4/30/2016 1/1

65 12 051 Removing and installing/renewing

central bass speaker -driver's side-
(under front seat)

Necessary preliminary tasks:

 Remove front seat
 Remove door sill cover strip

Release screws (1).
Remove cover of bass speaker (2).

Fold up the carpet (1) as shown.

Unfasten plug connection (3) and disconnect.
Unfasten screws (2).
Feed out central bass speaker support (4).
 4/30/2016 1/2

65 12 210 Removing and installing/replacing

CHAMP radio receiver (BMW
Professional radio)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Disconnect battery negative cable
 Remove radio and IHKA controls

Release screws (1).
Pull out the CHAMP (2) to the front.
Installation note:
Make sure CHAMP (2) is correctly seated on retaining lugs at
the marked points.

Unlock plug connections (2) and disconnect.

Remove CHAMP (1).

Replacement:
Carry out vehicle programming/coding.
 4/30/2016 2/2

 
Load service history:

- 05 Maintenance and Pre-Delivery Check

- Service history
 4/30/2016 1/1

65 20 350 Removing and installing/replacing

interference suppression filter

Necessary preliminary tasks:

 Remove trim panel for roof pillar at rear left
 Remove luggage compartment wheel arch panel on left.

Release screw (2).
Unlock plug connections (1) and disconnect.
Remove interference suppression filter (3) from C‐pillar.

Installation note:
Fit interference suppression filter (1) so that screw (2) engages
thread (3), and locating pin (5) engages in bore hole (4).
 4/30/2016 1/2

52 26 202 Removing and installing/replacing rear

panel on rear centre seat backrest

Unclip trim cover for lock with a plastic wedge.

Move trim cover for lock a little towards the middle.
Detach trim cover for lock by pulling towards rear.

Installation note:
Retaining lugs on the trim cover for the lock must not be
damaged.
Replace defective trim cover for lock.

Note:
Welt of backrest cover is partially positioned below the centre
armrest cover.

Carefully lift out the centre armrest cover in the marked area
(1).

Lever out welt in marked area.

 4/30/2016 2/2

Lever out welt in marked area.

Detach rear panel.
Installation note:
Insert the rear panel in the backrest frame first.
Insert welt of backrest cover in frame.
 4/30/2016 1/1

61 31 038 Removing and installing/replacing switch

for front passenger airbag deactivation

Special tools required:

 00 9 323

Warning!
Read and comply with safety regulations for handling
airbag modules and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause injury.

Necessary preliminary tasks:

 Disconnect battery earth lead

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.

Carefully lever out side cover (1) with special tool 00 9 323.

Disconnect plug connection (1).

Unlock latch mechanisms (4) in direction of arrow.
Feed switch for front passenger airbag deactivation (2) out of
side cover (3).
 
Installation note:
Make sure switch for passenger airbag deactivation (2) is
correctly seated in side cover (3).
 4/30/2016 1/1

32 31 003 Removing and installing/replacing upper

section of steering column shroud

Move steering column in "bottom" and "extended" position.

Pull steering column gap cover up carefully and clip out gap
cover.

Pull steering column shroud (1) up.

Clip steering column gap cover (1) out of steering column
shroud upper section.
Important!
Risk of damage!
Carefully pull steering column shroud upper section (1)
upward at rear and clip out.
 4/30/2016 1/1

51 31 015 Repairing damage to windscreen

caused by stone chips (clear and tinted
laminated safety glass)
Field of vision (no repairs acceplugle):

A 50 mm (gap between field of view / centre of vehicle)

B Up to end of wiper range, outside (field of view width)
C Restriction by wiper range (field of view height)
Important!
Repairs must only be carried out outside of the field of vision (refer to sketch).
If the stone chip damage is outside the field of vision, refer to repair instruction.
 4/30/2016 1/1

32 00 Wheel Alignment F20 / REAR WHEEL M135i

Observe test conditions!
Front axle:
Total toe-in 0° 14' ± 12’
Adjustment total toe-in* 0° 14' ± 4'
Toe difference** single wheel between left/ right max. 12'
Camber - 0° 53' ±  30’
(difference between left/right max. 30')
Adjustment camber* - 0° 53' ±  25’
Toe difference angle (difference between left/right max. 30') - 1° 33'
Castor angle (difference between
left/right max. 30')
Front wheel offset 0° ± 15'
Maximum steering angle
‐ Inner cornering wheel approx. ° 39° 48'
‐ Outer cornering wheel approx. ° 33° 36'
Rear axle:
Total toe-in 0° 18' ± 12'
Adjustment total toe-in*     0° 18' ± 4'
Camber (difference between left/right max. 30') -1° 45' ± 25'
Adjustment camber* -1° 45' ± 5'
Geometrical driving axis 0° ± 12'
*Note: To minimise adjusting errors (measuring inaccuracies), use a narrower
tolerance for adjusting toe/camber.
**Note: Toe difference front axle = criterion for steering wheel inclination
 4/29/2016 1/3

FTD-FTD-SBT2003-000103035   Abbreviations

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

00 01 03 (035)

Abbreviations

All models

Introduction

There are a large number of abbreviations used at BMW: in development, production, organisation,
sales/marketing, test plans and technical vehicle documentation.
 4/29/2016 2/3

BMW language: about 1,500 abbreviations used in technical areas alone!

To assist with diagnoses, BMW Service Technology has several lists of abbreviations. These abbreviations
should not appear cryptic, particularly to those who are coming into the workshop for the first time or from other
departments, but also anyone else interested in technology. Abbreviations can be simple keywords, whose
meaning is clear. These lists of abbreviations may help to clarify.
Lists of abbreviations

The following lists of abbreviations are available:

- Series and models with images: Update 01/2013

Series from recent years with images, sales names, engines etc.  [more ...]

- Engines since 1983: Update 01/2013

Engines and the related electronic engine control  [more ...]

- Gearbox: Update 01/2013

Gearboxes and the related electronic transmission control  [more ...]

- Control units: Update 01/2013

Current control units in diagnosis and programming [more ...]

- BMW Service Technology - Glossary: Update 07/2007

More than 700 abbreviations used in BMW Service Technology. New in relation to the 2004 list of
abbreviations:
 Some new abbreviations have been included.
 Some abbreviations have been deleted. Reason: Die number of abbreviations should be kept as
low as possible, in order to optimise and simplify the reading process.
 Some of the text the ”Use” column has been revised.

For technical reasons, the glossary is divided into the following systems:
 Introduction, abbreviations with numerals and characters [more ...]
 -A-
 -B-
 -C-
 -D-
 -E-
 -F-
 -G-
 4/29/2016 3/3

 -H-
 -I-
 -J-
 -K-
 -L-
 -M-
 -N-
 -O-
 -P-
 -Q-
 -R-
 -S-
 -T-
 -U-
 -V-
 -W-
 -X-
 -Z-
 Overview of Unified Parts Group [more ...]
Note: Thanks for your support and feedback.
Our sincere thanks to our colleagues in the diagnosis, programming, and integration departments,
to our repair instruction authors and Aftersales Training staff for taking the trouble to draw up their
lists, and for their support in aligning the data. Our special thanks to the company archives for
providing images of earlier models, and for their extensive and detailed editing work.

We can assume no liability for printing errors or inaccuracies in this document and reserve the right to introduce
technical modifications at any time.
 4/30/2016 1/2

64 50 ... A/C performance test

Observe the following conditions prior to the A/C performance test:

1. Connect diagnosis system. Check of the fault memory (no faults in the fault memory).
2. Attach a thermometer with separate display element to the head restraint. Lay display element outwards
out of passenger compartment.
3. Perform the test in a suitable workshop area with an ambient temperature above 18° C.
4. Vehicle temperature should be approximately the same as the ambient temperature in the workshop.
5. Engine must be at operating temperature (does not apply for electric vehicles).

 

Heat passenger compartment:

- ”A/C button” is not activated during the heating process

- Close all windows and doors.

- Set air recirculation function.

- Select air distribution mode for footwell and defrosting.

- On vehicles with CID: In A/C menu (CID) in Air distribution index tab: select 100 % footwell for driver
and front passenger and 100 % defrosting for driver (this applies here to driver and front passenger)

- Maximum temperature setting

- Maximum blower speed

- Start engine (does not apply for electric vehicles)

 

Cool down passenger compartment:

Switch on air conditioning compressor with "A/C button" at a vehicle interior temperature of 45 °C (measured
at the head restraint).

On vehicles with MAX‐AC button:

 Activation of MAX‐AC (= maximum cooling power)

 
 4/30/2016 2/2

On vehicles without MAX‐AC button:

 Set maximum cooling power by means of following steps:

- Setting minimum temperature

- Blower setting maximum

- Stratification maximum cold (4 blue bars)

- Only ventilation open

- Close remaining flaps (air outlet only from centre fresh air grille, left and right)

After 5 minutes measure both ventilation temperatures with a thermometer at the same time (fresh air grille
centre, left and right). The measured temperature must be ≤ 16 °C and the difference between right and left
may not be greater than 2 °C.

If one or both temperature specifications is not reached drain off heating and air conditioning system.
Measure amount of refrigerant drawn off.

If drawn-off quantity does not correspond to specified fill quantity: supplement refrigerant and repeat test.

If capacity is correct, continue troubleshooting by pressure measurement.

 4/30/2016 1/2

32 00 ... Additional work for camber correction

Note:
The camber adjustment is performed only with the replacement
of the swivel bearing. There are 3 different swivel bearings for
this!

Important!
Changes in axle geometry caused by accidents must
under no circumstances be rectified by camber
adjustment!

Note:
The swivel bearing may only be replaced if the camber is
outside the specified tolerance after toe adjustment.

Necessary preliminary tasks:

Adjust toe-in.

Check camber values; if necessary, replace swivel bearing with

over‐ or under-dimension variant.
Note:
Camber correction swivel bearings can only be identified from
 4/30/2016 2/2

the BMW part number (1).

See also the BMW spare parts catalogue!

Version BMW part number

Standard (except for M135i) 6 792 285/ 286

+ 30' 6 853 649/ 650

- 30' (= standard M135i) 6 853 651/ 652

These camber correction swivel bearings are used to correct

the camber values by 30 minutes. To be used only if the
tolerance values are exceeded or undershot!

After Installation note:

 Check directional stability of car; if necessary, repeat toe-
in adjustment
 4/30/2016 1/3

52 15 050 Remove or install left or right thigh

support from/on the front seat
(sport/manual)

Unlock and move thigh support (1) as far forward as possible.

Lever out the welt (3) from the seat cover (2) from the thigh
support (1).

Do not completely extend the thigh support to the end stop.

Keep Actuation (1) pressed to unlock the centering (2).
Carefully raise the end stop (3) for the thigh support with a screwdriver and pull the thigh support toward the
front out of the guide rails at the same time.
 4/30/2016 2/3

View of thigh support mechanism when

removed:
1. Screwdriver for unlocking the end stop
2. End stop for thigh support
3. Locking mechanism for the thigh
support

View of seat frame mechanism:

3. Guide rail on seat with depth retainer
4. Guide rail on seat with end stop

Unfasten plug connection (1) and disconnect.

Note:
 4/30/2016 3/3

Check guide rails (2) and adjusting mechanism (3) for damage.

 4/30/2016 1/3

41 51 ... Adjust door

Important:
Do not damage adjoining body components.
Minor corrections (realignment work) are permitted if the
existing adjustment options are not sufficient.

Note:
Observe gap dimensions.
The door must be provided with all add-on parts for correct
adjustment.
Adjust screwed body components from rear to front.
The following illustrations are schematic representations and
are to be applied to the relevant vehicle type.
 4/30/2016 2/3

Loosen striker and remove, If necessary.

Slacken screws for hinge (2) on door until door can still just be moved.
Front door: Tightening torque 41 51 2AZ.
Rear door: Tightening torque 41 52 2AZ.
If adjustment range is not sufficient, slacken screws for hinges (1) on body.
Note:
Screw connections only accessible from inside.
Front door: Tightening torque 41 51 3AZ.
Rear door: Tightening torque 41 52 3AZ.

Check that adjoining body components are flush in terms of

height and correct if necessary.
Note
Height adjustment of door must not be influenced by
striker.
When the door is closed, the striker must not touch or
scrape against the door lock. Look out for scratch marks.
 4/30/2016 3/3

Tighten down screws (1) until striker can still just be moved.

Move striker sideways in order to adjust transition between door
and adjoining bodywork parts.
Tightening torque 51 21 2AZ/51 22 2AZ.

After Installation note:

If the hinge is slackened on the body side, the area of the hinge
must be sealed in a u-shape with sealant (1).

 Tighten all screws to specified torque.

 Touch up unpainted surfaces in the appropriate colour.
 If necessary, adjust front door.
 4/30/2016 1/1

63 10 ... Adjust the fog lights (with electronic

headlight adjustment device
MAHA Lite 3)

Comply with test prerequisites for headlight adjustment!

 
Refer to the operating instructions for the headlight adjustment
device!

Switch on the headlight adjustment device by pressing any

button.
Press F2 button. The shown display screen appears.
Perform the following settings:
1. The passenger car must be selected.
2. Enter the setting dimension for the headlight with buttons
F1/F2: - 2,0 %
3. The right / left-hand traffic must be selected according to
the country.
4. Select the fog light type with the F3 button:

- EC: for halogen fog lights

- EC LED: for LED fog lights

The adjusted values are adopted for future measurements.

Press briefly the button for the applicable side of the vehicle (1)

until symbol (2) appears.
The following symbols appear in the display:
 O. K. (4): Adjustment is optimal. 
 O. K. (3): Adjustment is within the legal tolerance
range. Adjust fog light until O. K. (4) is displayed.
 Arrows (5): Adjustment is incorrect. Adjust fog light using
arrows (5) until O. K. (4) is displayed.
 4/30/2016 1/2

63 10 ... Adjust the high-beam headlight (with

electronic headlight adjustment device
MAHA Lite 3)

Important!
The high-beam headlight can only be adjusted in the
following cases:

- The low-beam headlight and high-beam headlight

are located in separate housings and each has a
separate range of adjustment (e.g. E52, BMW i 01).

- Low-beam headlight and high-beam headlight are

located in one housing with one separate range of
adjustment each.

- With separately mounted additional headlights (e.g.

MINI).
On vehicles from 1995, separate adjustment of the high-
beam headlight is not possible.
(Exception E52, BMW i 01, additional headlight MINI)

Comply with test prerequisites for headlight adjustment.

 
Refer to the operating instructions for the headlight adjustment
device!
 
Necessary preliminary work:
Adjust the low-beam headlight

Switch on the headlight adjustment device by pressing any

button.
Press F2 button. The shown display screen appears.
Perform the following settings:
1. The passenger car must be selected.
2. Enter the setting dimension of the headlight via the
buttons F1/F2: - 1.0 % to - 1.1 %
(see "light/dark boundary of the headlight in the headlight
adjustment device" in the document observe the test
prerequisites for the headlight adjustment).
 4/30/2016 2/2

3. The right / left-hand traffic must be selected according to

the country.
4. Select the headlight type via the button F3:

- EC: for halogen and xenon headlights

- EC LED: for LED headlight

The adjusted values are adopted for future measurements.

