1997 BMW 540i Wiring

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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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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
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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Exterior Trim. ~um~ers/
Front bumper, removing and installing
< Working underneath car:
Remove expansion rivets
(arrows) from lefl and right side
trim panels.
Remove bumper trim panels.
4 Remove driving light mounting fasteners (arrows) and dis-
connect wiring connectors.
4 Worlting at front of wheel wells
panel fasteners
(arrows).
remove left and right inner

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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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513-3
Interior ~rirnl
The console between the two front seats starts behind the shifler housing. It houses the parking brake handle, optional
telephone and oddments storage tray. The rear portion of the
console houses the ashtray and covers the emergency brake
cable ends.
NOTE-
The accompanying photos illustrate a model with automatic
transmission. Manual transmission models are similar.
Center console, removing and installing
4 Remove shift knob by pulling straight up (arrow).
Gently pry shift bezel
harness (arrow). up
out of console and disconnect wiring
Models equipped with automatic transmission remove neu-
tral safety switch fasteners (arrows) and remove bezel with
switch.