Okay, I think it's fully understood. Here's what's going on:
5D Mark II:
* If you turn off from power switch, and then open card door: A moment later, Canon firmware reads autoexec.bin without card LED activity (funny, no?). If you remove the card during this period, camera freezes without any LED blinking or other sign. Wait for at least 5 seconds before removing the card!
* If you turn off just by opening the card door, and leaving main switch ON: Canon firmware does not read autoexec.bin again, so it's perfectly safe to remove the card right away.
60D:
The 60D always turns on the SD card LED when there is SD card activity, so you already know when it's safe to remove the card. The behavior is almost identical to 5D Mark II, except that 60D has correct LED activity.
I'm trying to enable these LED blinks on all cameras.
550D:
There are no issues on this camera - it never reads autoexec.bin with main switch turned off.
50D:
Same as 5D Mark II (problem is present).
500D:
Same as 5D Mark II (problem is present).
600D:
Similar to 5D Mark II, but the card access is done right in the moment of opening the door. Therefore, it's hard to remove the card fast enough to cause issues, but the problem might happen on slow cards or fragmented filesystems.
1100D:
There are no issues on this camera - it does not try read autoexec.bin after you open the card door.
============
Side note: the cameras having this potential problem will also read autoexec.bin from the card (and execute it) when you change the lens with main power switch off.