Engine removal BMW 540i 2001 E39 Workshop Manual

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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
Remove rubber cover (A) and bolts (B) from door check lock-
plate on door.
Worlting inside door, remove door check assembly
Installation is reverse of removal.
Lubricate door check before installing.
- If removed, use new mounting bolts when reinstalling side-
impact airbag to door.
Tightening torque
Door
check to door frame 24 Nm (16 it-lb)
Door hinge adjustment
If the installed door is uneven or out of parallel, spacers can
be used to correct its position. Spacers are placed behind the
hinge and are available in two different thicltnesses
(0.5 mm
and 1.0 mm).
- Front and rear door adjustment procedure is similar.
Tightening torque Door hinge to door
frame 20 Nrn (15 ft-lb)

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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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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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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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41 2-2
Trunk Lid, Tailgate
This repair group covers trunk lid and tailgate removal and in-
stallation. Also included here are replacement proceduresfor
the gas-charged support struts that hold the trunk lid or tail-
gate in the open position.
NO JE -
The body is painted at the factory after assembly. Realign-
ment of body panels may expose unpainted metal. Paint all
exposed metal once the
work is complete.
Trunk lid, removing and installing
4 Raise trunlc lid.
Open tool ltit cover and remove screws attaching tool kit to
trunlc lid (black arrows).
Disconnect tool ltit cover retaining strap from
trunk lid and
remove tool kit.
Remove insulating liner expansion rivets (white arrows).
4 Pry out moulded trim cover (arrow).

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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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41 2-8
l~runk Lid, Tailgate Window strut removal
diagram
1. Rear window
2. Rear window gas strut
3. Inner strut support
4. Tailgate gas strut
5. Area to install protective tape
6. BMW special tool 51 2 153
7. BMW special tool 51 2 152

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Trunk Lid, Tailgate
Rear window gas strut, removing and
installing
- Tailgate and window struts are located in left and right sides
of roof.
- Open rear window.
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.
< Remove fasteners (A) from rear window hinge trim cover,
< While pressing detents (A) and (6) pull down (arrow) on trim
panel to remove.
- Close rear window and open tailgate and support.
- Remove weather stripping along rear of roof panel.
< Remove tailgate hinge trim panel fasteners (A).