Honda Bmw 5 Service Manual

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...

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....

... - 
Doors 
Remove rubber cover (A) and bolts (B) from door check lock- 
plate on door. 
Worlting inside  door, remove door check  assembly 
Installation is  reverse of removal. 
Lubricate door  check  before installing. 
- If removed,  use new  mounting  bolts when  reinstalling side- 
impact airbag to door. 
Tightening  torque 
Door 
check to  door  frame 24 Nm (16 it-lb) 
Door hinge adjustment 
If the installed  door is uneven or out  of parallel, spacers can 
be  used  to correct  its position....

. 
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   

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. 
Door  trim panel, removing and  installing 
Disconnect negative (-) battery cable. 
CAUTION-- 
Prior to disconnecting the battem read  the batfew discon- 
nection cautions  given in 
001 General...

411-8 
Doors 
< Pry off plastic plug (arrow)  from door handle  trim and remove 
screw. 
4 Carefully  pry out window switch  panel and disconnect elec- 
trical  harness  plugs. 
< Slide door  handle through trim  panel   

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...

411-10 
/Doors 
Sill trim panels 
Using a trim tool, gently  pry up door sill trim.  Starting  at A-pil- 
lar, press radius of trim downwards while  sliding trim forward 
off  trim clips. Remove clips from  body using  pliers. Save  for 
installation. 
Installation  is reverse  of removal. Replace any damaged 
plastic  parts or clips.   

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...

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...