2001 BMW 525i 20 pin

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Fenders, Ensine HOO~I
Hood release cable and spring pins,
adjusting
Before adjusting hood pins, be sure the hood is aligned even-
ly to fenders and front panel.
- Malte sure bowden cable, which connects both hood loclts
together, is seated in lock guide on both left and right loclts.
4 Loosen hood spring pin bolts (A) and retaining hoolt bolts (B)
at hood on left and right sides only enough to allow move-
ment.
- Lower (but do not fully latch) hood several times so pins on
hood center themselves in lower loclts.
NOTE-
Do not let hood lock with latch bolts loose
- Tighten hood spring pin bolts and latch bolts when alignment
is correct.
- Remove one bolt at a time from each side, clean and coat
with
LoctiteB 270 or equivalent, and reinstall. Repeat pro-
cess on all other bolts.
- Adjust rubber stop buffers above headlight assemblies. See
Hood, aligning.
- Test hood for correct closure and opening. If hood does not
spring open, lengthen spring pins.
- To lengthen spring pin, loosen locltnut (arrow) with wrench
inserted through spring, then turn pin counterclocltwise.

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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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Doors
~obr adjustment
Front fender to
4.25 mm i 0.25 mm (0.17 i- 0.01 in)
front door gap
Front
door to 4.5 mm i 0.25 mm (0.18 i 0.01 in)
rear door gap
Rear door to rear fender 4.0 mm i 0.25 mm (0.16 i 0.01 in)
Permissible deviation 1 .O mm (0.04 in)
from
~arallel
Tightening torque
Door hinge to door frame
20 Nm (15 it-lb)
Door check, replacing
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 relating to the
airbag system.
- Close door window completely.
- Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnecting the batter)! read the battery discon-
nection cautions given in
001 General Cautions and
Warnings.
- Remove interior door panel. See Door trim panels, remov-
ing and installing.
- Where applicable, remove side-impact airbag from door. See
721 Airbag System (SRS). Remove door vapor barrier.
Disconnect door
check by
(arrow) and removing pin. squeezing I mounting
pin tabs

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.
1 Doors
Door hinge assembly
1. Door
2. Spacer ring
3. Upper hinge
4. Hex bolt
5. Spacer ring
6. Lower hinge
7. Door check gasket
8. Doorcheck
9. Pin
10. Torx bolt
11. Gasket
12. Cover

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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.

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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.