electrical BMW 528i 2000 E39 Workshop Manual

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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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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.

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Trunk Lid, ~ail~atel
4 Loosen lower tailgate lock fasteners (arrows) so that tailgate
lock can center itself.
CAUTION-
The lower section of tailgate lock must not scrape against
the upper section.
The eccentric pin on the lower section of the tailgate
loclc rotates
when being locked from upper section of
tailgate lock.
- Disconnect tailgate latch actuator motor by squeeze locking
tabs on electrical harness connector and disconnecting.
CAUTION-
Eccentric pin in lower section of trunk lid lock must be at
lower dead center.
After disconnecting plug connector from actuator mo-
tor, tailgate is opened by electric
unloclcing fixture of up-
per section of tailgate loclc.
. For this reason, the cable connections to the upper
section of the tailgate loclc must remain connected.
Othe~tise the tailgate can only be opened by the emer-
gency handle. Eccentric pin of lower section of tailgate
loclc remains at bottom dead center point after unlock-
ing.
Tailgate alignment, height adjustment
4 Loosen left and right tailgate hinge fasteners (arrows) to al-
low tailgate to be adjusted.
CAUTION-
. When the hinge screws for the tailgate are released, the
position of the overall assembly changes with respect to
the body.
The position of the rear window frame to the tailgate re-
mains unchanged.
- Close tailgate carefully and check gap dimensions. See Tail-
gate alignment specifications below.
- Tighten hinge screws when gap dimensions are correct.

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Trunk Lid, Tailgate
4 Tighten left and right tailgate bracket iasteners (arrows)
4 Tighten upper left and right tailgate fasteners (arrows).
- Open tailgate while taking care not to change hinge posi-
tions.
4 Tighten lower tailgate hinge fasteners (arrows)
- Reconnect eccentric pin actuator motor electrical harness
Plug.
CAUTION-
The eccentric pin in the lowersection of the tailgate loclc turns
in the tailgate when the button is pressed.
- Operate button in tailgate to actuate loclting motor. Eccentric
pin should move to top dead center position.

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51 0-4
I Exterior Trim. Bumpers
4 Carefully remove mirror housing from frame
- Installation is reverse of removal.
NOTE-
Check mirror function before installing covering parts
Outside mirror assembly, removing and
installing
- Remove front door panel trim. See 41 1 Doors
4 Carefully lift inner trim panel up to remove from retaining clip
(arrow).
Disconnect electrical harness connectors for window anti-
trapping protection (B) and speaker (A), if equipped.

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Exterior Trim, ~umpersl
4 While supporting mirror, remove top mounting fastener
(arrow).
Lifi mirror up to remove from door, feed mirror electrical
harness through opening to remove.
- Installation is reverse of removal.
NOTE-
Checlt mirror function before installing covering parts.
Tightening torque
Outside mirror to door (M6) 6 Nm (4.5 It-lb)
BUMPERS
- Raise and properly support vehicle.
WARNING-
Male sure that the car is firmly supported on jacltstands de-
signed
forthe purpose. Place the jacltstands understructural
cliassis points. Do not place
jack stands under suspension
oarfs.

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Door Windows
Window anti-trap strip, testing
- To test function of anti-trap strip on any window:
With key
ON and window down, pull up window switch to
second detent, thus activating one-touch close operation.
Insert wooden block or other soft object between glass
and upper door frame.
Window should contact block, then immediately reverse
direction and lower by approximately
25 mm (1 in).
NOTE-
Anti-trap strip is integrated into the molding strip of the door
window frame.
Front window anti-trap strip, removing
- Remove front door panel and vapor barrier as described in
411 Doors.
< Remove window frame mold~ng strlp and peel toward inside
7 of vehrcle.
Separate anti-trap electrical harness connector
top front of door.
NOTE-
Wire color for anti-trap strip is dark gray.
(arrow) at

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Door Windows
molding and
anti-trap strip
4 If replacing molding with new one, transfer mounting clips
and foam insulation as necessary.
1. Window frame molding
2. Clip
3. Door corner speaker cover
4. Foam insulation
- After installation, recheck anti-trap protection.
Rear window anti-trap strip, removing
- Remove rear door panel and vapor barrier as described in
411 Doors.
4 Remove window frame molding strip, peeling it off fixed win-
dow partition
(arrows). Do not tear strip in area (A).
Disconnect electrical harness connector (arrow).
After installation, recheck anti-trap protection.

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512-12
I Door Windows
- Disconnect window from window guide rail as described in
Door window, removing
and installing. Do not remove
window from door.
* Push window up and use wedge to hold in position.
- If necessary, remove speaker unit from door.
- Removing window regulator from door:
Disconnect window motor electrical harness connector.
4 Remove lower window regulator fasteners (arrows).
Remove window regulator fasteners (arrows)
Loosen fasteners (arrows) and slide regulator up to remove
from mounts.
- Remove window regulatorthrough opening in bottom of door,
checking for any wiring that might become snagged during
removal.
- Installation is reverse of removal.
Be sure to route wiring harnesses to keep them away from
moving window mechanism. Use new wire ties as neces-
sary.
-
Tightening torques -
Window motor to regulator 5 Nm (44 in-lb)
502512211
Window regulator to door 8 Nm (71 in-lb)
Adjust window
as described earlier.
- -
W~ndow to guide 8 Nm (71 in-lb)
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I lnterior Trim
This repair group covers interior trim removal and installation
procedures.
- Refer to the following repair groups for additional information:
250 Gearshift Linkage
41 1 Doors (interior door panels)
@ 612 Switches
620 Instruments
640 Heating and Air Conditioning [IHKA control panel!
650 Radio
721 Airbag System (SRS)
lnterior trim repairs
lnterior trim and finish panels are clipped or screwed into
place. Many of the trim retaining clips are designed
to be used
only once. When removing trim that is held in place with clips,
it is a good idea to have spare clips on hand before beginning
the job.
WARNING-
Special precautions must be observed when servicing the
BMWSupplementai Restraint System (SRS). Serious inju-
ry may result if system service is attempted by persons un-
familiar with the BMW
SRS and its approved service
procedures. BMW
speciiies that all inspection and service
should be performed by an authorized BMW
dealer.
Before performing any work involving airbags, discon-
nect the negative
() battery cable. See 721 Airbag
System (SRS).
Airbags contain a back-uppowersupply within the SRS
control module. A
5 second discharge period should be
allowed after the battery cable has been disconnected.
CAUTION-
* When working on electrical switclies or lights, always dis-
connect the negative
(-) cable from the battery and insu-
late the cable end to prevent accidental reconnection.
a Prior to disconnecting the battery, read the battery dis-
connection cautions given in
W1 General Warnings
and Cautions.
To prevent marring the trim when working on interior
components, work with plastic prying
tools or wrap the
tips of screwdrivers and pliers with tape before prying