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7 Series - E65 / E66 (2002 - 2008)
Discussion of BMW's 4th generation E65/E66 7 Series flagship. The E65 generated much controversy, due to its radical styling and iDrive user difficulties. Nonetheless, the E65 broke records to become the best-selling 7-series iteration ever, especially after its 2005 facelift.

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  #1  
Old 01-03-2009, 12:04 PM
TitaniumMan TitaniumMan is offline
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Automatic trunk lid update, not staying open (Part 2)

Thanks to all for responding to my earlier queries re the trunk lid problem.

I was able to find the previous thread and access the pump (alas one of the 10mm bolts fastening the pump broke off but that's another story).

Anyways, I removed the pump, turned it upside down and removed the reservoir (without spilling a drop I might add). When the pump was installed (i.e. with the reservoir on top), the level was just below the cross). When removed, the reservoir level was above the cross). I topped it up to the top (i.e. where the clamp goes) but did not drain the old fluid (I wasn't sure how to get it out of the pump). I reinstalled (minus one bolt which I will need to drill out).

The good news is that the trunk now closes much better. The bad news is that although it opens, it will no longer stay open itself (in other words the trunk lid opens quickly but then slowly starts to drop down). Accordingly, I seem to have fixed one problem and created another. Any suggestions would be greatly appreciated. I have checked previous threads and they don't seem to discuss this problem after the other fix.

Sorry for starting a new thread but I wasn't sure if people would follow the old thread and as I have the trunk apart in my (unheated) garage and its cold I thought a new thread might reach the most people.

Thanks in advance.

TM
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  #2  
Old 01-03-2009, 05:15 PM
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jcarey jcarey is offline
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Quote:
Originally Posted by TitaniumMan View Post
Thanks to all for responding to my earlier queries re the trunk lid problem.

I was able to find the previous thread and access the pump (alas one of the 10mm bolts fastening the pump broke off but that's another story).

Anyways, I removed the pump, turned it upside down and removed the reservoir (without spilling a drop I might add). When the pump was installed (i.e. with the reservoir on top), the level was just below the cross). When removed, the reservoir level was above the cross). I topped it up to the top (i.e. where the clamp goes) but did not drain the old fluid (I wasn't sure how to get it out of the pump). I reinstalled (minus one bolt which I will need to drill out).

The good news is that the trunk now closes much better. The bad news is that although it opens, it will no longer stay open itself (in other words the trunk lid opens quickly but then slowly starts to drop down). Accordingly, I seem to have fixed one problem and created another. Any suggestions would be greatly appreciated. I have checked previous threads and they don't seem to discuss this problem after the other fix.

Sorry for starting a new thread but I wasn't sure if people would follow the old thread and as I have the trunk apart in my (unheated) garage and its cold I thought a new thread might reach the most people.

Thanks in advance.

TM
I replied to you in the other thread...
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  #3  
Old 01-03-2009, 05:33 PM
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kemosobe77 kemosobe77 is offline
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it sounds like there is air in the line. Can these things be purged like calipers?
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  #4  
Old 01-03-2009, 05:48 PM
TitaniumMan TitaniumMan is offline
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I was wondering the same thing kemosobe
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  #5  
Old 01-03-2009, 06:05 PM
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kemosobe77 kemosobe77 is offline
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I think you probably have to bleed it. If air was allowed in the system, then why the fluid. Why not just air?
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  #6  
Old 01-05-2009, 03:25 AM
bembo19 bembo19 is offline
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did you fill it to the brim ?? thats probably where your air is coming from !! its def seems to be a fluid problem as you have changed the character of the problem by topping it up ! so try it again and see what happens !
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  #7  
Old 01-05-2009, 06:09 PM
TitaniumMan TitaniumMan is offline
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Thanks Bembo.

I drained and refilled the reservoir to the + and now my trunk lid is worse than before. It won't stay up unless I hold it in place.

At least before it opened fine, it was just closing that was a problem. Any other thought?

Cheers
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  #8  
Old 01-05-2009, 08:39 PM
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you need to use this....
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  #9  
Old 01-06-2009, 10:43 AM
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This should seal this once and for all. Thres no need for Part 3. I was sure I posted this info once before. Here it is again :


E65/E66 (7 Series) equipped with HKL system (SA 316)

Troubleshooting Guide HKL system malfunctions.


A) The trunk lid will not open fully. The hydraulic pump makes a whining noise and the system is low on fluid.

CAUSE :
The material used in the hydraulic lines would allow the hydraulic fluid to evaporate through the lines when the trunk area was heated to very high temperatures, such as when the vehicle was parked in the sun. The fluid loss caused by this heating is gradual, and the system continues to work properly until the fluid gets low enough that the pump runs out of fluid before the lid is fully open or the fluid gets sufficiently aerated to cause the system to malfunction. Also, normal contraction of the hydraulic fluid due to low ambient temperatures could cause the system to malfunction in cooler weather because the fluid level in the reservoir drops below the critical level.

CORRECTION :

Remove the right side trunk trim and check the fluid level in the HKL reservoir to determine if it is low.Check the color of the printing on the hydraulic lines. If the printing is white, the hydraulic cylinder/lines assembly should be replaced with the improved parts. If the printing is yellow, the improved parts have already been installed and the system should be checked for leaks or other problems.