Press briefly the button for the applicable side of the vehicle (1)

until symbol (2) appears.
 
The following symbols appear in the display:
 O. K. (5): Adjustment is optimal. 
 O. K. (4): Adjustment is within the legal tolerance
range. Adjust high-beam headlight until O. K. (5) is
displayed.
 Arrows (3): Adjustment is incorrect. Adjust high-beam
headlight using arrows (3) until O. K. (5) is displayed.
 4/30/2016 1/3

63 10 ... Adjust the low-beam headlight (with

electronic headlight adjustment device
MAHA Lite 3)

Comply with test prerequisites for headlight adjustment!

 
Refer to the operating instructions for the headlight adjustment
device!

Note:
On vehicles with anti-glare high-beam headlight it is
sufficient to adjust the low-beam headlight.
Only in the event of a customer complaint regarding
dazzle/glare Adjust anti-glare high-beam headlight
separately.

Switch on the headlight adjustment device by pressing any

button.
Press F2 button. The shown display screen appears.
Perform the following settings:
1. Passenger car must be selected
2. Enter the setting dimension of the headlight via the
buttons F1/F2: - 1,0 % to - 1,1 %
(see "light/dark boundary of the headlight in the headlight
adjustment device" in the document observe the test
prerequisites for the headlight adjustment).
3. The right / left-hand traffic must be selected according to
the country.
4. Select the headlight type via the button F3:

- EC: for halogen and xenon headlights

- EC LED: for LED headlight

The adjusted values are adopted for future measurements.
 4/30/2016 2/3

Important!
Before
measuring/adjusting the
low-beam headlight, it is
absolutely necessary to
determine
the transparent screen of
the headlight!
An incorrect selection
leads to an incorrect
setting!

Transparent screen Type I:

Press briefly the button for the applicable side
of the vehicle (3) until symbol (1) appears.
 
Transparent screen Type II:
Press longer the button for the applicable side
of the vehicle (3) until symbol (4) appears.
 4/30/2016 3/3

 
The following symbols appear in the display:
 O. K. (2): Adjustment is optimal. 
 O. K. (5): Adjustment is within
the legal tolerance range. Adjust
headlight until O. K. (2) is displayed.
 Arrows (6): Adjustment is incorrect. Adjust
headlight using arrows (6)
until O. K. (2) is displayed.
 4/30/2016 1/4

REP-REP-RAF2041-4161014   Adjusting engine compartment lid

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/02

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

41 61 014 Adjusting engine compartment lid

Important!
These instructions only apply to vehicles without active
pedestrian protection!
Observe separate procedure for vehicles withactive
pedestrian protection!

Important!
Do not damage adjoining body components!
Minor corrections (realignment work) are permitted if the
existing adjustment options are not sufficient.

Observe gap dimensions.

 4/30/2016 2/4

Note:
Stop screw must not be damaged or missing. If necessary,
replace engine compartment lid hinge.
The stop screw is preset and must not be used to adjust the
engine compartment lid!

Slacken nuts (1) of hinges on left and right.

Tightening torque 41 61 1AZ.
Note:
If adjustment range is not sufficient, slacken screws on
body and slide hinge. (Refer to operation: Height
adjustment at hinge)

Adjust engine compartment lid sideways and lengthways.

Strikers must snap into place in engine compartment lid catch.
 4/30/2016 3/4

Height adjustment at hinge:

Slacken screws (1) and adjust engine compartment lid.
Tightening torque 41 61 2AZ.

Height adjustment at strikers:

Unclip the anti-twist lock (1).
Adjust height by turning the striker (2).
Height adjustment of engine compartment lid to side panel by
means of stop pad.
Note:
The engine compartment lid is correctly adjusted in the front
section by a combination of pulling the strikers and pressing the
stop pads.
Incorrect adjustment results in either wobbling of the engine
engine compartment lid or sluggish unlocking.

Important!
Check function of retaining hook.
 4/30/2016 4/4

After Installation note:

 Tighten all screws and nuts to specified torque.
 Touch up unpainted surfaces in the appropriate colour.
 If necessary, adjust front side panels.
 4/30/2016 1/1

63 10 014 Adjusting fog lights

Comply with test preconditions for headlight adjustment.

Important!
Do not damage adjusting screw when adjusting fog light.

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.

Adjust fog light (1) by turning adjusting screw.

 4/30/2016 1/2

54 12 003 Adjusting glass slide/tilt sunroof panel

Special tools required:

 00 9 315
 00 9 340

Installation note:
 Microencapsulated screws (Loctite) must be replaced and
may not be reused
 Screw connection must be completed within 20 minutes
(start of curing)
 Microencapsulated screws must not be retightened
 Clean thread of nut beforehand in event of repeated use

Necessary preliminary tasks:

 Remove both gaiters

Ideal setting:

- Distance:
 Distance A of glass slide/tilt sunroof panel (1) to
roof (2) must be the same at the circumference
 A = circumference 6.0 ± 0.5 mm

- Height:
 Front - flush to 0.75 mm deeper
 Rear - flush to 1.5 mm higher
Note:
Measure front and rear height adjustment over the entire cover
width.
Height over the entire cover width must lie within tolerance.
Measuring range only at straight range of glass slide/tilt sunroof
panel.
 4/30/2016 2/2

Loosen left and right screws (1).

Note:
For setting screws (1), only slacken until glass slide/tilt sunroof
panel (2) can just be adjusted.

Tightening torque 54 12 01AZ.

Height adjustment:
Check height of glass slide/tilt sunroof panel (1) in relation to
roof (2) with special tool 00 9 315.
Press glass slide/tilt sunroof panel upwards and downwards
until the ideal position has been reached.
Setting distance:
Check distance between gasket and roof (2) with special
tool 00 9 340.
It must be possible to slide the special tool against the same
level of resistance.
Slide glass slide/tilt sunroof panel forward and back until ideal
setting is reached.

Check function and adjustment.

Initialise glass slide/tilt sunroof.
 4/30/2016 1/1

63 10 004 Adjusting headlights

Comply with test prerequisites for headlight adjustment.

Important!
Do not damage adjusting screws when adjusting
headlights.

Carry out headlight adjustment at adjusting screws (1) and (2).

 
1. Adjusting screw primarily for vertical adjustment
2. Adjusting screw primarily for lateral adjustment
 4/30/2016 1/1

51 23 131 Adjusting left or right striker on engine

compartment lid

Adjusting striker is described in:

Adjusting engine compartment lid

Unclip anti-twist lock (1).

Unscrew retaining hook (2).
Installation note:
Adjust engine compartment lid
 4/30/2016 1/5

34 41 014 Adjusting parking brake

Special tools required:

 32 1 030

Perform inspection in the following manner:

When 1st ratchet is engaged, no braking force should
be exerted.
The difference in wheel circumferential forces between
the left and right wheels may deviate by max. 30 %
from the greater value (measured on brake test stand).
In event of larger deviations of wheel circumferential
force: carry out readjustment.
Braking with locked wheels must be possible with the
parking brake.
The parking brake must be reset if the actuation stroke
is greater than 10 teeth.

Note:
Accurate adjustment of the parking brake is only possible if the
parking brake Bowden cables and all moving parts on the
parking brake move easily and function correctly.
Basic setting of the parking brake is required:
- Parking brake shoes and add-on parts are replaced
- Brake discs are replaced
- In event of excessive actuation stroke (10 teeth)
- When replacing parking brake Bowden cables

1. Adjusting instructions for brake pads (basic setting)

Unclip gaiter for parking brake lever.
Lock adjustment unit (ASZE).
Actuate parking brake lever. Connect special tool 32 1 030.
Press limit position (1) of adjusting spring back to such an
extent that retaining hook (2) engages in limit position (1).
 4/30/2016 2/5

Completely unscrew one wheel stud on each rear wheel.

Installation note:
Tightening torque 36 10 1AZ.

Turn wheel until adjustment screw is visible in threaded hole.

Turn adjusting screw with a screwdriver until wheel can not be

turned anymore by hand.
Then at adjusting screw:
 Duo-servo brake ∅ 185 8 release catches
 Duo-servo brake ∅ 160 9 release catches
Important!
Basic setting with less than 8 catches on the duo-servo
brake may lead to the brake pads being damaged. A
reduction in the number of catches on the duo-servo brake
to shorten lever travel is not permitted.

Unlock adjustment unit (ASZE).

Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from limit position (1) of
adjusting spring.
 4/30/2016 3/5

Important!
Follow notes for Brake testing for test stand.

2. Adjusting instructions for parking brake Bowden cables

The parking brake lever must be applied 5 times with medium
hand force.
2.1 On brake test stand
0th tooth (parking  
brake released): Vehicles with manual transmission: Shift
lever in neutral position.
Vehicles with automatic transmission:
Selector lever position ”N”.

- Without locking differential ≤150 N.

- With locking differential ≤ 200 N

(possibly odd display).

1st tooth: No increase in braking force with regard

to 0th tooth. Indicator light can be lit.
2nd tooth: Indicator lamp must be lit.
3rd tooth: Increase in braking force.
 4/30/2016 4/5

5th tooth: The brake force display must have

reached ≥ 400 N.
Checking brake force differential at wheel:
Apply parking brake until a wheel circumferential force (brake
force display) of min. 1000 N is reached.
Max. permitted brake force differential right/left ≤35 % (referred
to greater brake value).

3. Bedding in the duo-servo parking brake

The following bedding-in instructions are applicable in case of
insufficient braking effect or after replacing brake discs and/or
brake pads.

3.1 On brake test stand

Apply parking brake lever until wheel circumferential force at
first wheel is 800 N.
Lock parking brake lever in next lower tooth.
Important!
Brake bedding-in time max. 2 minutes!

3.2 When driving on road

(If possible on company grounds or on an unused road)
When driving at low speed (maximum 40 km/h) apply parking
brake lever until a braking effect can be felt.
Pull parking brake lever into the next catch and continue driving
for maximum approx. 400 metres (maximum 40 km/h).
A basic requirement is that parking brake is adjusted uniformly.
 4/30/2016 5/5

Note:
If necessary, repeat bedding-in procedure.
Allow brake to cool down sufficiently.
 4/30/2016 1/2

32 00 620 Adjusting rear axle

Necessary preliminary tasks:

 Remove left and right covers from camber arm.

Note:
A camber change always means a toe change as well. The
camber must therefore be adjusted first.

Adjusting camber:
Replace nut (1) and apply 5 Nm.
Turn eccentric bolt (2) to adjust camber to setpoint value.
Tighten nut (1).
Tightening torque 33 32 9AZ.

Adjusting toe:
Replace nut (2) and apply 5 Nm.
Turn eccentric bolt (1) to adjust toe to setpoint value.
 4/30/2016 2/2

Tighten nut (2).
Tightening torque 33 32 7AZ.
 4/30/2016 1/3

51 24 004 Adjusting rear lid lock

Special tools required:

 00 9 322

Prerequisite:
Rear lid must be correctly adjusted to fit; if necessary, adjust
rear lid.
For ideal adjustment, refer to Body gap dimensions.

Completely screw in stop pad (1) left/right.

See Removing and installing/replacing bump stops on tailgate.

Lift out covers (1) using special tool 00 9 322.

 4/30/2016 2/3

Slacken screws (1) until striker (2) can still just be moved and
centres itself.
Important!
Striker (2) must not brush against rear lid lock.

Close rear lid.

Check gap dimensions and locking comfort.
If necessary, repeat procedure.
Note:
When the tailgate is closed, the striker must not touch or scrape
against the rear lid lock. Look out for scratch marks.

Open tailgate.

Tighten down screws (1).

Tightening torque 51 24 2AZ.
 4/30/2016 3/3

Screw out stop pad (1) left/right until they are in contact with the
tailgate.
It must be possible to pull out paper strips with moderate friction
resistance between the tailgate and stop pad (1).
Then screw out stop pad (1) one-half rotation further.
See Removing and installing/replacing bump stops on tailgate.
 4/30/2016 1/3

51 23 ... Adjusting/replacing bump stops

The illustrations are schematic representations and are to be

applied to the relevant vehicle type.

Version 1:
Following parts must not be damaged:

- (1) Bump stop

Adjust bump stop (1) to correct height by turning left or right.

Version 2:
Replace damaged bump stops (refer to EPC):

- (1) Bump stop with ejector

 4/30/2016 2/3

Press ejector (1) into bump stop and, in this position, twist
approx. 90° counterclockwise with a Phillips screwdriver.
This locks the ejectors (1) in the bump stops.
Adjust bump stop (2) to correct height by turning left or right.
Unlock the ejector (1) again after completing adjustment.

Version 3:
Replace damaged bump stops (refer to EPC):

- (1) Bump stop

Turn lock (1) 45° counterclockwise.

Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
4/30/2016 3/3
 4/30/2016 1/1

51 23 ... Adjusting/replacing bump stops

Necessary preliminary tasks:

Remove luggage compartment wheel arch panel.

Following parts must not be damaged:

- (1) Bump stop

- (2) Lock nut (following illustration)

General view of rear side:

 Adjust stop pads
Remove cap (1).
Adjust stop pad to correct height by turning screw (2) to
left or right.
 
 Remove stop pads
Release nut (3) and remove stop pads.
 4/30/2016 1/3

41 62 014 Adjusting tailgate

Special tools required:

 00 9 322

Important:
Do not damage adjoining body components.
Minor corrections (realignment work) are permitted if the
existing adjustment options are not sufficient.

Read contents of Body, General.

Observe gap dimensions.
The tailgate must be provided with all attachment parts for
correct adjustment.

Necessary preliminary tasks:

 Partially loosen rear headlining.
 4/30/2016 2/3

Note:
When the tailgate is closed, the lock striker must not touch or
scrape against the tailgate lock.
If necessary, remove lock striker.
 
Lift out cover (1) with special tool 00 9 322.
Release screws underneath. If necessary, remove lock striker.

Adjusting the tailgate sideways and vertically:

Slacken nut (1).
Slacken screws (2) on rear lid hinge to rear lid until such stage
that rear lid can still be moved.
Adjust tailgate.
Tightening torque 41 62 1AZ/ 41 62 3AZ.

Adjusting tailgate laterally and in longitudinal direction:

Slacken nuts (1) and adjust tailgate.
 
Tightening torque 41 62 2AZ.
Adjust stop pad.
Adjust tailgate catch.
 4/30/2016 3/3

After Installation note:

 Tighten all screws and nuts to specified torque.
 Touch up unpainted surfaces in the appropriate colour.
 4/29/2016 1/5

11 31 505 Adjusting timing of camshaft(s) (N55)

Special tools required:

 00 9 120
 00 9 250
 11 4 280
 11 4 281
 11 4 282
 11 4 285
 11 4 290
 11 9 340

Important!
For the positioning of the special tool11 4 281 on the
mounting flats of the intake camshaft, a collision with the
cylinder throttle return spring 1 can occur.
Rework special tool 11 4 281 on the basis of the following
description.

Necessary preliminary tasks:

 Remove cylinder head cover.
 Check timing.

With 1st cylinder in TDC firing position, cams of intake

camshaft (1) at 1st cylinder point upwards at an angle.
 4/29/2016 2/5

With 1st cylinder in TDC firing position, cams of the exhaust

camshaft (1) point upwards at an angle.

