1998 BMW 540i locking

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Doors
This repair group covers front and rear door repair informa-
tion. It includes removal and installation of front and rear
doors and trim panels.
For information on
airbag removal and installation, see 721
airbag.
For information on the power door windows and door glass
replacement, see
512 Door Windows.
For information on the power door
loclting system, see 515
Central Locking and Anti-Theft.
WARNING-
E39 cars are fitted with side-impact airbags in the front doors
and optional side impact
airbags in the rear doors. When
servicing doors, always disconnect the negative
(-) battery
terminal. See
721 Airbag System (SRS) for cautions and
procedures
relatinq to the airbaq system.
Front or rear door, removing and installing
- Disconnect negative (-) battery cable.
Prior to disconnecting the battery, read the battery discon-
nection cautionsgiven in
001 General Cautions and warn-
ings.
Remove harness connector mounting bolt (arrow) at door
pillar.

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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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Trunk Lid, ~ail~atel
Loosen bolts at lefl and right trunk
to point where lid can be moved. hinges
fasteners (arrows)
4 Remove plastic cover from lower trunlc lock. Loosen lock
bolts (arrows) until lock assembly can be moved.
CAUTION-
Before locking trunklid, check that trunk lid is not able to dam-
age the body or rear window.
4 Carefully close trunk lid and check side gaps (arrows). Min-
imum gap is 0.5 mm (0.02 in).
Adjust to fit side body panels.
Open trunlc lid.
Be careful not to alter adjustments.
Tighten lower trunlc lock fasteners.
Close trunk lid and check adjustments.
Repeat process if necessary.
- Close trunk lid. Measure gap between trunlc lid and lower
body panel.
Position lower section of rear trunlc lid
lock higher or lower
so that a
ciao of 5.0 mm (0.04 in) exists between trunlc lid
and
lowe;body panel. '
Check adjustment and repeat if necessary,
4 Screw out detent buffers (arrow) until left and right sides of
trunk lid rest against detent buffers with lid closed.

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Trunk Lid, ~ail~atel
4 Loosen lower tailgate lock fasteners (arrows) so that tailgate
lock can center itself.
CAUTION-
The lower section of tailgate lock must not scrape against
the upper section.
The eccentric pin on the lower section of the tailgate
loclc rotates
when being locked from upper section of
tailgate lock.
- Disconnect tailgate latch actuator motor by squeeze locking
tabs on electrical harness connector and disconnecting.
CAUTION-
Eccentric pin in lower section of trunk lid lock must be at
lower dead center.
After disconnecting plug connector from actuator mo-
tor, tailgate is opened by electric
unloclcing fixture of up-
per section of tailgate loclc.
. For this reason, the cable connections to the upper
section of the tailgate loclc must remain connected.
Othe~tise the tailgate can only be opened by the emer-
gency handle. Eccentric pin of lower section of tailgate
loclc remains at bottom dead center point after unlock-
ing.
Tailgate alignment, height adjustment
4 Loosen left and right tailgate hinge fasteners (arrows) to al-
low tailgate to be adjusted.
CAUTION-
. When the hinge screws for the tailgate are released, the
position of the overall assembly changes with respect to
the body.
The position of the rear window frame to the tailgate re-
mains unchanged.
- Close tailgate carefully and check gap dimensions. See Tail-
gate alignment specifications below.
- Tighten hinge screws when gap dimensions are correct.

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41 2-21
Trunk Lid, ~ailaatel
Rear window, adjusting
NOTE- Three versions of rear window are used on
Sport Wagon
models.
Tailgate must be correctly adjusted before rear window ad-
justments are made.
- . . . . . .. .. 4 With tailgate closeo ano rear window open, oosen ninge fas-
teners (arrows) to allow ninge to move.
- LoosL'n fasteners n lower section of ock to al ow movement.
- Care& ly c ose rear window:
Ad.~st gap dmensions and poston of rear window relative
to Oody panel. See Tailgate alignment specifications. .
FA-UTION- I
On transition area between rooflailgate, tailgate must not ex-
tend above height of roof
othe~lise wind noise will be creat-
ed.
- If necessary, adjust height of rear window frame by inserting
spacers between the hinge and the frame.
- Carefully open rear window, taking care not to alter adjust-
ment.
Tighten left and right rear window fasteners.
Close rear window and check adjustment, repeat step if
necessary. See Tailgate alignment specifications.
Rear window locking pin, adjusting
NOTE-- Several versions of rear window
locldng pin are used on
Sport Wagon models.
1999 528i model is shown. Other
models are similar.
For rear window adjustment specifications,
seeTailgate
alignment specifications.
Loosen lower assembly fasteners (arrows)

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41 2-22
1 Trunk Lid, Tailgate
4 With rear window open, loosen loclc nut (A) so that inclination
of loclting pin
(B) can be adjusted.
- Carefully close rear window, while ensuring that locking pin
is centered in rotary latch in lower section.
NOTE-
When closing rear window, be sure that there is a gap of ap-
proximately
1 mm (0.04 in) between the locliing pin and the
rotary latch in the lower section of lock.
- Open tailgate and tighten lower loclc assembly fasteners. Be
careful not to alter inclination of loclting pin
(B) when tighten-
ing loclc nut
(A).
4 To adjust height of rear window at lock, loosen loclc nut (A)
and turn locking pin (B).
Be careful not alter position of loclting pin when tightening
lock nut
(A).
CA UTIOG
After adjusting rear window, always checlr position of wiper
axis relative to drive disc and limit stop on rear window wiper
motor. Adjust if necessary See 611 Wipers and Washers.

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-
Exterior Trim, Bumpers
This repair group includes repair information for the outside
rearview mirrors, front and rear bumpers, and the easily re-
movable exterior trim parts.
Many of the mirror components are separately available from
an authorized
BMW dealer, including the glass and outside .
plastic housing.
The
E39 models offered two types of outside mirrors, stan-
dard mirrors or automatic dip mirrors.
Outside mirror glass, replacing
CAUTIOI\C
Mirrorshould be at or above room temperature before remov-
al.
Othe~lise, small plastic parfs or glass may break.
Outside mirror glass without automatic dip control,
replacing
Insert thin pry tool (plastic or tape-wrapped screwdriver) be-
tween bottom mirror edge and mirror housing and carefully
pry out mirror glass from housing.
If equipped with heated mirrors: remove heating element
har.
ness connectors from back of mirror glass.
Installation: Connect mirror heating harness if equipped.
Ensure correct alignment of locking pins.
Press mirror glass firmly until it
locks in place.

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-.- -
Exterior Trim, Bumpers
Outside mirror glass with automatic dip control,
replacing
4 Slide locking pin (arrow) right to release glass (A).
- If equipped with heated mirrors: remove heating element har-
ness connectors from
back of mirror glass.
4 Install mirror glass by placing glass on lugs (arrows) and turn
loclting pin until glass is locked in place.
Outside mirror housing, removing and
installing
- Remove mirror glass as described above.
4 Compress plastic retainers (arrows)
NOTE-
The front mirror housing is retained by either three or four
clips, depending on model.