51 24 7 134 592 Cylinder/Line Kit
51 24 7 133 667 HKL hydraulic fluid


B) The trunk lid opens fully. It then drops slowly back to approximately half open.
----This situation only affects vehicles produced before June 2003. For vehicles produced from March 2004, the trunk lid may drop slightly when it is opened for the first time after programming, resetting, replacement of the control module, etc. This is a normal situation. After this initial setting, the trunk lid will remain fully open.

CAUSE :
Weak trunk lid gas struts.

CORRECTION :
51 24 7 042 104 Trunk lid gas strut, left side
51 24 7 058 646 Trunk lid gas strut, right side


C) The trunk lid does not open or close fully.
This situation may happen intermittently depending on outside temperature. Noises may also be heard from the hydraulic pump.

CAUSE :
The connection between the hydraulic cylinder and the line is not tight.
---For vehicles produced from March 2003 until December 2003, the trunk lid opening or closing forces may be too low or the control module may have a coding error.

CORRECTION :
Check the hydraulic lines and the hydraulic fluid level. Also check the HKL control module coding index and replace or recode as necessary. Only control module with a coding index of 03 can be coded. Control module with a coding index of 02 cannot be coded and must be replaced.Do not replace the gas struts for this problem.This (HKL) module can be found on the right rear trunk area labeled HKL. You can see the coding index stamped on the control unit.


D) The trunk lid only moves in one direction.
When pressing the button to close the trunk lid, it tries to continue upwards after it has already been opened. In most cases,there will be a fault stored in HKL module.

CAUSE :
The module is defective.

CORRECTION :
61 35 6 980 008 HKL control module


E) The trunk lid does not stay open on a gradient of more than 10 degrees.
---affects vehicle produced up to October 2004.

CAUSE :
The trunk lid gas struts are not designed for parking on extreme gradients.

CORRECTION :
Replace the right side gas strut with Viagra equipped one.
51 24 7 158 951 Viagra gas strut, right side

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Last edited by BMW_tech; 01-06-2009 at 10:47 AM.
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  #10  
Old 01-06-2009, 08:57 PM
teejaylentz teejaylentz is offline
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I think I need the viagra struts - I have the problem where the trunk does not open on a gradient (and makes some pretty sad grinding/whining noise when you attempt to open on a gradeint). Per your response, I suppose this is "by design."
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  #11  
Old 01-07-2009, 07:40 AM
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Quote:
Originally Posted by teejaylentz View Post
I think I need the viagra struts - I have the problem where the trunk does not open on a gradient (and makes some pretty sad grinding/whining noise when you attempt to open on a gradeint). Per your response, I suppose this is "by design."
I got that out of an SIB mentioned in other post so thats their excuse and Im just passing it on to my friends. You are quite right about your initial diagnosis, that would be your correction and Im certain it would open at an incline even if you add a heavy spoiler on the trunklid.
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  #12  
Old 01-09-2009, 12:30 PM
bembo19 bembo19 is offline
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i filled mine past the + mark ! one thought though ! is your pump mounted resevoir on top or underneath ??
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  #13  
Old 04-13-2013, 05:05 PM
HuweyII HuweyII is offline
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Quote:
Originally Posted by BMW_tech View Post
D) The trunk lid only moves in one direction.
When pressing the button to close the trunk lid, it tries to continue upwards after it has already been opened. In most cases,there will be a fault stored in HKL module.

CAUSE :
The module is defective.

CORRECTION :
61 35 6 980 008 HKL control module
This my exact problem. Thanks so much for the great post!

Anyone know where I can buy this module? I found it in the trunk, remove and replace couldn't be easier, if only I had a new one. I've been googling but so far I've struck out. In the past I've been able to get strange things like this from PelicanParts but they don't seem to carry this one.
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  #14  
Old 04-13-2013, 05:08 PM
nr123 nr123 is offline
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Mine is none of the above - my truck lid opens fully, then closes shut.

I can keep it open by pushing it back all the way and holding it for a few seconds.
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  #15  
Old 04-13-2013, 05:33 PM
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Sounds like the hydraulic struts are bad.
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  #16  
Old 04-13-2013, 05:55 PM
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Quote:
Originally Posted by first_745li View Post
sounds like the hydraulic struts are bad.
+1
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  #17  
Old 04-14-2013, 07:45 AM
mws mws is offline
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Thanks, BMW Tech, This is a quote from TIS as far as I can see. Not trying to be difficult, but I would have told the poster to buy TIS, myself. I'm not one for posting documented info on the net. I'm more about posting stuff the documents don't cover--which is what forums are good for. But the discussion is good, since I too am experiencing none of the above.

I have a 2004 wreck that has a very good and fast trunk lid mechanism and my 03/2003 lifts slowly and then falls on my head in pretty much any temperature, half of the time (not just after programming). So I will try the hood struts first and if that does not work, I will check the color of the hydraulic lines and probably switch the entire system over. Good troubleshooting opportunity.
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  #18  
Old 04-15-2013, 12:05 AM
HuweyII HuweyII is offline
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I found several sources on the internet for new (~$250) and used (~$125) modules. This was the magic number to search for: 61356964008

http://bit.ly/116buiU
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  #19  
Old 08-23-2016, 08:38 AM
Erictamblyn Erictamblyn is offline
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The hydraulic fill solved the problem

My trunk was not opening or closing correctly. I followed the instructions in this video and it worked great. It did take about 12 assisted open/closing with some gentle pressure for the fluid to fully engage. My system was likely very dry. Hopefully this video helps others...

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