Part numbers (2) on intake and exhaust camshafts (1) point

upwards.

Secure special tool 11 4 285 with bolts (1) to cylinder head.

Note:
Fit special tool 11 4 282 underneath on side of intake camshaft.

Mount reworked special tool 11 4 281 on the intake camshaft.

Mount special tool 11 4 281 on the exhaust camshaft.
 4/29/2016 3/5

Important!
Only use special tool 11 4 280to loosen central bolts (1
and 2) of VANOS unit.

Release central bolts (1 and 2).

Release chain tensioner (1).

Tightening torque 11 31 7AZ.
Important!
Have a cleaning cloth ready. A small quantity of engine oil
will emerge after the screw connection has been released.
Make sure no engine oil runs onto belt drive.

Installation note:
Replace sealing ring.

Turn increment wheel (2) in direction of arrow until retaining

pins (1) on special tool 11 4 290 match up.
11 4 290Slide on special tool in direction of arrow.
 4/29/2016 4/5

Use bolts to fasten special tool 11 4 290.

Installation note:
Replace both central bolts.
Screw in both central bolts.
Release both central bolts 90°.

11 9 340Screw special tool into cylinder head.

Pretension timing chain with special tool11 9 340

00 9 2500,6 Nm

Use special tool 00 9 120 to tighten central bolts of intake

adjuster.
Tightening torque 11 36 1AZ.
 4/29/2016 5/5

Use special tool 00 9 120 to tighten central bolts of exhaust

camshaft adjuster.
Tightening torque 11 36 1AZ.

Remove all special tools.

Crank engine on the central bolt twice in the direction of engine
rotation and check the timing.
Assemble engine.
 4/30/2016 1/2

32 00 601 Adjusting toe-in on front axle

Important!
Changes in axle geometry caused by accidents must
under no circumstances be rectified by camber
adjustment!

Note:
Camber and toe-in influence each other. Adjust the toe-in first in
order to simplify the adjustment procedure.
The camber adjustment is performed only with the replacement
of the swivel bearing. There are various swivel bearings (+/ -
30') for this purpose.
-> See also Additional work for camber correction and BMW
Spare Parts Catalog!

Firstly align steering by means of markings on cap (1) and

steering gear (2).
Then bring steering wheel into straight-ahead position and
secure with steering wheel arrester.

Adjust toe-in:
Clean thread on track rod.
Loosen screw (2).
Turn tie rod (3) to adjust toe-in to setpoint value, if necessary
counterhold track rod end (1).
Tighten screw (2).
Tightening torque 32 21 2AZ.
If necessary, correct installation position of gaiter.
 4/30/2016 2/2

After Installation note:

 Check directional stability of car; if necessary, repeat toe-
in adjustment
 4/30/2016 1/1

34 11 280 Removing and installing/replacing front

left protective plate

Necessary preliminary tasks:

 Remove front brake discs.

Release screws (1) and remove brake guard plate (2).

Installation note:
Tightening torque 34 11 3AZ.
 4/30/2016 1/7

61 01 07 (629)

Automatic engine start-stop function

Automatic transmission, twin-clutch gearbox

Situation:
As a ”BMW EfficientDynamics” measure, the automatic engine start-stop function
(development code: Automatic Engine Start-Stop = MSA) helps to reduce fuel
consumption and CO2 emissions. The combustion engine is switched off and on
automatically under certain conditions.
Vehicles concerned: The automatic engine start-stop function in will be phased in as from 04/2010 in
connection with the twin-clutch gearbox in the M3 (E9x) and automatic transmission in the
F04.

Note:
The automatic engine start-stop function is also installed as standard on
these vehicles.
Procedure:
 4/30/2016 2/7

Index Explanation Index Explanation Index Explanation

1 Vehicle moving. 2 Gear selector switch in 3 Combustion

position "D". engine running.

Driver presses
accelerator pedal.

4 Vehicle is 5 Gear selector switch 6 Combustion engine

decelerated remains in position is switched off after 1
down to "D". second.
standstill.
Driver presses the Rev counter shows
brake pedal to “0”.
decelerate and bring
the vehicle to a
standstill.

7 The driver 8 Gear selector switch 9 Combustion engine

wishes to remains in position starts up.
resume the "D".
journey.
Driver takes foot off
brake pedal and then
 4/30/2016 3/7

presses the
accelerator pedal.

Prerequisites of an automatic engine shutdown

The automatic engine start-stop function will only stop or start the engine if certain prerequisites are met.

Engine shutdown

The engine is switched off when:

- The vehicle is stationary (speed < 0 kmh).

- The engine speed is virtually at idle speed.

- The vehicle has been driven at > 10 km/h since the engine was last shut down.

- The vehicle has been driven at 10 km/h since the last change at terminal 15.

- The brake is pressed.

- Steering wheel movement is not moved. Steering wheel must be aligned straight.
Engine start

The engine is started automatically when:

- Brake pedal is released or the accelerator pedal is pressed.

Note:
The aforementioned criteria apply only to the automatic engine start-stop function, in other words,
not if the engine has been switched off with the SST (START‐STOP button).

Switch-off inhibitors and switch-on prompts

Besides its main function of propelling the vehicle, the internal combustion engine has to provide other auxiliary
functions.

These auxiliary functions are necessary for maintaining operating safety and convenience functions and
complying with emissions requirements.

Certain prerequisites are therefore governed by switch-off inhibitors and switch-on prompts, either preventing
the engine from being shut down or prompting an engine restart.

Note:
The customer should be alerted to possible switch-on prompts (engine starts without customer's
intervention)!

Switch-off inhibitors

The engine continues running although the vehicle is at standstill and held with the brake pedal.
 4/30/2016 4/7

The following preconditions act as switch-off inhibitors and prevent the engine from shutting down:

- Engine adaptation (e.g. cylinder adjustment)

- Regeneration of the diesel particulate filter

- Carbon canister needs purging

- Insufficient knock resistance of fuel

- Engine fault

- Engine coolant temperature

- below a defined value (depending on engine version approx. 20 ‐ 60 °C)

- above a defined value (depending on engine version approx. 100 ‐ 130 °C)

- Automatic transmission not ready

- Gearbox adaptation active

- Drive position “S”, “M”, “N”, “R”

- Driving surface incline too great

- Assist system active (Active Cruise Control, Parking Assist, Hill Descent Control)

- Stop-and-go driving

- Last MSA stop was too long

- Air conditioning requirements:

- Automatic air conditioning: MAX AC button pressed

- Automatic air conditioning: Defrost button pressed (request to defrost the windscreen)

- Air conditioning system: high blower speed and low blower temperature, compressor button
pressed

- Air conditioning system: high blower speed and air distribution directed to windscreen, compressor
actuated

- Ambient temperature ≤ 3 °C

- Engine speed > 1200 rpm

- Battery condition:
 4/30/2016 5/7

- State of charge too low

- Measured battery state of charge not plausible

- Battery temperature too high (approx. 50 °C)

- Starting voltage drop from previous ASSF start too low

- Vehicle rolling
Hybrid cars:

- High voltage power management: Temperature too low or too high

- Load on vehicle electrical system too high

- High-voltage battery unit: State of charge too low or too high

- Hybrid system fault

Switch-on requesters

The following preconditions result in an engine start:

- Vehicle starting to roll

- Steering wheel turned

- Switching the drive position (to “S”, “M”, “N”, “R” with automatic transmission; "S", "D", "N", "R" with DKG;
"N", "R" with DKG M3 US version)

- Power management: State of battery charge too low, battery temperature too high, power requirement of
active electrical loads too high

- Air conditioning requirements ‐ cooling

- Partial vacuum in brakes not low enough

Hybrid cars:

- High voltage power management: Temperature too low or too high

- Load on vehicle electrical system too high

- High-voltage battery unit: State of charge too low or too high

- Hybrid system fault

Safety requirements

Following preconditions deactivate the automatic engine start-stop function:

 4/30/2016 6/7

- Engine compartment lid is raised.

- Driver leaves vehicle: Secured by door contact, seat belt buckle and brake pedal

- Vehicle towed away

- Ignition key is no longer detected

- MSA button

- Battery not learned (battery data may be lost after changing the battery, disconnecting the battery or
programming the engine control)
Note:
Renewed starting is always possible via the start/stop button.

Important!
Even if the seat belt is not fastened and the bonnet is open, the engine can still start if the
vehicle's speed exceeds 5 km/h.

ASSF button

Note:
No Start/Stop button is fitted in the F04. On this vehicle, the automatic engine start-stop function is
an integral part of the high voltage system.

New generation ASSF button:

The ASSF button (2) is arranged below the Start/Stop button.

The automatic engine start-stop function can be deactivated manually with the ASSF button (2). The automatic
engine start-stop function is activated with every terminal change (terminal 15 on) and with the engine
stationary or if the ASSF button (2) is pressed repeatedly.

ASSF button on the M3 (E9x):

 4/30/2016 7/7

On the M3, the ASSF button (1) is integrated in the centre console control panel (2).

Pressing the ASSF button:

ASSF button not pressed (1) ‐ LED off

ASSF button pressed (2) The Auto Start Stop function is

deactivated at the customer's request ‐ LED on.

The Auto Start Stop function is active each time the engine has been restarted.

Notes for Service department

The Auto Start Stop function will only operate in certain conditions.

The function includes an automatic feature that examines the safety and comfort-based conditions that govern
an engine start or engine stop.

Note:
In the event of customer queries, always check these prerequisites against the Checklist in Annex
1.

 
 4/30/2016 1/11

61 01 07 (335)

Automatic engine start-stop function

Manual gearbox

Situation:
As a ”BMW EfficientDynamics” measure, the automatic engine start-stop function
(development code: Automatic Engine Start-Stop = MSA) helps to reduce fuel
consumption and CO2 emissions. The drive unit is switched off when the car halts e.g. at
traffic lights, by engaging neutral and disengaging the clutch. To restart it, it is sufficient to
operate the clutch pedal.
Vehicles concerned: Phased-in as from March 2007 in manual gearbox vehicles.

Note:
The automatic engine start-stop function is installed as standard on these
vehicles.
Procedure: Functional sequence ASSF (automatic engine start-stop function)

Engine shutdown

The driver brakes the vehicle to a

standstill (e.g. at traffic lights).

The driver engages neutral and

releases the clutch.
 4/30/2016 2/11

The engine cuts out automatically.

The ”Start/Stop” symbol appears in the instrument panel (see ”Display concept”).

Engine start

The driver wishes to resume the

journey.

The driver presses the clutch pedal.

The engine starts.

A gear can be engaged and the

journey continued.

The ”Start/Stop” symbol in the

instrument panel goes out and the
time and temperature appear (see
”Display concept”).

Prerequisites for an automatic engine shutdown

 4/30/2016 3/11

The automatic engine start-stop function will only stop or start the engine if certain conditions are met.

Engine shutdown

The engine is switched off when:

- The vehicle is stationary (speed < 3 kph).

- The vehicle has been driven at > 5 km/h since the engine was last stopped.

- The vehicle has been driven at 5 km/h since the last change at terminal 15.

- The manual gearbox is in neutral.

- The clutch pedal is not pressed and the steering wheel not turned (steering wheel must be aligned
straight).

- The engine speed is virtually at idle speed.

Engine start (with action by the driver)

The engine can be restarted by the driver with the aid of the automatic engine start-stop function if the driver
actively intervenes by pressing the clutch pedal down fully (or pressing the START‐STOP button).

Following this action by the driver, the engine will only start if the gearbox or transmission is in the neutral
positon and the drive train is not engaged.

Engine start (without action by the driver)

Without active intervention by the driver it may be necessary for the engine to be started (See also ”Switch-on
prompts”)

The engine starts without any action on the driver's part if:

- The vehicle starts to roll (forwards or reverse).

- The brake pressure falls below a defined threshold value.

- The battery charge falls below a particular threshold value.

- The condensation sensor detects condensation on the windscreen (IHKA).

- With the air conditioning compressor switched on, the evaporator temperature rises above a particular
threshold value.
Note:
The aforementioned criteria apply only to the automatic engine start-stop function, in other words,
not if the engine has been switched off with the SST (START‐STOP button).

Switch-off inhibitors and switch-on prompts

Besides its main function of propelling the vehicle, the internal combustion engine has to provide other auxiliary
functions.
 4/30/2016 4/11

These auxiliary functions are necessary for maintaining operating safety and convenience functions and
complying with emissions requirements.

Certain conditions are therefore governed by switch-off inhibitors and switch-on prompts, either preventing the
engine from being stopped or prompting its restarting.

Note:
The customer should be alerted to possible switch-on prompts (engine starts without customer's
intervention)!

If for instance the evaporator temperature with the air conditioning is above a certain threshold value, this may
serve as a switch-off inhibitor or switch-on prompt.

Switch-off inhibitors

The engine continues to run even though the gear lever is in the idle position and the clutch pedal has been
fully released.

The following conditions act as switch-off inhibitors and prevent the engine from shutting down:

- Air conditioning requirements:

- Automatic air conditioning: MAX AC button pressed

- Automatic air conditioning: Defrost button pressed (request to defrost the windscreen)

- Air conditioning system: high blower speed and low blower temperature, compressor button
pressed

- Air conditioning system: high blower speed and air distribution directed to windscreen, compressor
actuated

- Ambient temperature ≤ 3 °C and with air conditioning activated > 30 °C

- Engine coolant temperature below a particular value (depending on engine version approx. 20 ‐ 50 °C)

- Carbon canister needs purging

- Engine speed > 900 rpm

- Battery condition:

- State of charge too low

- Measured battery state of charge not plausible

- Battery temperature too high (approx. 50 °C)

- Starting voltage drop from previous ASSF start too low

- Partial vacuum in brakes not low enough

 4/30/2016 5/11

- Steering wheel movements by the driver

- Vehicle rolling
Switch-on requesters

The switch-on prompt is regarded as an automatic engine start and depends on the following conditions:

- Battery condition ‐ battery charge too low

- Air conditioning requirements ‐ cooling

- Partial vacuum in brakes not low enough

- Vehicle starting to roll.

Special features of switch-off inhibiting and switch-on request

Battery condition and on-board power supply

The battery condition is a key factor influencing whether switch-off inhibiting and/or switch-on requests are set.
The battery condition is calculated in the APM (Advanced Power Management). This function is integrated into
the engine control (see energy management) and has been specifically extended for the automatic engine
start-stop function.

The aim is to permit reliable starting of the combustion engine after a defined immobilisation period, in terms of
the on-board power supply. Before the combustion engine is switched off, a reliable prediction of the minimum
usable, absolute residual capacity and the minimum voltage level in a subsequent hot start is made. The APM
calculates the condition of the electrical on-board power supply based on the battery condition.

If the battery's charge condition drops into the red zone after the engine has been switched off by the automatic
engine start-stop function, the automatic engine start-stop function starts the engine.

Air conditioning requirements (heating mode / air conditioning operation)

If the coolant temperature is well below the target outlet temperature (heating-up mode), this is treated as a
switch-off inhibitor. In the heating mode, the electric auxiliary water pump (N47) and electric main water pump
(N43) are activated upon an ASSF engine shutdown. This is prompted by the heating and air conditioning
controls via the bus system.

