1997 BMW 528i Gas

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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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51 0-6
Exterior Trim, Bumpers
Front bumper assembly
1. Bumper support shock
absorber
2. Bumper support shock absorber seal
3. Bumper mounting bolt
4. Bumper support
5. Bumper to body gasket
6. Bumper cover
7. Grill panel
8. Lower bumper grill
9. Spoiler
10. Towing hinge flap

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l Seats
Seat repair and component replacement is possible once the
seat has been removed from the vehicle.
Before servicing front seats read safety regulations on han-
dling
airbag modules and pyrotechnic seatbelt tensioners.
See
720 Seat belts and 721 Airbag system (SRS).
WARNING-
. The front seats are equipped with pyrotechnic seat belt
tensioners. These tensioners are powerful devices and
should be handled with exfreme care. Incorrect handling
can trigger off the tensioner and cause injury.
BMW recommends that all repair or replacement
worlc
on pyrotechnic devices must be carried out by a quali-
fied
BMW technician.
Be sure to disconnect the battery and wait
5 seconds
before attempting to work on pyrotechnic devices.
During body straightening and welding with an electric
arc welder, always disconnect the battery and the con-
nection to the pyrotechnic gas generators.
Seat switch and memory module, removing
and installing
- Remove front seat. See Front seats, removing and install-
ing.
- Carefully pull seat adjusting ltnobs straight out to remove.
Remove screw fastener
(A) and trim clips (B), turn side panel
downward to remove.
Disconnect electrical harness connector
(arrow).

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540 Sunroof
General . . . . . . . . . . . . . . . . . . . . . . . . . . . ,540-2
Sunroof Adjustments. . . . . . . . . . . . . . . .540-2
Sunroof electronic controls, initializing . . . . ,540-2
Sunroof, normalization. . . . . . . . . . . . . . . . . ,540-3
Sunroof, characteristic curve . . . . . . . . . . . .540-3
Sunroof panel, emergency closing . . . . . . . ,540-4
Sunroof, adiustino . . . . . . . . . . . . . . . . . . . . ,540-5
~unroofwitil steel roof panel, adjusting . . . ,540-5
Sunroof with glass roof panel, adjusting . . . ,540-7
Sunroof Components . . . . . . . . . . . . . . 540-8
Sunroof components (glass)
. . . . . . . . . . . . 540-8
Sunroof panel, removing and
installing (steel or glass)
. . . . . . . . . . . . . . . 540-8
Sunroof panel gasket, replacing
(steel or glass)
. . . . . . . . . . . . . . . . . . . . . . . 540-9
Sunroof motor, replacing
. . . . . . . . . . . . . . 540-10

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1 Sunroof
Sunroof assembly removal and installation involves headliner
removal, and is not covered in this manual. After sunroof re-
pairs, be sure to follow initialization and adjustment proce-
dures given earlier.
I Sunroof comDonents
1. Left rubber boot suppori
2. Left upper control rail
3. Left side water channel repair ltit
4. Left lower control rail
5. Left cover
6. Left side slider
7. Cross member
8. Sunroof frame
9. Trim panel
10. Gasket
11. Glass roof cover
m5sm.7 - -.
Sunroof panel, removing and installing
(steel or glass)
4 To remove sunroof panel, open sunroof and remove wind
blocker
by removing Tom screw (arrow) on each side.

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Sunroof
4 Remove three Torx screws (arrows) on each side, and lift
panel out.
- Installation is reverse of removal. Adjust sunroof height and
gap as described earlier. See Sunroof, adjusting.
Tightening torques
Wind blocker to roof (Torx)
1 Nm (9 in-lb)
Sunroof panel to roof (Torx)
6 Nm (4.4 ft-lb)
Sunroof panel gasket, replacing
(steel
or glass)
- Remove sunroof panei. See Sunroof panei, removing and
installing (steel or glass).
Pull old seal from panel.
Coat new seal and channel in sunroof panel with soapy
water.
* Starting at back center of panel, install new seal, taking
care to not pull seal too tightly around four corners of
panel.
- Installation is reverse of removal. Adjust sunroof height and
gap as shown earlier in this repair group. See Sunroof, ad-
justing.
Tightening torques
Wind
bloclter to roof (Torx)
Sunroof panel to roof (Torx) 1 Nm (9 in-lb)
6 Nrn (4.4 ft-lb)

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- -
Seat Belts
Front seat belt tensioner, removing and
installing
- Disconnect battery negative (-) cable in trunk.
The
front seat belt loclts are equipped with pyrotechnic (ex-
plosive charge) automatic tensioners. These tensioners are
designed to automatically retract and tension the seat belt by
55 mm (approximately 2 inches) in the event of an accident.
CAUTION-
Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Warnings and Cau-
tions.
WARNING-
Pyrotechnic seat belt tensioners are powerful devices and
should be handled with extreme care. Incorrect handling
can trigger the tensioner and cause injury
BMW recommends that all repair or replacement work
on pyrotechnic devices must be carried out by a quali-
fied BMW technician.
Be sure to disconnect the battery and wait
5 seconds
before attempting to work on pyrotechnic devices.
Pyrotechnic devices cannot be repaired. Always re-
place them.
Never treat pyrotechnic components with cleaning
agents or grease.
- Do not expose pyrotechnic components to tempera-
tures above
75% (167°F).
Pyrotechnic components can only be tested electrically
when installedusing the
BMWService Tester (DISplus,
GTI, or MoDiC).
Do not fire a pyrotechnic gas generatorprior to dispos-
al. It must be fired by a special disposal company or
shipped
back to BMW in the packaging of the new com-
ponent.
During body straightening and welding with an electric
arc welder, always disconnect the battery and the con-
nection to the pyrotechnic gas generators.
- Remove front seat as described in 520 Seats.
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