height BMW 540i 2000 E39 Owner's Guide

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400-4
I Bodv-General
Bumpers
The front and rear bumpers are clad in high quality
deform-
able plastic and, at solid barrier impact speeds of 4 kph (2.5
mph), provide protection with virtually no damage to the
bumper
orthe vehicle. In addition to hydraulic dampeners.
which absorb the initial impact energy, these bumpers are
backed by compressible tubes. These deform in a controlled
manner at impact speeds greaterthan that
forwhich bumpers
and hydraulic dampeners are designed. This helps avoid ex-
pensive damage to the body at impact speeds up to 14 kph (9
mph).
The E39 Sport Wagon was introduced to the US market in
911 998 (model year 1999). It shares many components with
the E39 sedan and is identical to it from the B-pillar forward.
US
marltet 5 Series Sport Wagons are available in two vari-
ants:
6-cylinder
(5251, 528i) powered by the 2.8 liter M52 TU en-
gine (1 999) or the 2.5 liter M54 engine (2000 and later)
* V-8 (540i) powered by the 4.4 liter M62 TU engine
The wheelbase of the Sport Wagon is the same as the sedan.
Howeverthe body is 30
mm (1.2 in) longer and 10 mm (0.4 in)
higher.
The Sport Wagon rear suspension was redesigned to elimi-
nates the upper rear spring strut mounting on the E39 sedan.
The use of separate coil springs and
shoclc absorbers results
in a flat, wide floor in the cargo area. See
300 Suspension,
Steering and Brakes-General.
The self-leveling air spring suspension system (electronic
height control or EHC) is standard on Sport Wagon V-8 mod-
els and optional on 6-cylinder models.
Sport Wagon cargo capacities are shown below.
Sport Wagon load capacities
Cargo capacity
Rear seat up 909 liters (32.1 cu ft)
Rear seat folded down I809 liters (63.9 cu ft)
Load limit
Cargo compartment
460 Kg (1014 lb)
Roof
I00 Kg (220 lb)

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400-5
Body-General
Tailgate
The E39 Sporl Wagon tailgate is large with a low sill for easy
cargo loading. The tailgate opens to an angle of
88" mea-
sured from the rear roof pillar (D-pillar) and to a height of
2029
mm (79.8 in) measured from the ground to the upper edge of
the raised tailgate.
The rear window is bonded to a load bearing frame and can
be opened separately from the main tailgate. Tailgatesupport
gas springs are recessed into cavities in the roof.
Tailgate lock system
A mechanical tailgate lock cylinder is not used; the tailgate is
opened by the unlock pad above the license plate, the remote
tailgate switch located in the drivers kick panel, or via
FZV
(Iteyless entry) control.
4 An emergency release mechanism is incorporated into the
latch assembly to open the hatch from the vehicle interior if a
malfunction occurs.
The tailgate lock assembly includes an automatic soft close
(SCA) feature. The electrical operation of SCA is a function of
central body electronics
(ZKE Ill). The SCA actuator is locat-
ed in the rear cowl panel below the tailgate. The actuator is
controlled by a load relay in the General Module. A locking
cam is mounted on an eccentric that is driven by the actuator.
4 The SCA cam always turns in the same direction to open or
close the tailgate. The cam turns
180" to open or to close.
When the cam turns in the up direction the notch in the cam
SCA actuator pushes on a lever on the back of the latch in the tailgate. This
mechanically unlocks the latch. The tailgate is raised up and
can be opened.

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Body-General
SAFETY AND SECURITY FEATURES
A number of new or improved safety and security features are
incorporated in
E39 cars.
Safety cage
4 The body safety cage is a continuation of an established
BMW concept for passenger protection. Tubular impact
structures built into the body provide protection against pas-
senger injury during front or rear impacts.
Door locks and door handles
4 The door handles allow easy door opening, but are secure in
accidents.
Electrical components in the locks are fully encapsulated and
cannot be picked easily. The door handles, latches and
loclc
assemblies offer reliability and security against theft.
Door position and
loclc condition are detected by hall sensors.
Roof padding
In addition to the side and head protection airbags, there is
supplementary padding at the roof pillars and along the roof
above the doors. This is positioned to present energy absorb-
ing
surlaces to passengers thrown around by side impact
forces.
Seat belts
Each front seat belt assembly has a height-adjustable anchor
at the 8-pillar.
An automatic pyrotechnic (explosive charge) tensioner tight-
ens the front belt at the buckle upon impact, snugging up lap
and shoulder segments of the belt. The tensioners are de-
signed to automatically tension the belts by about
2 inches
(55 mm) in the event ofa collision.
A force limiter puts an upper limit on the amount of iorce each
belt can exert on the passenger.

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400-9
Body-General
Battery safety terminal
(BST)
4 Starting with 1999 models (9198 production and later), a py-
rotechnic (explosive charge) device automatically discon-
nects the battery positive terminal during impacts. Key
features,
like power windows and door locks, remain opera-
tional.
Security
Electronic immobilization (EWS)
Ignition key transponder signal All
E39 vehicles incorporate an electronic immobilization sys-
tem known as EWS. This svstem uses a wireless comrnuni-
cation link between a transponder chip in the ignition key and
the ring antenna surrounding the ignition switch. The EWS
control module blocks the starting of the vehicle unless the
correct coded ignition key is used.
NOTE-
Electronic immobilization is sometimes referred to as the
driveaway protection system.
Antitheft alarm (DWA)
This is adealer-installed option for which the E39 vehicles are
factory-wired. When armed, the system monitors door
loci(
contacts and trunk and engine hood locks and sounds a siren
if it detects tampering.
E39 interiors have a unique character, with a combination
of
sporty features and innovativedesign. All body versions were
made in a wide choice of interior and exterior colors. New col-
ors with matching leather or leatherette upholstery were intro-
duced for each model year.
Driving
comfort is enhanced by power steering, tilt steering
wheel, height-adjustable front seats, and electrically adjust-
able and heated rear-view mirrors. Inside the car there are
reading lights at four seating positions.