In the event of an ASSF engine shutdown, climatic comfort may be reduced (formation of humidity/odours)
because the air conditioning compressor is not running and consequently delivers no cooling power.

If the evaporator temperature rises above a threshold value during the ASSF engine shutdown when the air
conditioning is switched on, this is treated as a switch-on prompt and the engine starts automatically.

If the condensation sensor measures a value that suggests condensation, with the automatic air conditioning
switched on, the automatic engine start-stop function is suppressed (switch-off inhibiting). If this occurs during
an ASSF engine shutdown, a switch-on request is issued.

Insufficient braking pressure

To ensure that there is always sufficient braking effect (including when the engine is shut down), the partial
 4/30/2016 6/11

vacuum in the brake servo must always be monitored. If necessary, the engine is started automatically as soon
as the partial vacuum falls below 500 hPa during an ASSF engine stop.

Steering servo

The engine will not be switched off for as long as the steering wheel is being turned. Steering servo is always
assured. Only when the automatic engine start-stop function ceases to identify any movement of the steering
wheel via the steering column switch cluster can the engine be switched off. This information is provided via the
bus system.

Safety requirements

- Protection against automatic engine starting while working in the engine compartment:

If the bonnet is opened, the automatic engine start-stop function is deactivated to prevent an automatic
engine start while working in the engine compartment.

- Renewed starting is always possible via the start/stop button.

- The automatic engine start-stop function can be reactivated after the bonnet is closed and either the
engine has been started or a speed of > 5 km/h has been reached.

- Protection if the vehicle is left

If the driver leaves the vehicle, the automatic engine start-stop function is deactivated to prevent the
engine from starting automatically.

The driver's seat belt buckle is monitored to this end.

The automatic engine start-stop function is deactivated when the driver's seat belt buckle is released. An
ASSF engine shutdown is only permitted again once it has been identified that the driver's seat belt
buckle is fastened and either the engine has been restarted or a speed of > 5 km/h has been reached
once (only switch-off inhibitor).

The status of the seat belt buckle switch is indicated by the safety system via the bus system.
Important!
Even if the seat belt is not fastened and the bonnet is open, the engine can still start if the
vehicle's speed exceeds 5 km/h.

Protection when vehicle moving

An engine shutdown must never take place while the vehicle is moving. An engine shutdown is only possible at
a speed of less than 3 km/h.

There is also a protective feature to prevent an automatic engine start with the power transmission engaged. If
the drive train is engaged on a vehicle, an automatic engine start is prevented. The zero-position sensor in the
transmission monitors whether or not power transmission has been interrupted.

System-related deactivation of the automatic engine start-stop function

The Auto Start Stop function may also be deactivated for system-based reasons (the engine remains off). This
 4/30/2016 7/11

is indicated to the driver by a CC message in the dashboard when a start is requested. There may be the
following reasons for system-based deactivation:

- Set belt buckle signal

- Engine compartment lid contact switch

- Engine emergency running

- Implausible sensor or bus signals when vehicle tow-started.

- Ignition key is no longer detected (Comfort Access).

Note:
- Engine running and key taken out of vehicle ‐ no ASSF engine shutdown

- Engine in ASSF engine shutdown status and key taken out of vehicle ‐ no ASSF engine start

The engine can only be started by the driver pressing the start/stop button.

Deactivation via a safety function

If the Auto Start Stop function is deactivated by a safety function during an ASSF engine stop, the engine can
only be restarted via the start/stop button and from a speed of 5 km/h.

Deactivation by system fault (emergency-run concept)

If a fault is detected in the system network of the automatic engine start-stop function (signal inputs, bus signals
etc.), a switch-off inhibitor is set or the automatic engine start-stop function deactivated.

Fault recognition while the engine is running thus prevents any subsequent engine stops by the automatic
engine start-stop function. In the event of a fault recognition in an engine stopped by the automatic engine start-
stop function, a distinction is made between the following instances.

1. If safety-relevant faults are identified (fault in zero-position sensor, brake vacuum sensor, clutch sensor,
enable line, engine compartment lid contact switch or driver's seat belt buckle), the automatic engine
start-stop function is deactivated immediately and an automatic ASSF engine start is no longer permitted.

2. If other faults DME/DDE emergency operation, etc.) that are not safety-critical are identified, the next
ASSF engine start is still permitted. No further ASSF engine shutdowns are permitted.

3. The automatic engine start-stop function is disabled in the event of faulty bus communication with the
DME/DDE engine control.

Note:
If the automatic engine start-stop function is deactivated by a system fault, a CC message (ID397)
is flashed up in the instrument panel (see display concept).

Deactivation by external factors

If the seat belt buckle or bonnet are opened during an ASSF engine stop, the automatic engine start-stop
function is deactivated and an engine start is only possible with the Start/Stop button or from a speed of >
5 km/h. If the driver attempts to start the engine by pressing the clutch pedal, the CC message ID450 is flashed
 4/30/2016 8/11

up after 1 to 2 seconds (see "Display concept").

Deactivation by ASSF button

Note:
The graphic shows the pushbutton (1) still showing the development code MSA (Automatic Engine
Start-Stop).

For correct designation, see under ”Pressing the ASSF button”

The automatic engine start-stop function can be deactivated manually with the ASSF button (1). The automatic
engine start-stop function is activated with every terminal change (terminal 15 on) and with the engine
stationary or if the ASSF button (1) is pressed repeatedly. The signal from the ASSF button (1) is read in by the
IHKA and passed on to the engine control. The indicator light in the ASSF button (1) is actuated by the IHKA.

Pressing the ASSF button:

ASSF button not pressed (1) ‐ LED off

ASSF button pressed (2) (the automatic engine start-stop

function can be deactivated at the customer's request) ‐
LED on.
 4/30/2016 9/11

The automatic engine start-stop function is active each time the engine has been restarted.

Display concept

The following displays are used in conjunction with the automatic engine start-stop function:

If the engine can be started via the ASSF function, this

status is indicated permanently in the instrument panel.

If the customer wishes to display the temperature and

time, they can change over the display by pressing the
BC roller.

If there is a fault in the ASSF hardware that causes the

automatic engine start-stop function to be deactivated, a
CC message is displayed.

Text of CC message:”Automatic Start/Stop

failure” (ID397).

If the automatic engine start-stop function is deactivated

in order to assure operational reliability (”seat belt buckle
unfastened”), a further CC message is displayed as soon
as there is a switch-on prompt.

Text of CC message:”Automatic Start/Stop

failure” (ID450).

Notes for Service department

 4/30/2016 10/11

The automatic engine start-stop function will only operate under certain conditions.

The function includes an automatic feature that examines the safety and comfort-based conditions that govern
an engine start or engine shutdown.

Note:
In the event of customer queries, always check these conditions against the Checklist in Annex 1.

Important!
If the engine compartment lid contact switch is over-extended (workshop mode), the information
”switch closed” is given. The automatic engine start-stop function is active.

An automatic engine start is possible.

Terminal 15 is automatically switched off via the signal from the door contact by opening or closing
the driver's door with ASSF deactivated (e.g. ”seat belt unfastened”) and the driving lights
switched off.

Terminal 15 can be permanently switched on again by subsequently pressing the START-STOP

button.

Perform this process before the vehicle programming or diagnosis.

The automatic engine start-stop function is dependent on information from the energy management. In the
event of the battery being changed or after every flashing process, the reference data on the charge and quality
status of the battery may be lost. They will only be available again after a teach-in period of approx. 6 hours
(bus system must be in sleep mode). The automatic engine start-stop function cannot be activated during this
teach-in phase for reasons of reliability.

Faults stored in the ASSF system fundamentally result in the automatic engine start-stop function being
deactivated. Before renewing parts, always perform a functional check to exclude the possibility of a
malfunctioning sensor!

After working on vehicles with the automatic engine start-stop function involving one of the following actions,
the automatic engine start-stop function is switched off until the new standby current/battery parameters have
been learned.

In the following instances, the customer's attention should be drawn to the delay until the next ASSF engine
shutdown:

- After disconnecting the battery

- After programming the engine control (note exceptions).

Be sure to observe the safety precautions when working on vehicles with automatic engine start-stop function!
Before performing work on the engine, always make sure that the automatic engine start-stop function is
switched off to prevent an automatic engine start while working in the engine compartment!

The automatic engine start-stop function is deactivated by:

- ASSF button

- Seat belt buckle

 4/30/2016 11/11

- Engine emergency running

- Open the engine hood

In most test modules in which individual component functions and/or lines are checked rather than the
automatic engine start-stop function, the automatic engine start-stop function is switched off until the next
terminal change for reasons of safety. This takes place automatically, i.e. a job that temporarily deactivates the
automatic engine start-stop function is performed without the Service technician being able to influence events.

Important!
In the event of a fault in the seat belt buckle, engine compartment lid contact switch or ASSF
button, the automatic engine start-stop function is not deactivated automatically. This could
potentially result in the engine starting automatically while servicing work is being carried out in the
engine compartment.

Be sure to observe the safety precautions when working on vehicles with automatic engine start-
stop function!

To prevent an automatic engine start while working in the engine compartment, always make sure
that the automatic engine start-stop function is switched off via ”Deactivate ASSF button/release
seat belt buckle and bonnet”.

If it cannot be guaranteed that the automatic engine start-stop function is switched off, for reasons
of safety it is prohibited to continue working.
 4/29/2016 1/2

61 20 ... Battery replacement information

 

A vehicle battery is constructed for the installation location and the individual power requirements of the
particular vehicle. These individual power requirements depend on the motorisation and different types of
equipment. The individually assigned vehicle battery is the ideal compromise between the power
requirements of the vehicle electrical system and the weight and service life of the vehicle battery.

 

Vehicles with the automatic engine start-stop function or particular engine types and optional equipment are
equipped with a special vehicle battery (AGM battery), since only this battery type can provide elevated power
requirements over the extended service life. Installing a different vehicle battery can cause problems with
vehicle electronics, can reduce functions or can cause leakage of battery acid.

 

In the event of an accident where the airbags are deployed in vehicles with a vehicle battery in the luggage
compartment, the electrical connection between the vehicle battery and the trigger is automatically
disconnected through pyrotechnics. This prevents possible short-circuiting.

 

Proper operation of all of these safety and convenience functions requires a battery that conforms with
specifications and that is properly registered in vehicles with energy management systems (IBS, power
module).

 

Vehicles with energy management systems (IBS, power module): Register battery replacement

The vehicle electrical system is informed about the vehicle battery characteristic data, such as type, size, age
and current power capacity. Therefore, there will always be only one work scope provided that is permitted by
the current status of information.

If the performance readiness drops below a defined minimum, a Check Control message will be generated to
advise the driver that the battery must be replaced.

When installing a new vehicle battery, the battery must be registered and thus must also be registered with
the vehicle electrical system.

Note:

Only this registration/logon will ensure that the corresponding Check Control message will go out
again.
 4/29/2016 2/2

Diagnosis system:

Register battery replacement

 Service functions

 Body

 Voltage supply

 Register battery replacement

 

When retrofitting, a more powerful battery may be used. Standard batteries may always be replaced by AGM
batteries with the same specifications.

When installing a battery of a different size or a different battery type, this change in vehicle data must be
programmed into the vehicle data in accordance with specifications.

Programming system:

 Battery retrofitting
 4/30/2016 1/3

34 00 050 Bleeding brake system with DSC

Necessary preliminary tasks:

 Remove the left engine compartment cover.
 Read and comply with General Information.

Important!
When replacing or repairing, observe the filling and
bleeding instructions for the following parts:

- Tandem brake master cylinder

- Hydraulic unit

- Components and lines which are fitted between

these assemblies.
Connect bleeder unit with max. 2 bar filling pressure.
A second person is needed to help carry out this work.
Use only BMW-approved brake fluids, see BMW operating
fluids.

Important!
Check relevant equipment manufacturer's operating
instructions for each device.
Charging pressure should not exceed 2 bar.

Connect bleeder unit to expansion tank and switch on.

Connect ISID to the vehicle and select a brake bleeding

procedure.
 4/30/2016 2/3

Completely bleed the brake system.

Connect vent hose with collecting vessel to vent valve on rear
right brake caliper.
Open vent valve and purge until clear, bubble-free brake fluid
emerges.
Close vent valve.
Follow same procedure on rear left, front right and front left
wheel brake.

Bleed the rear axle brake circuit.

Connect vent hose with collecting vessel to vent valve on rear
right brake caliper.
Open vent valve.
Run bleeding procedure with ISID with vent valve open.
After completing routine, press brake pedal 5 times to floor;
clear and bubble-free brake fluid must flow out.
Close vent valve.
Repeat procedure at rear left.

Bleed front-axle brake circuit.

Connect vent hose with collecting vessel to vent valve on front
right brake caliper.
Open vent valve.
Run bleeding procedure with ISID with vent valve open.
After completing routine, press brake pedal 5 times to floor,
 4/30/2016 3/3

clear and bubble-free brake fluid must flow out.

Close vent valve.
Repeat procedure at front left.

Switch off bleeder unit and remove from expansion tank.

Check brake fluid level. If necessary, top up/draw off to "MAX"
level.
Close expansion tank.
Note:
Pay attention to gasket (1) in sealing cap.
 4/30/2016 1/1

41 00 ... Blind rivet

1.0 Recommended tools and equipment

- Blind riveting tongs

- Rivet head extension

Sourcing reference BMW Workshop equipment catalogue

Setting blind rivets:

- Refer to repair instructions for rivet size.

- Position bore holes for blind rivets in accordance with specification in repair instructions. If necessary,
carry over the positions of the blind rivets to the new part.

- Drill holes that exceed the outer diameter of the blind rivet (example ∅ 4.2 mm with 4 mm blind rivet and
∅ 6.8 mm with 6.5 mm blind rivet).

- Deburr bore holes.

- Apply adhesive.

- Insert blind rivet. If necessary, remove adhesive that has emerged.

Position blind rivet tool vertically. Use rivet head extension if accessibility is poor.

- Rivet blind rivet with blind rivet tool. In the meantime clean rivet head if dirty with adhesive. Risk of
damage to rivet head by penetrating adhesive.

- Seal blind rivet with sealantD1 (risk of corrosion).

- Seal cavities after work on vehicle paintwork on with cavity preservation (risk of corrosion).
 4/30/2016 1/2

41 00 ... Bonding steel on steel

Important!

These repair instructions apply to structural components.

Such components include engine supports, A-pillars, B-pillars, etc.

Follow the vehicle-specific repair instructions.

Only use the repair procedures described there.

Conform with safety regulations!

 

Overview of topics:

1. Equipment

2. Preparing the surface

3. Bonding coat

4. Hardening times

5. Subsequent treatment

 

1.0 Equipment

- Sandpaper

- Cleaning agent R1

- Adhesive K1

- Cartridge gun

 

2.0 Preparing the surface:

- For better adhesion, remove oxide film and paint from the adhesive areas with a stainless steel wire
 4/30/2016 2/2

brush or special sandpaper.

- Clean bonding surfaces with cleaning agent R1.

- Allow cleaned surfaces to dry for approx. 5 minutes.

Bonding surfaces must be completely dry.

 

3.0 Adhesive application:

- Processing temperature of glue cartridge 18 °C ‐ 30 °C.

- Object temperature, vehicle and new parts, min. 15°C.

