the help of a assistant, support hood and remove retain-
ing clips
(A) on upper end of pressurized lifting struts. Pull
struts off hood.
Loosen upper hinge bolts
(B)
Remove lower hinge bolts (C). Lift hood off carefully.
Installation is reverse of removal.
* Repair any paint damage and paint any exposed metal
Check hood alignment. See
Hood, aligning.
NOTE-
The hood was fitted and attached to an unfinished body at
the factory Unfinished
sun'aces exposed by this procedure
must be touched up with paint,

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Doors
This repair group covers front and rear door repair informa-
tion. It includes removal and installation of front and rear
doors and trim panels.
For information on
airbag removal and installation, see 721
airbag.
For information on the power door windows and door glass
replacement, see
512 Door Windows.
For information on the power door
loclting system, see 515
Central Locking and Anti-Theft.
WARNING-
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures
relatinq to the airbaq system.
Front or rear door, removing and installing
- Disconnect negative (-) battery cable.
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in
001 General Cautions and warn-
ings.
Remove harness connector mounting bolt (arrow) at door
pillar.

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411-3
Doors
4 Pull up on locking clip and remove connector.
4 With door fully open, unscrew pin bolts (arrow) from top and
bottom hinges.
Disconnect door
check by squeezing mounting pin tabs
(arrow) and driving pin up.
Remove door by lifting up off lower hinge halves.
CAUJION-
Be careful not to damage door or otherpainted body surfac-
es.
Make sure no load is placed on wirinq harness.
Installation is reverse of removal. Keep in mind the following:
Mount and align rear doors first, followed by the front
doors.
Align door so that panel gaps are equal on either side, see
specifications at the end of this procedure. If necessary,
adjust door hinges. See Door hinge adjustment.
* Adjust door striker so that trailing edge of front door is
slightly higher
(I mm 10.04 in.) than leading edge of rear
door. See
515 Central Locking and Anti-Theft.
Repair any paint damage and paint any exposed metal.

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Doors
~obr adjustment
Front fender to
4.25 mm i 0.25 mm (0.17 i- 0.01 in)
front door gap
Front
door to 4.5 mm i 0.25 mm (0.18 i 0.01 in)
rear door gap
Rear door to rear fender 4.0 mm i 0.25 mm (0.16 i 0.01 in)
Permissible deviation 1 .O mm (0.04 in)
from
~arallel
Tightening torque
Door hinge to door frame
20 Nm (15 it-lb)
Door check, replacing
WARNING -
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures relating to the
airbag system.
- Close door window completely.
- Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnecting the batter)! read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove interior door panel. See Door trim panels, remov-
ing and installing.
- Where applicable, remove side-impact airbag from door. See
721 Airbag System (SRS). Remove door vapor barrier.
Disconnect door
check by
(arrow) and removing pin. squeezing I mounting
pin tabs

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WARNING -
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures relating to the
airbag system.
Door trim panel, removing and installing
Disconnect negative (-) battery cable.
CAUTION--
Prior to disconnecting the battem read the batfew discon-
nection cautions given in
001 General Cautions and warn-
ings.
Q Open door, and remove screw (arrow) located
in air
duct.
< Pry out seat memory switch and disconnect wiring harness.

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411-8
Doors
< Pry off plastic plug (arrow) from door handle trim and remove
screw.
4 Carefully pry out window switch panel and disconnect elec-
trical harness plugs.
< Slide door handle through trim panel

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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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.-
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.