411 doors BMW 540i 1997 E39 Workshop Manual

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YOU are now in Volume I
I
Foreword ................... .. ........................................................................\
.......... v
Index
........................ .. ................................................................ rear of manual
General, 001 General Warnings and Cautions 002 Vehicle Identification and VIN Decoder
Maintenance OiO 020 Maintenance
Engine
100 Engine-General 110 Engine Removal and Installation
113 Cylinder Head Removal and
Installation
116 Cyiinder Head and Valvetrain 117 Camshaft Timing Chain
119 Lubrication System
200 Transmission-General
2 Transmission 210 clutch 230 ManualTransmission
I20 Ignition System
121 Battery, Starter, Alternator
130 Fuel Injection
160 Fuel Tank and Fuel Pump 170 Radiator and Cooling System
180 Exhaust System
240 Automatic Transmission
250 Gearshift Linkage 260 Driveshaft
Suspension, 300 Suspension, Steering and 330 Rear Suspension
Brakes-General 331 Final Drive
Steering and No Front Suspension 340 Brakes
320 Steering and Wheel Alignment
400 Body-General
410 Fenders, Engine Hood 411 Doors
412 Trunk Lid, Tailgate
510 Exterior Trim, Bumpers 512 Door Windows
Equipment 513 Interior Trim
7
Equipment and 720 seat Belts
Accessories 721 Airbag System (SRS)
OBD On-Board Diagnostics
. ............ ..
515 Central Lociting and
Anti-Theft
520 Seats 540 Sunroof
.................................................................... Foreword .............................. .. v
Index ................... .. ................................................................ rear of manual
Electrical
6 system
600 Electrical System-General 620 Instruments
610 Electrical Comoonent Locations 630 Liohts
611 wipers and washers 612 Switches eati in^ and Air Conditioning
Radio
. ........... ........ .........................
Electrical Wiring Diagrams

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General ........................... .41 1.2 Door hinge adjustment ................ 41 1-5
Door hinge assembly
.................. 41 1-6 Doors ............................. 411-2
Front or rear door. removing
Door Panels ....................... 41 1-7
and installing ....................... .41 1.2 Door trim panel. removing and installing ... 41 1-7
Door check. replacing
................. .41 1.4 Sill trim panels ...................... 41 1-1 0

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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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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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411-10
/Doors
Sill trim panels
Using a trim tool, gently pry up door sill trim. Starting at A-pil-
lar, press radius of trim downwards while sliding trim forward
off trim clips. Remove clips from body using pliers. Save for
installation.
Installation is reverse of removal. Replace any damaged
plastic parts or clips.

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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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51 2-8
Door Windows
Door window, adjusting
Whenever the door window or window regulator is removed,
window adjustment should be checked. The glass should
contact the top of the window squarely and should seat
against the window seal uniformly.
NOTE-
If the window does not contact the window seal uniformly,
wind noise or water infiltration may result.
- Remove door panel as described in 411 Doors.
- Disconnect negative (-) cable from battery. Remove airbag
unit and vapor barrier from door. See 721 Airbag System
(SRS).
WARNING-
Prior to disconnecting the batteg read the battery discon-
nection cautions given in
001 General Warnings and
Cautions.
Longitudinal adjustment
- Adjustments are made with window in open position.
Loosen window guide rail mounting nuts (arrows), but do not
remove.
Slide window glass in longitudinal direction to adjust
Tighten guide rail nuts.
Tightening torque
Window regulator guide rail to door
10 Nrn (89 in-ib)

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512-9
Door Windows
Vertical adjustment
- Adjustments are made with window in open position
4 Loosen window clamping fasteners (arrows), but do not
remove.
Adjust rear clamp and tighten fastener.
Tighten front clamp fastener.
4 Raise door window up to stop:
Check gap (A) at window front edge,
Checlc gap (5) at window top edge.
NOJE-
Measure window frame between door window edge and
panel.
Front window gap settings
Front of window
(A) 5.4 mm (0.21 in)
Top of window
(6) 10 mm (0.39 in)
Tightening torque Window regulator guide
rail to door 10 Nm (89 in-lb)
Door window, removing and installing
- Remove door panel as described in 411 Doors
- Reconnect window switch and lower window down to conve-
nient height and disconnect window switch.
- Disconnect negative (-) cable from battery, then remove air-
bag unit and vapor barrier from door. See 721 Airbag Sys-
tem (SRS).
WARNING -
Prior to disconnecting the battery, read the battery discon-
nection cautions given
in 001 General Warnings and
Cautions.

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Door Windows
Tilt window glass carefully inside door cavity and lift out of
door.
Installation is reverse of removal.
Replace plastic window retainers once glass is inside door.
Use new mounting bolts when reinstalling side-impact
air-
bag to door.
Adjust window as described earlier,
Sedan and Sport Wagon doors are similar. There are two win-
dow rails in each front window regulator, only one in the rear.
Otherwise the front and rear regulators are similar.
WARNING-
E39 cars are Wed with side-impact airbags in the front
doors. Some are equipped with
airbags in the rear doors
as well. When servicing the door windows on cars with
side-impact airbags, always disconnect the negative
(-)
battery cable. See 721 Airbag System (SRS) for cau-
tions and procedures relating to the
airbag system.
Prior to disconnecting the battery, read the battery dis-
connection cautions given at the front
001 General
Warnings and Cautions.
NOTE-
Because window operation is electronically controlled, a win-
dow motor does not have mechanical endpositions. For this
reason it can be removed and installed with the window in
any position and does not need reinitialization.
Front window regulator removing and
installing
NOTE-
BMW recommends removing the window regulator and mo-
tor as one unit, then separating the two on the bench.
- Remove front door panel as described in 411 Doors.
- Disconnect negative (-) cable from battery, then remove air-
bag unit and vapor barrier from door. See 721 Airbag Sys-
tem (SRS).