1997 BMW 540i engine removal

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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).

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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.