- After applying the adhesive, check whether an adhesive component has emerged at the back of the
glue cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge. Contact
national hotline.

- Join components and secure in position.

- Remove excess adhesive. Do not use solvent cleaning agents.

 

4.0 Hardening times:

- Refer to Notes regarding adhesive K1

 

5.0 Subsequent treatment of bonding surfaces:

- Protect the repair area with cavity sealant.

 4/29/2016 1/4

61 13 ... Butt connector for repairing a plug

connection

Special tools required:

 61 0 300
 61 4 340
 61 0 240

Important!
1. Identify cause of damage (e.g. sharp-edged body
components, faulty electrical loads, jammed
mechanisms, corrosion caused by ingress of water,
etc.).
2. Read out fault memory
3. Eliminate cause of damage.
4. Disconnect battery negative terminal
5. Make sure that no safety-related system according
to circuit diagram (e.g. antilock braking system,
active rear-axle kinematics, airbags, etc.) are
influenced. Otherwise replace faulty wiring harness
or use repair cable (sourcing reference: BMW Parts
Department)
6. Carry out function test and read out fault memories
again
7. Eliminate new faults if applicable and clear fault
memories

Note:
The repair range IV for vehicle electrical system contained the
required special tools and individual parts for retrofitting and
repair work with the aid of fan connectors.
The case can no longer be ordered. Order individual parts for
wiring harness repair through BMW Parts Department.
 Refer to Service Information:
SI 02 04 07 341
 4/29/2016 2/4

Choose repair kit.

Example: Repair kit, circular connector system D 2.5.

Remove following parts:

(1) Pre-packaged end of cable with requisite wire cross-section
(2) Crimp connector for selected wire cross-section
(3) Shrink-fit hose

Open secondary lock on housing.

Mark damaged contact (4) with socket number of housing and
press it out of housing using appropriate special tool contained
in special tool set 61 0 300).
See repair instructions
Notes for opening contacts and locks of different plug contact
systems.

Important!
 Check maximum length of repair cable
 If more than one wire is to be repaired, the individual
interfaces must be offset so that the wiring harness
is not too thick at the repaired point.
 4/29/2016 3/4

Adhere to following procedure:

 Cut off wire with faulty contact at point which is easily
accessible
 Strip insulation from end of wire at wiring harness end
 Cut preassembled wire end to length and strip insulation
Refer also to repair instruction:
Cutting to length and stripping insulation from cables

Crimp butt connector on preassembled wire end.

Special tools:
 61 4 340 (0.35 - 2.5 sq mm)
 61 0 240 (4.0 - 6.0 sq mm)
See repair instructions
Crimping on stop parts

Push shrink-fit hose (8) onto free wire end.

Crimp unused wire end to butt connector.

 4/29/2016 4/4

Pull shrink-on sleeve over butt connector.

Important!
Do not burn shrink-on sleeve.

With hot air blower, shrink the shrink-on sleeve on both sides
(9) of shrink-fit hose until glue emerges uniformly all round.
Insert contact in housing.
Close secondary lock on housing.
 4/30/2016 1/1

66 53 013 Calibrating reversing camera

Note:
Calibration of reversing camera must be carried out after the
following work:
 Removal and installation/replacement of reversing
camera
 Body repair work at rear end of vehicle

Important!
Follow instructions and specifications in procedure.
To obtain an optimum result, always adhere to the
following conditions:
 Vehicle standing level on headlight aiming station
 Rear seat bench is unoccupied
 Do not swap seats during calibration
 Steering wheel in straight-ahead position
 Do not move steering wheel

Note:
Also switch on reversing camera by means of PDC button.
 
Calibration can only be carried out with the BMW diagnosis
system.
Use of a special tool is no longer required from 03/2011!
 
Service functions:
 Complete vehicle
 Body
 Camera systems
 4/30/2016 1/3

51 16 ... Calibrating the compass on the inside

mirror

Note:
It may be necessary to alter the magnetic deflection zone if the
vehicle is more than two ranges away from the set deflection
zone.
For numbers of magnetic deflection zone, refer to operating
instructions.

It may be necessary to calibrate the compass if:

- ”C” appears in compass display

- there is no compass display

- not all compass directions are displayed correctly

 
Different time-based adjustment menus can be obtained by
means of the control button:

- 0 to 3 seconds: Display ON/OFF

- 3 to 6 seconds: Adjustment of the magnetic field zones (0

-15)

- 6 to 9 seconds: Calibration (C)

- 9 to 12 seconds: Right-hand drive or left-hand drive

vehicles (R or L)

- 12 to 15 seconds: English or German (E or O)

 
For further information, see System description.

Adjusting magnetic field zone:

- Press and hold down control button (A) on inside mirror

(2) with a suitable tool (1) for 3‐-6 seconds. The currently
set magnetic field zone is indicated in the compass
display (B) (default setting ”8” for Central Europe).
Release control button (A) briefly and select magnetic
field zone (1-15) by pressing control button (A) again.
Release setting button (A) when the desired magnetic
 4/30/2016 2/3

field zone is selected. The selection menu is automatically

exited after approx. 5 seconds.

- The compass must be recalibrated after the magnetic

field zone has been changed.

Calibrating compass:

- Press and hold down setting button (A) on inside

mirror (2) for 6‐9 seconds. Release setting button (A) as
soon as ”C” is indicated in the compass display (B).

- Drive vehicle 2 to -3 times in a full circle at approx. 7-

10 km/h. The circle must be at least twice the vehicle's
turning circle. Calibration is complete as soon as a valid
direction is displayed.

- For convertibles and vehicles with hardtops only:

The digital compass must be calibrated once with the soft
top or hardtop closed and once with the soft top or
hardtop open.

Setting right-hand drive or left-hand drive vehicle:

- Press and hold down control button (A) on inside

mirror (2) for 9‐12 seconds. The currently set vehicle type
is indicated in the compass display (B) (default setting "L"
for left-hand drive vehicle). Release setting button (A)
briefly and select vehicle ("L" or "R") by pressing setting
button (A) again. Release setting button (A) when the
desired vehicle type is selected. The selection menu is
automatically exited after approx. 5 seconds.

- The compass must be recalibrated after the right/left hand

drive vehicle setting is made..

Setting language of compass display:

 4/30/2016 3/3

- Press and hold down control button (A) on inside

mirror (2) for 12‐-15 seconds. The currently set language
is indicated in the compass display (B) (default setting ”E”
for English). Release setting button (A) briefly and select
language (E for English or O for German) by pressing
setting button (A) again. Release setting button (A) when
the desired language is selected. The selection menu is
automatically exited after approx. 5 seconds.
 4/29/2016 1/2

16 01 99 (455)

Carbon canister blocked

E38/E39, all except diesel

Complaint:
- When driving, distracting noises such as rumbling and cracking may come from the area
of the fuel tank.
- Loud suction noises may occur when the tank lock is opened.
- The fuel supply may fail if the fuel pump is damaged due to contact with the fuel tank.
Cause: Due to extreme ambient conditions (smog, high air humidity, etc.), the carbon canister
may block up. This will impair the ventilation of the fuel tank and so will lead to the
development of a vacuum in the fuel tank. These issues are interlinked and will cause the
stated complaints.
Affected vehicles: E38/E39, all except diesel Production period: Series introduction up to 09/99

Procedure: In the event of a complaint, install an carbon canister with a modified filter fleece. Due to
the modified pore size, this filter fleece will prevent the carbon canister from becoming
blocked.

Replacement of the carbon canister see Repair instructions 16 12 010.

In series production, the carbon canister will be installed with the modified filter fleece from
09/99.
Parts:

Designation Part number

1 x carbon canister (with modified 16 13 6 752 623

filter fleece)
Reimbursement: Material and labour costs incurred can be claimed through the usual warranty channels
subject to current warranty terms.

Defect code 16 13 90 14 00
This defect code is not contained in the official defect code
catalogue but has been included in the system,

Install carbon canister with modified filter fleece:

Job number
16 12 010

Flat rate units E38/E39 without self-levelling

suspension: 5 FRUs
E38 with self-levelling suspension: 9
FRUs
Warranty type 1
 4/29/2016 2/2

Warranty stage 1 (within vehicle warranty) 2 (outside

vehicle warranty)
Invoicing is limited to 36 months/100,000 km and expires in June
2001 .
 4/30/2016 1/1

37 12 012 Carry out ride height adjustment

Note:
Ride height adjustment must be carried out after the following
work:
 Removal/replacement of ride height sensor or its control
rod (only necessary on vehicles with air suspension)
 Replacement of EHC control unit
(F01/F02/F04/F07/F11/F15/F16)
 Replacement of ICM control unit (Integrated Chassis
Management)

Connect diagnosis system.

Switch the ignition on.
Carry out ride height adjustment (menu item: ”Service
function”).
Important!
Following ride height adjustment, for vehicles with:

- Run Flat Indicator:

initialise Run Flat Indicator

- Tyre Pressure Monitor: Resetting Tyre Pressure

Monitor
 4/29/2016 1/4

REP-REP-RAF010-0000337   CBS reset

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

00 00 ... CBS reset

Important!
The CBS maintenance jobs can be reset in the car. It is
always recommended to reset the CBS jobs via the
diagnosis system. It is only possible to code the statutory
intervals specific to individual countries with the diagnosis
system.

CBS reset with diagnosis system

Important!
To be able to check and/or correct the car's on-board date
properly, the diagnosis system requires the correctly set
tester system date!
The jobs may only be reset after the service measure has
been completed.
The brake pads can only be reset with a new brake pad
wear sensor.

The CBS jobs can be reset via the diagnosis system on the
following path:
 Start diagnosis
 Carry out vehicle identification
 Function selection
 Service functions
 Maintenance
 4/29/2016 2/4

 CBS reset

CBS reset in the car

On the vehicle, service operations can be reset at the
instrument panel.
Note:
A reset is only possible in the car if:
 there is no Check Control message
 availability of the service job is under 90 %
 on-board date must be correctly set
Resetting of a service job must always be carried out after a
maintenance measure has been completed.
The resetting process is interrupted it the time is exceeded or if
a terminal is changed.

Important!
If engine oil and vehicle check are reset at the same time,
always reset engine oil first.

Switch the ignition on.

Press the trip distance recorder reset button (1) (referred to as
button in the following) for approx. 10 seconds until the 1st
service job appears in the display (2).
Bring up the next item by briefly pressing the button again.
Select the desired service job.

If a reset is possible, this is displayed in the instrument panel as

”Reset executable” (1).
 4/29/2016 3/4

Start the reset by pressing the button for 3 seconds.

Confirm text message ”Execute reset?” (1) by pressing the

button for 3 seconds again.

The status of the reset is indicated in the display by a progress

bar and in text as ”Reset running” (1).

The reset is confirmed after completion as ”Reset

successful” (1).
 4/29/2016 4/4

CBS reset of inspections/tests required by law

Input the target for the inspections/test required by law (§
vehicle / § emissions) by clicking on the job with the controller in
the CBS menu of the Control Display at:
 Press controller to call up  i  menu
  Select Info sources and press controller
  Select Service and press controller
  Select Service requirements and press controller
  Select Stat. vehicle insp. and press controller
  Select Status and press controller
  Select Schedule date for service and press controller
 The target month or the target year can be set and
acknowledged by turning and pressing
 4/30/2016 1/2

65 07 97 (247)

CD changer: Malfunction

All models with CD changer

Situation:
Despite intensive supplier checks, no malfunction can be found with a large number of CD
changers returned under warranty.

These CD changers are often returned without the CD magazine and in an unsuitable
transport condition while bearing the label ”Failed”. This generally results in the CD
changer being classified as kFg (no fault found) and returned to the dealer. The warranty
claim is rejected.

Important notes for CD changers in the vehicle:

- As opposed to CD changers in the home, mobile CD changers are subjected to an

extremely wide range of different influences.

The mechanics must be spring-mounted, which (depending on the manufacturer) is

provided by a rubber damper with an air reservoir or an oil damper. For this reason
the transportation retainers must always be removed before installing the CD
changer.

- The CD changer can hold and properly position 12 cm standard CDs. Please note
that the CDs must not be too thick as well as deburred around the central hole or
outer edge.

- Transparent CDs and CDs with asymmetrical dimensions can no longer be reliably
detected and positioned by the laser beams in the CD changer. Asymmetric CDs
cause the CD magazine to jam in the CD changer. The magazine can no longer be
removed from the changer.

- Ensure the spring suspension is set correctly for replacement units. Depending on
the installation position, set the ”installation position” on the CD changer to
horizontal or vertical. On the E36 Compact, set the ”installation position” on the CD
changer to 45°.

- The magazine compartment must be closed at all times to prevent dust and other
contaminants from entering the CD changer and impairing the system function.

- Ensure all CDs are clean to avoid soiling the laser and impairing the CD changer
function.

- No guarantee is given that CDs burned at home will be played. The quality of the
audio playback depends on the quality of the blank CD, the CD burner and
parameters selected when burning the CD.
 4/30/2016 2/2

- The CD changer is not suitable for rewritable CDs (called CD-RWs).

Affectedvehicles: All BMW models with CD changer (optional equipment 672)

Procedure: In the event of a customer complaint, always diagnose the exact cause of the failure
before replacing the CD changer.

As the fault cause may be a faulty CD magazine or caused by faulty CDs/homemade

CDs, always test the system with a new CD magazine and different CDs to see if the
customer complaint is reproduced.

Note for obligatory return markets:

For the warranty parts inspection, it is absolutely mandatory that the CD changer is always
returned together with the customer's original CD magazine and the device connecting
lines. The CD changer must be fitted with transportation retainers when returned: A CD
changer without any form of transportation retainer may be damaged during transport.

Please return the CD changer in the original packaging of the replacement CD changer.

CD changers without a CD magazine and transportation retainer will be returned

immediately by the Warranty Parts Centre (GWTZ) and the warranty application will be
rejected.

Furthermore, ensure that each CD changer or CD magazine returned is accompanied by

the blue complaint and repair documentation completed in full(part number: 01 30 9 789
549).The number of CDs in the changer must also be recorded in the repair
documentation.
 4/30/2016 1/1

33 02 95 (007)

Changeover of differential oils

All models with optional equipment 209

Situation:
A new oil for all differentials with a limited-slip differential (optional equipment 209) has
been approved for the launch of the Z3 Roadster. The new oil is called “BMW synthetic
final drive oil MSP/A” and will replace “BMW final drive oil MSP”.
Effect: The MSP oil must not be filled into the Z3 Roadster with limited-slip differential under any
circumstances. For such cases, MSP/A is mandatory, because an incorrect filling will lead
to creaking noises when driving.
Procedure: The rear axle final drives must be filled with the specified oils.

The MSP oil that is available in the dealer organisation can be used up in all models other
than the Z3 Roadster.
Parts: Hypoid oils for differentials with a disc self-locking differential

- BMW synthetic final drive oil MSP/A

55-l container 83 22 9 407 870

205-l container 83 22 9 407 871

- Castrol SAF-XJ
- Veedol SAF 44
 4/30/2016 1/2

72 01 96 (083)

Check accessories kit

All models

Situation:
Since February 1996, a cross-department standardisation programme has been in force
for the small parts previously supplied loose in the vehicle accessory packs.

