Engine removal BMW 540i 2001 E39 Workshop Manual

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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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Door windows1
Rear 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.
- Disconnect negative (-) cable from battery
- Remove door panel as described in 411 Doors
- Remove airbag unit and vapor barrier from door. See 721
Airbag System (SRS).
- 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.
Loosen fastener (arrow) and slide window regulator up and
out of mount.
Disconnect wiring harness connector (A) and remove fasten-
ers
(6).
Remove window regulator and motor through opening in
door.
- Installation is the 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 Nrn (44 in-ib)
Window regulator to door
Window to guide
8 Nrn (71 in-lb)
8 Nrn (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

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51 3-6
Interior Trim
Remove parking bralte lever side cover fasteners (arrows)
4 Unclip trim boot for parking brake lever and pull boot and
handle forward off brake lever. Remove parking
bralte cover
fastener
(arrow) and remove cover.
4 Remove fasteners at rear of console (arrows).
4 With left and right seats in lowest position, remove side con-
sole fasteners
(arrow).
- Remove left and right side console trim covers. See Lower
- Remove center console.
- Installation is reverse of removal.

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Interior Trim
The E39 dashboard assembly includes the instrument clus-
ter, passenger side
airbag, glove compartment, fuse and re-
lay panel, radio. IHKA control panel oron-board monitor (if
equipped with GPS). The dash is made up of an upper and
lower sections. The lower section must be remove before the
upper section can be removed.
Dashboard removal is a complex operation. Read the proce-
dures through before starting work.
Lower dash panel assembly, removing and
installing
- Disconnect negative (-) cable from battery and cover termi-
nal with
insulating material.
--7
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nectioncautionsgiven atthe irontin001 General Warnings
and Cautions.
- Place steering column in down and extended position.
4 Remove left side foot well panel fasteners (A and B).
< Using a plastic trim tool, gently pry left and right steering col-
umn trim panels (white arrow) to remove and release snap
clip on column boot
(black arrow).
I 1 < Remove instrument cluster trim panel fasteners (arrows).
Pull trim panel out and disconnect harnesses for light
switches.
- Remove radio volume control knob.

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interior Trim
Remove right side lower dash fastener (arrow)
< Remove left side console trim panel fasteners (black arrow)
and slide panel backward (white arrow) to remove.
4 Remove left slde lower dash fastener (arrow)
4 Remove upper dash fastener (arrow).
- Pull bottom of lower dash out to remove
- Installation is reverse of removal, noting the following:
Instrument cluster harness connector
loclting levers must
be in up position before installing connectors.
If replacing instrument cluster with new unit,
recode new
cluster using
BMW scan tool DISplus, MoDiC or equiva-
lent.

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513-12
Interior Trim
< Remove steering column trim panel by releasing clips (ar-
rows).
< Remove left side mounting fasteners (arrows).
Lilt dash panel upwards and remove through passenger
door.
- Installation is the reverse of removal.
Window and door post trim panels,
removing and installing
Windshield post trim (A pillar), removing and Installing
- On 1998 and later cars, disconnect battery negative (-) cable
I
WARNING-
On 1998 and later models, front Head Protection System
(HPS)
airbags are installed in the driver and passenger side
windshieldpost
trim (A-pillar). See 721 Airbag System
(SRS) for warnings and cautions regarding airbags.
< Remove A-p~llar trim panel fastener cap (arrow)

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Interior ~riml
4 Remove fastener (arrow) beneath trim cap.
Working from top carefully pull trim panel away from
A-pil-
lar and pull up to remove.
- Installation is reverse of removal.
If necessary replace defective or broken mounting clips.
Door post trim panel (B-pillar), removing and installing
4 Remove seat belt fastener (arrow) from seat frame.
- Remove front and rear door sill trim panels.
- Pull front and rear rubber door seal away from trim panel.
4 Carefully pull bottom of lower trim panel away from door post
to release clips.
Pull trim lower panel straight down (arrow) to remove.

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51 3-1 4
llnterior Trim
Carefully pry bottom of upper trim panel away from door post
to release clips.
Pull upper trim panel straight down (arrow) to remove.
Installation is reverse of removal.
If necessary replace defective or
broken mounting clips.
Rear window pillartrim (C-pillar), removing and installing
(models without rear
HPS airbags)
1 I
WARNING-
On 1998 and later models, rear Head Protection System
(HPS)
airbags may be installed (optional equipment) in the
driver and passenger side C-pillar area.
The procedure given
below does not cover models with rear HPS airbags. See
721 Airbag System (SRS).
4 Carefully pry interior light out of C-pillar trim panel and dis-
connect wiring harness.
Carefully pry trim panel out at top to release clips,
- Pull trim panel straight up to remove.
- lnstallation is reverse of removal.
If necessary replace defective or broken mounting clips.

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51 3-1 5
I Interior Trim
Dash panel support, removing and
installing
- Remove lower dash panel. See Lower dash panel assem-
bly, removing and installing.
- Remove upper dash panel. See Upper dash assembly, re-
moving and installing.
- Remove upper steering column fasteners. See 320 Steering
and Wheel Alignment.
4 Remove dash support fasteners (arrows).
Remove wire ties as necessary and remove support.
- Installation is reverse of removal.
Rear parcel shelf, removing and installing
(models without rear
HPS airbags)
WARNING-
On 1998 and later models, rear Head Protection System
(HPS)
airbags may be installed (optional equipment). The
procedure given below does not covermodels with rear HPS
airbags. See721
Airbag System (SRS).
- Remove C-pillar trim panels. See Rear window pillar trim
panel (C-pillar), removing and installing.
- Remove rear seat backrest. See 520 Seats.
- Rear parcel shelf removing:
Remove center headrest fasteners.
Remove
seatbelt floor mounting fasteners.
Carefully pry out safety belt trim panels and feed
seatbelt
through slots.
. . . - -. . . . . . . . . Remove expansion rivets and slide pane fonvard to re-
move.
< Remove expanson r:vets (arrows).
Remove vent panels (A).
Remove speafter pane s (B).
Remove center head rest s-pporl fasteners (C).
Slioe parcel shelf forward lo remove.
- lnsta lation s reverse of removal.