BMW 1989-1995 525i Service Manual page 338

411 -2
DOORS
00 11666
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3. Hinge pin
4. Hinge pin boll
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1. Retaining Clip
2. Washer
Fig . 4. Door hinge assembly.
00 11637
Fig. 3. Door harness connector being removed from A-pillar. Re-
move mounting screws at A. then separate connector by
pulling up lock (t op arrow).
Door Ad justment
• Door gap to fender!
rear door 5.5 ± 0.5 mm (0.216±0.020 in.)
• Deviation in parallel 1 mm (0.040 in.)
Door hinge bearing sleeve, replacing
Check the door bearing sleeves with the door installed.
Open the door fully and lift up on the door end (nearest the
outside handle) to check for worn hinge bearing sleeves .
If
any play is detected. the bearing sleeves are most likely worn .
1. Remove door. See Front or rea r door, removing and
installi ng.
0011638
Fig . 5. Door hinge bearing sleeve. Arrow Indicates bearing removal
direction.
NOTE -
If
replacing the upper bearing sleeve. first unbolt the
hinge half from the door. Mark the position of the hinge
before removing. On the lower hinge. the hinge half
with the sleeve is on the body.
2. Remove hinge pin from hinge half. See Fig. 4.
NOTE -
A special BMW service tool (BMW tool no. 41 5 0 10j is
used to install the bearing sleeve into the bearing half.
The tool is used to peen and flatten Ihe end of the bear-
Ing sleeve to the hinge. An appropriate size mandrel
can be used as an alternative.
3. Drift old bearing sleeve from hinge half. See Fig. 5.
4. Install new bearing sleeve.
5. The remainder of installation is the reverse of removal.
Lubricate bearing surfaces before installing door.
Front door panel, removing and installing
1. Carefully pry out mirror adjustment switch and discon-
nect harness connector from switch.
2. Remove Torx screw (T 15) from armrest through mirror
adjustment switch opening.
3. Unscrew door locking knob.
DOORS