The small parts are now wrapped in a clear plastic cover and stored in the luggage
compartment.

The vehicle key is also wrapped in a clear plastic cover in the glove compartment.

The door/ignition key (master key) is secured by the wiper switch.

The composition of the accessories kit depends on the level of equipment fitted to the
vehicle and is stored in the vehicle as follows:

1. In the luggage compartment, wrapped in a clear plastic cover:

- Torch
- Aerial rod for radio
- Aerial rod for telephone
- Cigarette lighter
- Magazine for CD changer
- Magazine with CD for navigation system
- Number plate mount
- Leather wallet
- Remote key for auxiliary heater
- On-board literature (Owner's Handbook, Supplementary Owner's Handbook, Radio
Operating Instructions, Service Booklet, Dealer Index)
- Bumper cover with lashing eyes fitted
- Luggage compartment wall plugs for optional equipment 818 without through-loading
system
- Spark plugs for M models
- Vehicle hoist securing point E36 (optional)
2. In luggage compartment, loose:

- Wiper blades for driver and front passenger side, only for vehicles destined for
overseas with disposable wiper blades
- Hubcaps
- Floor mats
- Footrest, US version only
- Rear footrests
 4/30/2016 2/2

- Removable trailer tow hitch head

- Vehicle hoist securing point (national-market version 807, 810, 812 and 838 in
additional clear plastic cover)
3. In the spare wheel recess:

- Adapter for wheel stud cover

- Vehicle hoist securing point E36 (optional)
Procedure: The accessories pack in each vehicle received must be checked for the contents listed
above. The clear plastic cover for the parts listed under Points 1 and 2 must be
undamaged.

Note:
Damaged or missing parts from the accessories pack are claimed from the
insurance or billed to the shipping company responsible. The shipping
company is only liable for missing parts if the clear plastic cover is ripped
open.
 4/29/2016 1/3

13 31 029 Check fuel delivery pressure

(N20,N26 ,N55 )

Special tools required:

 13 5 270
 11 4 310
 11 5 364
 13 3 060

Important!
Lines are under pressure!

Wear safety goggles and gloves.

Fuel can emerge spontaneously at high velocity when the fuel
line is released!

Recycling:
Catch and dispose of escaping fuel with auxiliary
materials.
Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

 Connect BMW diagnosis system
 Remove rear underbody protection.
 4/29/2016 2/3

Unscrew nuts (1).

Remove guard plate (2).
Release fuel lines from protective plate.
Disconnect fuel delivery line.
Catch and dispose of escaping fuel in a suitable container.
Installation note:
Ensure the fuel delivery line is installed correctly (no chafing
points).
Make sure retaining tabs latch correctly.

Unscrew adapter (1) from special tool 13 5 270.

Insert special tool 13 5 270 into disconnected fuel line.

Screw onto special tool 13 5 270, the special tool 11 4 310.
Screw IMIB 100 bar pressure sensor (1) on the special tool
11 4 310.
Note:
 4/29/2016 3/3

As an alternative to the 100 bar IMIB pressure sensor (1), the

25 bar pressure sensor can also be used. For this, screw on
special tool 11 5 364 instead of special tool 11 4 310 onto
special tool 13 5 270. Or directly screw the pressure
manometer from the set of special tools 13 3 060 onto the
special tool 13 5 270.

Establish fuel delivery pressure. Read off fuel delivery pressure

on IMIB and compare with values in diagnosis system.

Assemble engine.
Check fuel system for tightness.
 4/29/2016 1/5

13 31 032 Check fuel pressure

Special tools required:

 13 0 290
 13 3 060
 11 4 310
 13 0 291
 13 0 292
 13 0 293

Necessary preliminary work:

 Connect BMW diagnosis system.

Important!
Lines are under pressure!

Wear protective goggles and gloves.

Fuel can emerge spontaneously at high velocity when the fuel
line is released!

Recycling:
Catch and dispose of escaping fuel with auxiliary
materials.
Observe country-specific waste disposal regulations.
 4/29/2016 2/5

Check fuel delivery pressure:

To check the fuel delivery pressure, special
tool 13 0 290 must be assembled as follows.
Screw adapter 11 4 310 onto line 13 0 291.
Screw the IMIB 100 bar pressure sensor (1)
onto adapter 11 4 310.
Alternatively, the pressure gauge from the set
of special tools 13 3 060 can be screwed onto
line 13 0 291.
 4/29/2016 3/5

Between lines 13 0 291 and 13 0 292, mount

a shutoff tap (2) and a T-piece (3) from the set
of special tools 13 3 060.
Close up T-piece (3) from the set of special
tools with the cap 13 0 293.

Note:
The graphic shows F07 The procedure is identical for other
vehicles.
Remove circlip (1).
Unlock and detach fuel line (2) to fuel tank from fuel line (2) to
high pressure pump.

Install special tool (1) 13 0 290 into detached fuel line with IMIB
fuel pressure sensor (100 bar).
Connect IMIB with fuel pressure sensor.
Establish fuel delivery pressure. Read off fuel delivery pressure
on IMIB and compare with values in diagnosis system.
 4/29/2016 4/5

Check fuel holding pressure:

To check the fuel holding pressure, special
tool 13 0 290 must be assembled as follows.
Screw adapter 11 4 310 onto line 13 0 291.
Screw the IMIB 100 bar pressure sensor (1)
onto adapter 11 4 310.
Alternatively, the pressure gauge from the set
of special tools 13 3 060 can be screwed onto
line 13 0 291.
Between lines 13 0 291 and 13 0 292, mount
a shutoff tap (2) and a T-piece (3) from the set
of special tools 13 3 060.
Mount pressure gauge (4) from special tool
set 13 3 060 onto T-piece (3) from special tool
set 13 3 060.

Note:
The graphic shows F07 The procedure is identical for other
vehicles.
Remove circlip (1).
Unlock and detach fuel line (2) to fuel tank from fuel line (2) to
 4/29/2016 5/5

high pressure pump.

Install special tool (1) 13 0 290 with pressure gauge (2) and

IMIB 100 bar fuel pressure sensor (3) into the detached fuel
line.
Establish fuel delivery pressure.
Close shutoff tap (4) and switch off the engine.
Read off fuel holding pressure of high pressure pump from IMIB
tester and compare with values in diagnosis system.
Read off fuel holding pressure to fuel tank on pressure
gauge (2) and compare with values in diagnosis system.

Assemble engine.
Check fuel system for leak tightness.
 4/29/2016 1/1

00 00 ... Check horn, headlight flashers and hazard warning flashers

 

Horn

Check function.

 

Note:

In the case of twin-tone fanfares, make sure that both fanfares are working properly.

 

Headlight flasher

Activate headlight flashers, check high-beam headlights and blue indicator light in instrument panel for correct
operation.

 

Hazard warning lights

Check function.

 

Note:

After consultation with the customer, rectify faults and issue a separate invoice.
 4/30/2016 1/5

72 11 ... Checking automatic seat belt

General considerations when checking seat belts:

The seat belts must be checked after an accident.

For the check, you should start by trying to get information on which seats in the vehicle involved in the
accident were occupied. If this is not possible, check all the seat belts in the vehicle and replace them if
necessary.

In the event of deformations on the vehicle, you must subject the components of the restraint system affected
in this area such as e.g.

- Seat Belts

- Anchor fitting tensioner

- Seat belt height adjustment

- Belt buckle tensioner

- Triggering sensors

- etc.

to a function check and a visual inspection.

If you are in any doubt as to the unimpaired operability of restraint system components, these components
must be replaced in the interests of safety!

If a seat belt has to be replaced following an accident (e.g. in the event of a frontal and/or oblique collision
with permanently deformed impact absorbers/deformation elements or cross-members), the complete seat
belt must be replaced! The complete seat belt comprises:

- Upper seat belt

- Lower strap

- Anchor fitting tensioner

- Seat belt buckle (buckle tensioner)

- Seat belt height adjustment

- Mounting bolts of all components

 4/30/2016 2/5

The following must also be checked and if necessary replaced:

- seatbelt mounts on the vehicle body

- Seatbelt mounts on the seat

- seat rails.

- Seat structure (frame, etc.)

Alignment tests on the seat and the seat rails are not permitted!

The following explanations and the checklist for the automatic seat belt can provide help.

An unusable seat belt or a seat belt worn in a serious accident should be destroyed immediately after removal
to guarantee that it can not be used again.

Checking automatic reel and seat belt strap:

The automatic reel has two independent activation systems for seat-belt locking.

The first activation system locks the automatic reel when driving quickly around curves, driving in tight curves,
on extreme inclinations (vehicle rolls over) and during sharp braking or crash.

To check, the seat backrest must be placed in the upright position and both hands held in a supporting
position close to the steering wheel. The brakes are then operated with full intensity while driving on a dry
roadway and at double walking speed.

The seat belt must lock.

The second activation system provides additional safety and is controlled by inertia mass.

If the reel locks when the seat belt strap is pulled out suddenly, this system is also OK.

In addition, the automatic electric reel (EMA) must eliminate belt slack.

Check whether an attempt was made to eliminate belt slack:

- Enter, close doors and latch seat belt buckle contact, left

- EMA eliminates belt slack

If belt slack was not eliminated, the procedure described below must be followed:

- Allow vehicle to assume complete sleep mode and repeat the functional check.
 4/30/2016 3/5

- All doors must be closed!

- EMA, left, must be installed and connected correctly.

- Work through all fault entries before the functional check is carried out again.

Replace defective or actuated automatic electric reels.

Automatic reel does not require servicing and must not be opened.

Precondition for complete, problem-free retraction of seat belt straps:

- the straps must not be twisted!

- the straps must not be damaged!

When placed to one side, the seat belt straps of the front seats must retract fully.

With the seat belt straps in the rear seat bench, a small remaining loop is acceptable due to increased friction
between the strap and the rear seat bench cover if:

- this remaining loop is fully retracted when the seat belt strap is reguided.

Seat belt strap should only be cleaned with a lukewarm soap solution or a commercial mild detergent.

Seat belt strap must never be cleaned chemically or dyed.

The automatic reel and seat belt strap must be replaced in the event of:

1. creasing

2. unravelling

3. pinches

4. cracks and tears

5. traces of melting

6. traces of wear on coating of buckle tongue or on seat belt guide loop.

Checking lower strap (belt buckle tensioner):

To fasten a seat belt, the buckle tongue should insert easily and with a loud click in the lock.

When the ”Red button” is pressed, the buckle tongue must be ejected from the lock under spring pressure.
 4/30/2016 4/5

If the seat belt buckle cover is missing or damaged, the lower strap must be replaced.

Replace the triggered belt buckle tensioner including the complete seat belt with seat belt height adjustment
and mounting bolts and check the

- seatbelt mounts on the vehicle body

- Seatbelt mounts on the seat

- seat rails.

- Seat structure

Criteria for a triggered mechanical belt buckle tensioner:

- very low position of seat belt buckle (comparisons with new part).

Criteria for a triggered pyrotechnical belt buckle tensioner:

- very low position of seat belt buckle (comparisons with new part).

- Airbag indicator light permanently lit: read out airbag system fault memory.

The belt buckle tensioners can be triggered under certain circumstances even when the seat is not occupied.
If it is definite that the seat belt system was not used (seat was not occupied), there is no need to replace the

- upper strap

- Add-on parts (seat belt height adjustment, screws)

- seatbelt mounts on the vehicle body

- Seatbelt mounts on the seat

- seat rails.

after a check.

Checking end fitting pretensioner:

Replace the triggered end fitting pretensioner including the complete seat belt with seat belt height
adjustment, lower strap and mounting bolts and check the

- seatbelt mounts on the vehicle body

 4/30/2016 5/5

- Seatbelt mounts on the seat

- seat rails.

- Seat structure

Criteria for a triggered end fitting pretensioner:

- A triggered end fitting pretensioner can be recognised from the wrapped seat belt strap around the
shaft.

- Airbag indicator light permanently lit: read out airbag system fault memory.
 4/30/2016 1/1

34 00 009 Checking brakes on test stand

Necessary preliminary tasks:

 Check tyres for damage
 Check tyre treads
 Checking tyre pressure

Important!
The corresponding system must be deactivated on
vehicles equipped with DSC.
The DSC indicator and warning light in the dashboard
must light up!

The brakes must be at normal operating temperature. To do so,

gently warm up the brake discs and brake drums while dry by
braking the vehicle several times.

Important!
Only brake test stands with test speeds of 2.5-6 km/h may
be used.
Maximum brake bedding-in time 2 min.
You must observe the regulation contained in the
operating instructions of the relevant test stand
manufacturer.
Failure to do so may result in damage to the vehicle and
the system and also personal injury.
 4/29/2016 1/5

11 31 005 Checking camshaft timing (N55)

Special tools required:

 11 0 300
 11 4 281
 11 4 282
 11 4 285

Important!
When the engine is shut down, the intake and exhaust
camshaft adjusters are normally locked in their initial
setting. In order to avoid incorrect timing adjustment, it is
essential to check the locking of the camshaft adjuster and
if necessary perform locking by rotating the camshafts.

Important!
For the positioning of the special tool11 4 281 on the
mounting flats of the intake camshaft, a collision with the
cylinder throttle return spring 1 can occur.
Special tool 11 4 281 reconditions at following description.

Check for freedom of movement of throttle return spring at

intermediate lever cylinder 1.
Recondition special tool 11 4 281.
Rework chamfer on special tool 11 4 281 as shown in the range
 4/29/2016 2/5

of 50 millimetres long and 8.5 millimetres wide.

Recondition chamfer on special tool 11 4 281 to 8.5 millimetres

(see picture).

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove underbody protection.

Remove fastener (1) in direction of arrow.

Installation note:
Install fastener (1) with bore facing outwards.
 4/29/2016 3/5

Rotate crankshaft at central bolt into TDC setting.

Slide special tool 11 0 300 in direction of arrow into dowel hole
and secure crankshaft.
Important!
If the flywheel is secured in the correct dowel hole with
special tool 11 0 300, the engine can no longer be moved
at the central bolt.

Note:
Vehicles with automatic transmission can only be secured to
the specified position on flywheel (1) (see arrow).

With 1st cylinder in TDC firing position, cams of intake

camshaft (1) point upward at an angle.
 4/29/2016 4/5

With 1st cylinder in TDC firing position, cams of the exhaust

camshaft (1) point upwards at an angle.

The timings are correct when the part numbers or read code (1)
and the intake and exhaust camshafts point upwards.

Secure special tool 11 4 285 with bolts (1) to cylinder head.

Note:
Fit special tool 11 4 282 underneath on side of intake camshaft.

Mount reworked special tool 11 4 281 on the intake camshaft.

Mount special tool 11 4 281 on the exhaust camshaft.
 4/29/2016 5/5

If necessary, adjust valve timing.

Assemble engine.
 4/29/2016 1/3

11 00 039 Checking compression of all cylinders

(N55)

Special tools required:

 11 0 222
 11 0 224
 11 8 731
 11 8 732

Important!
High tension - mortal danger!
Interrupt voltage supply to ignition coils.
Read and comply with notes on compression pressure
check.

Necessary preliminary tasks:

 Remove spark plugs.

Unscrew tip (1) from special tool 11 0 222.