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41 0-8
(Fenders, Engine Hood
Hood, aligning
When installing the hood, align the hinges as close to the orig-
inal painted surface as possible. Movement of the hood on its
attaching hardware may require touch-up paint.
The hood should be aligned so that gap
(arrows) to fender is
as even as possible.
4 If height adjustment at rear of hood is off, adjust height using
adjusting screw in lower hinge
(arrow). Loosen and reposi-
tion as necessary.
If height adjustment at
ing adjusting screw: rear
of
hood cannot be completed us-
Q Loosen lower hinge screws (1) and (2).
Add or remove washers as needed to correct height set-
ting.

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Trunk Lid, Tailgate
Rear window and tailgate, alignment
- Alignment procedures involve adjusting tailgate, window, and
spoiler to have equal space between
iefl and right sides and
to be flush with body. Measurement locations and specific di-
mensions are shown.
- If alignment has been disturbed during repair, adjust fit of tail-
gate to body. Then adjust fit of rear window to tailgate.
Clearance of the rear window is adjusted by adding or re-
moving shims between hinge bracket and rear window
(maximum of three shims).
Adjust spoiler gap to body last.
Height of spoiler is set by alignment of the rear tailgate.
Gap of spoiler to body is set by adjusting spoiler attach-
ment fasteners.
- Lateral and vertical alignment of the window and tailgate is
done using hinge bolts. Fine adjustment of the tailgate to the
body is made using rubber stop buffers and latch assembly.
Spoiler gap specification Rear spoiler to roof 4.25
- 5 mm
(0.167 - 0.197 in)
Max. deviation from parallel 0.5
mm (0.019 in)
Tailgate alignment, preliminary work
- Open rear window and tailgate.
< Remove lower sill trim panel fasteners covers (arrows) and
fasteners.
- Remove rear window and tailgate trim panel.
- Checlc left and right side lateral guides and tailgate latch ful-
crums for wear or damage. Replace
if necessary.

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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, ~ail~ate]
< Adjustment D:
a = 4.5 rnrn + ll- 0.5 rnrn (0.18 in + 0.041- 0.02 in)
b = 3.7 rnrn +2 l- 1 rnrn (0.1 5 in + 0.081 - 0.04 in)
4 Adjustment E:
1 tailgate lid
a=1.3rnrnil rnrn(0.05ini0.04in)
2 rear side panel
b = 4.5 rnrn + 11 - 0.5 rnrn (0.1 8 in + 0.041 - 0.02 in)
4 Adjustment F:
a = 1.3 rnrn 21 rnrn (0.05 in 20.04 in)
b = 1 rnrn 20.5 rnrn (0.04 i0.02 in)
* c=1.3rnrn+lrnrn/-1.3rnrn(0.05in+0.04in-0.05in)
d = 4.5 rnrn + 1 rnrn I - 0.5 rnrn (0.18 in + 0.041 - 0.02 in)
CAUTION-
Rear window frame must not extend above height of roof.
Olherwise, wind noise will be created.

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Trunk Lid, Tailgate
4 To periorm contact pattern test, coat lower latch areas A, 6
and C with grease.
Carefully close and reopen tailgate.
Check that upper section of tailgate lock does not scrape
against lower latch.
* Eccentric pin in lower section of tailgate loclc must not
scrape against upper section
(B) of tailgate lock.
The contact pattern (C) of upper section of tailgate lock on
eccentric pin should be centered.
- To adjust height of upper section of tailgate lock, loosen fas-
teners, move upper section of lock and retighten fasteners.
Repeat contact pattern test after height adjustment.
Tailgate lateral guide, adjusting
< If necessary, loosen lateral guide to body fasteners (arrows)
to allow it to move.
Move lateral guides to center position.
< Loosen lateral guide to tailgate fasteners to allow it to move.
- Close tailgate to center guides with respect to each other.
NOTE-
The bracket of the lateral guide continues to touch against
the body without clearance as does the lateral guide against
the tailgate.
- Open tailgate and tighten guide fasteners.

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41 2-21
Trunk Lid, ~ailaatel
Rear window, adjusting
NOTE- Three versions of rear window are used on
Sport Wagon
models.
Tailgate must be correctly adjusted before rear window ad-
justments are made.
- . . . . . .. .. 4 With tailgate closeo ano rear window open, oosen ninge fas-
teners (arrows) to allow ninge to move.
- LoosL'n fasteners n lower section of ock to al ow movement.
- Care& ly c ose rear window:
Ad.~st gap dmensions and poston of rear window relative
to Oody panel. See Tailgate alignment specifications. .
FA-UTION- I
On transition area between rooflailgate, tailgate must not ex-
tend above height of roof
othe~lise wind noise will be creat-
ed.
- If necessary, adjust height of rear window frame by inserting
spacers between the hinge and the frame.
- Carefully open rear window, taking care not to alter adjust-
ment.
Tighten left and right rear window fasteners.
Close rear window and check adjustment, repeat step if
necessary. See Tailgate alignment specifications.
Rear window locking pin, adjusting
NOTE-- Several versions of rear window
locldng pin are used on
Sport Wagon models.
1999 528i model is shown. Other
models are similar.
For rear window adjustment specifications,
seeTailgate
alignment specifications.
Loosen lower assembly fasteners (arrows)