Ele BMW 540i 1997 E39 Workshop Manual

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I
< Unclip door panel from door perimeter using a plastic trim
panel tool. Pry panel retaining clips off one at a time.
- Lift bottom of door trim panel up and away from window trim
to release clips.
- Pull door panel upwards to release center mount clip.
- Disconnect radio speaker wiring harness.
- Remove door trim panel.
< Before installing door trim panel, replace any damaged plas-
tic clips (arrows).
NOTE-
Yellow door trim clips (white arrows) at front are longer than
white door trim clips (blaclc arrows).
4 Checlt if support clip for door bracltet remains on door (ar-
row).
4 If so, remove support clip from door and replace in bracltet on
door trim panel (arrow).
- Remainder of installation is reverse of removal. Note the fol-
lowing:
Align metal retainers on window sill with openings on top
of door panel.
Checlc door-lock mechanism and window for ease of
movement.

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41 2 Trunk Lid. Tailgate
........................... General
......................... Trunk Lid
Trunlc lid. removing and installing ........
Trunk lid. adjusting ...................
Trunk lid support strut.
removing and installing
................
Tailgate (Sport Wagon Models) .....
Tailgate. emergency release ...........
Tailgate and window strut diagram .......
Window strut removal diagram .......... 412-8
Rear window gas strut.
removing and installing
................ 412-9
Tailgate gas strut. removing and installing
............... 412-10
Tailgate. removing and installing
........ 412-1 1
Rear window. removing and installing
.... 412-12
Rear window and tailgate. alignment
..... 412-13

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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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. .- -
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.

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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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Exterior Trim, Bumpers
This repair group includes repair information for the outside
rearview mirrors, front and rear bumpers, and the easily re-
movable exterior trim parts.
Many of the mirror components are separately available from
an authorized
BMW dealer, including the glass and outside .
plastic housing.
The
E39 models offered two types of outside mirrors, stan-
dard mirrors or automatic dip mirrors.
Outside mirror glass, replacing
CAUTIOI\C
Mirrorshould be at or above room temperature before remov-
al.
Othe~lise, small plastic parfs or glass may break.
Outside mirror glass without automatic dip control,
replacing
Insert thin pry tool (plastic or tape-wrapped screwdriver) be-
tween bottom mirror edge and mirror housing and carefully
pry out mirror glass from housing.
If equipped with heated mirrors: remove heating element
har.
ness connectors from back of mirror glass.
Installation: Connect mirror heating harness if equipped.
Ensure correct alignment of locking pins.
Press mirror glass firmly until it
locks in place.