Important!
Then check the Schrader valve that is now visible for
secure seating.
 4/29/2016 2/3

Prepare special tool 11 0 222 in conjunction with 11 8 732

and 11 8 731.

Screw special tool 11 0 222 into special tool 11 8 731 to 10 Nm.

Important!
Oil thread on special tool 11 8 731.

Screw special tool 11 0 222 by hand into spark plug thread and

connect special tool 11 0 224.
Depress accelerator pedal and actuate starter until
compression pressure stops rising.
 Nominal values, compression pressure
 4/29/2016 3/3

Assemble engine.
Delete fault memory.
 4/29/2016 1/3

17 00 009 Checking cooling system for

watertightness (N47 D16/20 K/U/O/T 1,
N57 D30 O/T 1, N55)

Special tools required:

 00 2 030
 17 0 100

Warning!
Risk of scalding!
Only perform this repair work after engine has cooled
down.

Protective measures/rules of conduct:

 Wear safety goggles
 Wear protective gloves
 Observe national/country-specific regulations

Important!
Risk of skidding due to coolant on the floor.
Danger of injury!
 4/29/2016 2/3

Catch and dispose of drained coolant in drip tray (1) and if

necessary special tool 00 2 030 (universal hydraulic lifting
equipment).
Recycling:
Observe country-specific waste disposal regulations.

Checking pressure drop in cooling system:

Open the sealing cap on the coolant expansion tank. Mount
special tool 17 0 101 / 17 0113 from special tool set 17 0 100.
Generate excess pressure and wait approx. 2 min.
Cooling system is impervious to watertightness if pressure drop
is max. 0.1 bar.

Checking pressure relief valve in sealing cap:

Note:
While the driving at high ambient temperatures, the design may
cause the pressure relief valve in the sealing cap to open
slightly and air together with dissolved coolant to escape. This
coolant vapour condenses on the surface of the expansion tank
and leaves toes when the vehicle has cooled down. These toes
do not indicate whether the sealing cap is defective or not. With
vehicle standstill for an extended period of time, the residual
escaping coolant can cause the pressure relief valve in the
sealing cap to stick; therefore test procedure the sealing cap
again 2 to 3 times.
Replace the sealing cap only after you have checked three
times and there is an incorrect opening pressure.

Checking pressure relief valve in sealing cap:

Screw sealing cap (1) onto special tool 17 0 114  from the
 4/29/2016 3/3

special tool set 17 0 100.

Build up pressure with special tool (hand pump) 17 0 101;
observe pressure gauge to ascertain when opening pressure is
achieved.
Compare opening pressure of pressure relief valve.
 4/29/2016 1/3

11 12 729 Checking cylinder head for water leaks

(N55)

Special tools required:

 11 4 342
 11 4 344
 11 7 191

Important!
Pressure-test cylinder head to max. 3 bar.
Heat cylinder head to 60 °.
Check for bubble formation in a water bath.

Necessary preliminary tasks:

 Remove cylinder head.
 Disassemble cylinder head.

Fit special tool 11 7 191.

Installation note:
Secure special tool to 15 Newton metres.
 4/29/2016 2/3

Fit special tool 11 4 342 with screws (1). Screw in knurled

screw in direction of arrow.
Sealing flange must rest flat.

Secure special tool 11 4 344 with bolts (1).

Note:
Compressed air at valve max. 3 bar.
Heat cylinder head to 60 °.
Check for bubble formation in a water bath.

Assemble engine.
4/29/2016 3/3
 4/29/2016 1/5

11 40 000 Checking engine oil pressure (N55)

Special tools required:

 11 6 410
 11 9 240
 11 9 250
 13 6 051
 2 212 823
 11 4 310

Important!
The regulated oil pump can only be checked and
measured with the diagnosis system.
Vehicles with a regulated oil pump have a hydraulic valve
fitted.
Diagnosis path:

- DME Digital Motor Electronics

- Complete vehicle

- Power train

- Engine electronics

- Engine oil

- Oil-pressure control

Special tool 11 9 250 must be converted for N55

Necessary preliminary tasks:

 Connect BMW diagnosis system to vehicle.
 Observe diagnosis instructions.
 Protect drive belt against dirt
 Have a cleaning cloth ready to catch escaping oil
 4/29/2016 2/5

Secure special tool 11 9 250 at hexagon head in a vice.

Release insert (2) using a slotted screwdriver (1) in direction of
arrow.

Release screw piece (1) on special tool 11 6 410.

Install special tool 11 6 410 in special tool 11 9 250.

Insert central bolt with a slotted screwdriver (1) hand-tight.
 4/29/2016 3/5

Insert screw piece (1) hand-tight in direction of arrow on special

tool 11 6 410.

Release oil filter cover with special tool 11 9 240.

Tightening torque: 11 42 1 AZ.

Carefully detach filter element.

Installation note:
Check all O-rings for damage, replace if necessary.
 4/29/2016 4/5

Install filter element (1) in special tool 11 9 250.

Installation note:
Coat O-ring with engine oil.

Order number for special tool: Bolt 2 212 823 with 11 4 310 .

Screw the pressure sensor (1) hand tight.
Apply light coating of oil to sealing ring at pressure sensor (1)
100 bar.

Measure the engine oil pressure with diagnosis system.

Order number for special tool: Screw 2 212 823 to oil filter
housing.
Special tool 11 4 310 on special tool, order number: 2 212 823.
Screw in pressure sensor (1) 100 bar at special tool 11 4 310
(finger-tight).
 4/29/2016 5/5

Connect cable (2) of IMIB (Integrated Measurement Interface

Box) to pressure sensor (1) 100 bar.
Graphic N20.

Start engine and check engine oil pressure by means of

diagnosis.
 4/30/2016 1/3

36 10 713 Checking one road wheel on balancing

machine for lateral and radial runout
(wheel removed)

Special tools required:

 36 1 030
 36 1 031
 36 1 032
 36 1 033
 36 1 034
 36 1 035
 36 1 036

Necessary preliminary tasks:

 Remove wheel

Mount wheel in balancing machine.

To avoid clamping errors, fit the wheel on the balancing
machine in the same way as it is also fitted on the vehicle
(valve position facing down).

Use suitable wheel centring element supplied with

corresponding balancing machine.
1. Basic flange
 4/30/2016 2/3

2. Wheel centring element

3. Type flange
4. Clamping nut
Also refer to section on Workshop Equipment.

Use special tool 36 1 030 for checking.

Special tool 36 1 030 consists of:
(1) Base 36 1 031
(2) Post with clamp 36 1 032
(3) Holder with clamp 36 1 033
(4) Clamp 36 1 034
(5) Measuring roll 36 1 035
(6) Dial gauge36 1 036
 

Position special tool 36 1 030 on tyre tread surface.

Turn wheel by hand and measure max. radial tyre runout.
Note:
Measuring device must be vertical to tyre tread surface.

Position special tool 36 1 030 on tyre sidewall.

Turn wheel by hand and measure max. lateral tyre runout.
Note:
Measuring device must be vertical to tyre side wall.
Never measure on tyre inscription!
If necessary, check disc wheel (wheel rim) for radial and face
 4/30/2016 3/3

runout.
 4/30/2016 1/1

34 00 010 Checking thickness of brake pad

Special tools required:

 34 1 260

Note:
The thickness of the outer brake pads can be determined
without removing the wheels.
If necessary, move vehicle until opening for brake pad wear
indicator (brake pad) can be seen through rim styling.

Insert special tool  34 1 260 wheel rim into opening for brake
pad wear indicator.
Press special tool onto brake pad. Slide ring (1) in direction of
arrow up to stop and read off measured value.
Note:
(A) Brake disc
(B) Brake pad with backplate
 Remaining brake pad thickness of front brake.
 Remaining brake pad thickness of rear brake.
 4/29/2016 1/1

00 11 ... Checking/topping up oil level in rear axle

final drive

Warning!
Danger of poisoning if oil is ingested/absorbed through the
skin!
Danger of injury if oil comes into contact with eyes and
skin!
 

Risk of damage!
To avoid serious damage to the rear axle final drive, it is
essential to use only approved gearbox oils in the rear
axle final drive.

Necessary preliminary tasks:

 If necessary, remove trailing links.
 

Open screw plug (1).

Tightening torque 33 11 2AZ.
Check oil level.
If necessary, pour in final drive oil up to lower edge of opening
for screw plug (1).
Installation note:
Renew screw plug (1) with O-ring.
 4/30/2016 1/3

36 10 715 Checking wheel rim for lateral and radial

runout

Necessary preliminary tasks:

 Remove wheel
 Check wheel for lateral and radial runout
 Remove tyre from disc wheel
 Remove dirt from rim base and rim flange

Important!
Disc wheels are not allowed to be repaired!

Mount disc wheel in balancing machine.

Use suitable wheel centring element supplied with

corresponding balancing machine.
1. Basic flange
2. Wheel centring element
 4/30/2016 2/3

3. Type flange
4. Clamping nut
Also refer to section on Workshop Equipment.

Place dial gauge sensor on rim shoulder.

Turn wheel by hand and measure max. radial runout.
Carry out measurement on both rim shoulder sides.
Note:
Dial gauge must be vertical to rim shoulder.

Position sensor on rim flange.

Turn wheel by hand and measure max. lateral runout.
Carry out measurement on both rim flanges.
Note:
Dial gauge must be vertical to rim flange.

Important!
Avoid clamping errors during subsequent installation work.
4/30/2016 3/3
 4/30/2016 1/2

51 02 02 (834)

Cleaning and care of leather in vehicles

All model series

Situation:
The leather used by BMW is a high-quality natural product prepared using state-of-the-art
processing techniques.

As it is a genuine natural product, its specific characteristics and peculiarities must be

taken into account in its use and care.

Lengthy periods in direct sunlight (for convertibles) may lead to slight bleaching and loss
of softness in the leather.

Regular cleaning and care are necessary, for dust and dirt from the road (leather's arch
enemy) can penetrate the pores and folds, causing the leather to lose its visual appeal.
Affected vehicles: All BMW vehicles with leather finish

Action: As dirt and grease slowly attack the protective coating of the leather finish on a vehicle,
treatment with BMW's premium leather care agent is needed once or twice a year,
depending on the degree of soiling.

Here, the precleaned leather surfaces of the seats, door trims and dashboard can be
cleaned and cared for in a single work cycle.
Procedure: 1. Preclean the leather surface with a microfibre cloth.

2. Thinly apply BMW's premium leather care agent with a soft, clean sponge (by-pack)
(shake well before use). Rub into soiled areas more intensively.

3. Allow to dry and the rub down with a clean cloth (by-pack).

Note:
BMW premium leather care agent:

High-quality oils maintain the natural characteristics of the leather. The

typical smell of leather is refreshed.

This product provides UV protection (combined leather cleaning and care

agent). It was presented in September 1999 and has been available from
BMW Parts Service since January 2002 in two different containers.

Important!
Work using BMW premium leather care agent cannot be reimbursed through
warranty as this is a cleaning and care operation.
Parts:

Part number Description Quantity

83 12 0 411 413 Leather care kit with UV protection 1

 4/30/2016 2/2

Note:
Current contents and range of parts can be found in the spare parts
catalogue.
 4/30/2016 1/3

64 51 001 Cleaning evaporator

Special tools required:

 2 344 001
 2 289 613

Warning!
When handling cleaning agent, observe following
protective measures:
Wear protective rubber gloves and protective goggles.
If cleaning agent comes into contact with eyes or skin,
wash immediately with lots of water.
Comply with notes and instructions on handling cleaning
agents

Note:
For information on cleaning agent and rinsing again, refer to
Service Information.
For spraying device, observe Service Information Spraying
device for the air conditioning system.
Special tool 2 344 001 must be used for left-hand drive
vehicles.
Special tool 2 289 613 must be used for right-hand drive
vehicles.

Important!
To avoid dirtying vehicle interior:

 Close all air vents

 The air conditioning must be set to the air recirculation
function
 Cover carpet in work area
 4/30/2016 2/3

Recycling:
Carry out the cleaning operation in a suitable washing bay
as the emerging cleaning agent escapes through the drain
openings in the transmission tunnel.
 
After completing cleaning, allow the vehicle to drip-dry for
approx. 5 minutes.

Necessary preliminary tasks:

 Remove rear underbody protection
 Remove microfilter for passenger compartment
ventilation
 4/30/2016 3/3

Insert special tool 2 344 001 into the microfilter housing (1) as shown.

Position special tool 2 344 001 up against the top left limit position as shown.
Move special tool 2 344 001 from the top downwards (1) to limit position.

Note:
If special tool 2 344 001 jams:
Move special tool 2 344 001 slightly to the right (2) until it can be moved from the top to the bottom.

Note:
Set air conditioning to footwell ventilation and fresh air mode.
Open side windows/doors.
Start the vehicle and let the air conditioning run for approx. 5
minutes at maximum blower output.
In order to eliminate the last remnants of cleaning agent, repeat
this process shortly before handover to the customer.
 4/30/2016 1/2

21 01 97 (251)

Clutch diagnostics

All models with manual transmission

Situation:
Our field observations recognise a certain diagnostic uncertainty in regards to the clutch
and its components. That means that a replacement of individual components is done
without removing the actual cause or a replacement of several components is done of
which only one is the actual cause

In addition clutches from the Warranty Parts Centre or in the scope of the warranty part
visual inspection by the market are refused and sent back at the cost of the dealers on
which:

- damages from external forces or

- damages from overheating because of misuse are recognised.
Measure: In the scope of continuos quality improvement, in the meantime for all models a new
clutch lining has been instituted in the series.

Series introduction of the new clutch linings:

M43(318i only) 11/94

M52(328i only) 01/95

M52(320i only) 05/95

M41, M42, M43 11/95

M50, M51, M52 04/96

M62 06/96

Only the new clutch linings will be delivered by the BMW Parts Department.

In addition since January 1997 an optimised release lever is installed in the series (all
models). This can be recognised by an embossed stamp on the inside.

1 - Embossed stamp
 4/30/2016 2/2

With this background the following

user guide is to be observed for
clutch complaints:

- Clutch slipping.

Please refer to Enclosure 1.

- Clutch does not disconnect or not
completely (gear shift jerky, gears
are difficult to engage).

Please refer to Enclosure 2.

- Stiff clutch control.

Please refer to Enclosure 3.

- Clutch control too loose / clutch
engagement point hard to feel.

Please refer to Enclosure 4.

- Clutch stick/slip.

Please refer to Enclosure 5.

- Noises from the gearbox / dual-
mass flywheel (ZMS) in idle.

Please refer to Enclosure 6.

- M51 Vehicle shaking in idle.

Please refer to Enclosure 7.

Parts:

Release lever M40, M42, M43, PN 21 51 1 204 229

M44, M50 without dual-mass
flywheel, M51, M70

Release lever M41, M50 with PN 21 51 1 223 302

dual-mass flywheel, M52, M60,
M62

Clearing of the parts store (up to dealer) was requested.

 4/29/2016 1/1

12 14 700 Coding control module (DME / DDE)

Switch off ignition.

Connect MoDiC or DIS/GT1 Tester.

Switch on ignition.
Select ”Coding” program.
For subsequent procedure, follow instructions in MoDiC or
DIS/GT1 Tester.
Carry out adjustment of following control units:

- EWS (electronic immobilizer)

- DME (Digital Motor Electronics) or

- DDE (Digital Diesel Electronics)

Refer to ”Diagnosis and Coding” service information bulletins on
subject of coding.
 4/29/2016 1/10

31 10 001 Completely removing and installing front

axle with engine and transmission
(.N55)

Special tools required:

 17 2 050
 00 9 030
 13 5 161
 13 5 162

Important!
When removing, note that the unit weights approx. 250 to
450 kg.
Check the vehicle payload.
Footwell at front is loaded with approx 200 kg.
Note safety information of table lift!

Necessary preliminary tasks:

 Position vehicle on vehicle hoist so its weight is centred.
 Disconnect battery.
 Suction off the air conditioning.
 Remove expansion tank.
 Remove fan cowl with electric fan.
 Drain coolant.
 Remove bulkhead sound insulation.
 Detach vacuum line from brake booster.
 Detach engine wiring harness in electronics box and set
aside.
 Remove complete propeller shaft.
 Remove front brake pads.
 Remove both brake calipers at the front and hang them to
one side.
 4/29/2016 2/10

Unlock and detach thermostat on radiator (1).

Release screw (1).
Tightening torque 17 22 4AZ.
Remove engine oil pipe from thermostat (2).
Unlock and detach coolant hose (3).

Release hose clamp (1) with special tool 17 2 050 and detach

coolant hose (2).

Unlock and detach charge air line (1) and charge air pipe (2) of
charge air cooler and set to one side.
 4/29/2016 3/10

Release screws (1) and remove refrigerant lines (2).

Tightening torque 64 52 1AZ
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to install sealing rings without
damaging them.

Release clamping bolts (1) on steering shaft at the bottom of

the steering gear and pull off.
Installation note:
Clean screw threads to remove all remnants of screw locking
adhesive.
Replace clamping bolts.
Tightening torque 32 31 2AZ.

Unlock and detach both electrical connectors (1) on steering

gear.
Unclip cable routing from front axle support and fold back cable
toward engine support.
Installation note:
Replace faulty cable clips.
 4/29/2016 4/10

Recycling:
Catch and dispose of escaping fuel with auxiliary
materials.
Observe country-specific waste disposal regulations.

Release screws (1) and remove protective plate (2).

Unfasten fuel line (1) and disconnect.

Unlock and detach tank ventilation line of carbon canister (2).
 4/29/2016 5/10

Close off fuel line (1) with special tool 13 5 161.

Close off fuel line (2) with special tool 13 5 162.

Open connector housing (1), pull electrical connection out of

bracket and disconnect.
Disengage cable with rubber grommets from holders (2).
Installation note:
Check that the electrical connectors and rubber grommets are
correctly mounted.

Note 31 00 Mobile table lift document.

 4/29/2016 6/10

Important!
Coordination of
table lift from
left to right.

Position engine on
working surface of
table lift A.
Position
transmission on
working surface of
table lift A.
Work surface of
table lift B can be
adjusted in length
(see arrow).

Structure of table
lift.
Position adapter
(50) on work surface
of table lift B for
transmission cross-
member with
coordinates 3/2 and
3/7.
 4/29/2016 7/10

Position adapter
(80) on work surface
of table lift B under
transmission with
coordinates 7/5.
Position adapter
(60) on work surface
of table lift A for
front axle support
with coordinates 2/1
and 2/8.
Position adapter
(10) on work surface
of table lift A for
swivel bearing with
coordinates 4/1 and
5/8.
Position adapter
(70) on work surface
of table lift A for
front axle support
with coordinates 7/2
and 7/7.

Possible attachment
points of front axle
support (1 and 2)
and transmission
cross-member (3).
 4/29/2016 8/10

Adapt and secure (3) wheel hub adapter (1) on left and right of
wheel hub (2).

Release left and right spring strut screws (2).

Tightening torque 31 31 1AZ.
Installation note:
Clean inside contact surface at spring strut dome.
Align spring strut with boreholes on spring strut dome using
centring pins and push up.
 4/29/2016 9/10

Release screws of transmission cross-member (manual

gearbox).
Tightening torque 23 32 3AZ/4AZ.

Release screws (1) on left and right.

Tightening torque 51 11 6AZ.
Unclip cable tie (2).
Installation note:
Replace faulty cable clips.

Release bolts (1-3).
Carefully lower the front axle complete with the motor and
transmission.
Installation note:
Note the installation location and tightening sequence of the
screws.
 4/29/2016 10/10

Check threads for damage; if necessary, repair with Helicoil

thread inserts.
 Bolt (1) M12x45
 Screw (2) M12x165
 Screw (3) M14x60
Tightening torque 31 10 1AZ.

Installation note:
Position the table lift beneath the vehicle.
Adjust the table lift to the vehicle inclination using the adjusting
screw (2).

After installation:
 Check and add engine oil.
 Fill and bleed hydraulic system.
 Check line connections for leak tightness
 Check and clear the fault memory
 4/30/2016 1/8

41 11 205 Completely replacing left carrier support

When replacing the right carrier support, follow the special

procedure concerning the vehicle identification number. (order
new body part with vehicle identification number if necessary)

Read contents of Body, General.

Follow procedure for repair stage 2.
Strip down vehicle.

The following new body parts are required (refer to Electronic

Parts Catalogue).

- (1) Carrier support, outer wheel arch section

- (2) Wheel arch inner section support member

- (3) Carrier support end plate

Following consumables are required:

Material Quantity

Adhesive K1 1

Blind rivet N1 4

Blind rivet N7 5
 4/30/2016 2/8

Punch rivets N5 56

Sealant D1 1

Cleaning agent R1 1

Removing carrier support

Open welded connections in areas (1).

Open weld joint in area (1).

 4/30/2016 3/8

Mark severance cut (1) as pictured and cut off carrier support.
Open weld connections in area (2) and remove outer part of
carrier support.

Important!
Covered welding spots.
In areas (1), undo welded connections for both external
panels.

Release welded connections in area (1) and remove sheet

section (2).

New part preparation

 4/30/2016 4/8

Release welded connections and take off components (1)

and (2) that are not required.

Adjust new parts with add-on parts to fit and secure.

Areas (1) and (2): join using bond-and-rivet method.
In area (1), drill a 6.8 mm dia. bore hole for blind rivet N1.

Areas (1) and (2): join using bond-and-rivet method.

In areas (1) and (2), set 8 6.8 mm diameter bore holes for blind
rivets.
Prepare areas (3) for joints by welding.
 4/30/2016 5/8

Areas (1) to (3): join using bond-and-rivet method. (punch

rivets)

In area (1), prepare new part/engine support for plug-welding.

Area (2): join using bond-and-rivet method.
Remove new parts.

Important!
Structure bonding!
Observe preparation of bonding surfaces.
 4/30/2016 6/8

Installing carrier support

Clean all bonding surfaces with cleaning agent R1.
Apply adhesive  to bonding surfaces.
Install and secure inside part of carrier support (new part) with
add-on parts.

In area (1), rivet new part with blind rivet N1.

In area (2) rivet new part with 4 punch rivets N5.

In areas (1) weld new part.

 4/30/2016 7/8

Install and secure outside part of carrier support (new part).

In areas (1) and (2), rivet new part with blind rivets .

Area Remarks

1 N1

2 N7

In areas (3) weld new part.

Important!
Risk of damage!
Avoid excessive application of heat to adjacent adhesive
areas.

In areas (1) to (3), rivet new part with punch rivets N5.

Area Number

1 22

2 15

3 3

Note:
Do not seal new parts in adhesive rivet areas (1) and (2).
(visible area)
 4/30/2016 8/8

Install and secure carrier support end plate.

In areas (2), rivet new part with 12 punch rivets N5.
Weld new part in area (1).
Important!
Risk of damage to adhesive area!
Avoid applying excessive heat to the neighbouring
adhesive areas!

Note:
Do not seal new parts in the area of the adhesive riveting.
(visible area)

Remove excess adhesive.

Do not use any cleaning agents containing solvents.
 4/29/2016 1/1

17 00 Coolant, Cooling System Test F20 / F21 / F22 / N55

Model series F20, F21 F22
Model designation M 135i, M
M 135i xDrive 235i
Coolant quantity on vehicles with manual gearbox 6,7 l 6,7 l
Coolant quantity on vehicles with automatic transmission 7,2 l 7,2 l
Top-up quantity of coolant in the event of repair with disconnected coolant hoses. 2,0 l 2,0 l
Observe the mixture ratio and filling level!
Test pressure for cooling system excess pressure (in bar) 1,5 1,5
 4/30/2016 1/2

41 00 ... Corrosion protection

Note:

Following repairs, the corrosion protection work already begins with the correct removal of the
underbody protection, anti-drumming layer and seam sealing in the repair area.

The products recommended by BMW are optimized with regard to corrosion protection.

1.0 Removing and applying sealing materials:

1.1 Removing sealing materials:

Important!
- Do not burn off PVC material (sealant) with an autogenous torch or similar or heat to
temperatures above 180 °C. This would generate highly corrosive hydrochloric acid and release
harmful vapour.

- The new lining does not form a satisfactory bond with burnt PVC material which means that
subsequent rust creep may set in.

Remove PVC material with a rotating steel brush, or heat PVC to maximum 180 °C with a hot air blower and
scrape off with a spatula.

1.2 Applying sealing materials:

All weld joints sealed off with body sealing compound in original state must be primed and sealed off again
thoroughly after repairing. Replace damaged or removed anti-drumming layers.

Note:

Spray gun required for body sealing compound (order no. 81 49 0 300 887).

 

Seal blind rivet with sealant (risk of corrosion).

Seal affected cavities with cavity preservation (risk of corrosion).

2.0 Basics of cavity preservation:

Carry out cavity preservation after all body repairs.

Concluding cavity preservation is the most important part of all corrosion protection measures.
 4/30/2016 2/2

Use the cavity protection spray only for smaller-scale straightening work where the parts in question are
easily accessible. Use the pressure cup gun for all other repairs. Cavity protection agent is available in
different container sizes.

Use the relevant sensors with tubes for the different cavity areas.

Required tools can be found in the Aftersales Assistance Portal (ASAP) ‐ Service/Technology ‐ Workshop
Equipment (Start BMW) ‐ Shop Workshop Equipment or at www.bmwgroup‐wep.com.

 

Important!

Incorrectly performed cavity protection can, especially in the case of steel/aluminium joints, give rise
to a non-calculable product liability and safety risk.

The best repair is worth nothing if the subsequent cavity protection measures are not conscientiously carried
out.

 

2.1 Cavity preservation of steel parts:

New doors and lids must be sealed with cavity protection agent after being painted.

New sheet-metal parts or cavities, weld seams and folds formed by new sheet-metal parts must be sealed
with cavity protection agent after being painted.

The cavities affected must be sealed with cavity protection agent after all straightening work.

 

2.2 Cavity preservation of aluminium parts:

New doors, lids and side panels made of aluminium are not sealed with cavity protection agent.

After all straightening work on aluminium components, the cavities affected must be sealed with cavity
protection agent after being painted.

After all welding work (E52 only) on aluminium components, the cavities affected must be sealed with cavity
protection agent after being painted.

Cavities, seams and folds formed from new sheet metal parts or extruded profile must be sealed with cavity
protection agent after being painted.
 4/30/2016 1/6

65 13 00 (641)

Deactivating and reactivating airbags/acoustic seat belt reminder

All Series from model year 1994

Situation:
If expressly desired by the customer and at the customer's responsibility, the following
airbags can be deactivated and reactivated depending on the vehicle type:
 Driver's and front passenger airbag
 Front left and/or front right side airbags
 Rear left and/or rear right side airbags
 Front left and/or front right head airbags
 Rear left and/or rear right head airbags

Important note when travelling with children:

Children younger than 12 years of age or smaller than 150 cm may only travel if they are
secured in suitable child restraint systems. Child restraint systems may only be used on
the front passenger seat when the airbag is deactivated, as otherwise there is a
substantial risk of injury to the children if the airbag is deployed, even if they are seated in
a child restraint system. If it cannot be prevented that children lean out of their seat in the
direction of the door trim panel, the side airbag in the rear should be deactivated.
Otherwise, there is a risk of considerable injury if the side airbag deploys.

 
Vehicles concerned: The following exceptions relating to the deactivation or reactivation of the airbag must be
observed.
 E64 Production period: from series introduction until August 2005)

The different seat/seat belt system (SGS) means that the legal standard ECE‐R21
”new” cannot be met. For technical reasons, the E64 cannot be approved in
accordance with ECE‐R21 ”old”, as in the case of the E46 Convertible. For this
reason, it is not permissible to deactivate the front passenger airbag by means of
conversion (encoding).
 E83 Production period: from September 2004

A modification to the front passenger airbag cover means that the front passenger
airbag is no longer to be deactivated by conversion (encoding). For these vehicles, a
key switch is available optionally and as a retrofit kit.
 R50/52/53 Vehicles with "JOHN COOPER WORKS sports seats":

The decisive document for installation is the installation instructions for "Retrofitting
John Cooper Works sports seats" The vehicle's operating licence is not invalidated if
"John Cooper Works sports seats" are retrofitted. The "JOHN COOPER WORKS
 4/30/2016 2/6

sport seat" is an element of the European operating licence of the MINI (R50/R53).
Approval of the installation by a technical control organization and entry into the
vehicle documents is not required.

Thus, the following documentation in the appendices of the service information is not
required when installing the "JOHN COOPER WORKS sport seats":

- Procedure for deactivation or reactivation of the airbags in the dealer

organisation; Section "Documentation of the conversion" (Appendix 1)

- Documentation of the customer agreement and the performed work

(Appendix 3)

 All BMW F-series, BMW i and MINI from R58:

In these vehicles, deactivation/activation of the airbags is only possible using a

factory-installed key switch.

The key switch cannot be retrofitted!

It is not possible to deactivate/activate the airbags by means of conversion.

 
Procedure: Deactivating / reactivating airbags

Important!
For vehicles with belt force limiter without key switch, the seat belt must be
exchanged for a "seat belt without belt force limiter" when the front
passenger airbag is deactivated.

It is not necessary to replace the seat belt in the E46/C.

If the front passenger airbag is reactivated, the seat belt must again be
replaced with a "seat belt with belt force limiter" when the front passenger
airbag is reactivated.

In Australia and Korea it is not permitted to deactivate the front passenger

airbag.

For vehicles for which a key switch is available for deactivating/reactivating the airbags is
optionally available, retrofit kits are also available for retrofitting a key switch (exception:
all BMW F-series, BMW i, MINI from R58)

Tables 1 and 2 provide an overview of the measures needed for deactivating/reactivating

the airbags and the acoustic seat belt warning, taking the stipulations for the specific
models into account.

Important!
The combination of certain equipment specifications, national-market
versions and country-specific regulations may result in deviations to the data
 4/30/2016 3/6

presented in Tables 1 and 2. If in doubt, contact Technical Support before

carrying out any work.

Key:

1 - Deactivation occurs through a conversion with the diagnosis system.

2 - Deactivation takes place via a factory-installed or retrofitted key switch.

3 - Deactivation takes place via a factory-installed key switch, which cannot be retrofitted.

Table 1: Airbag deactivation/reactivation

Model series Date of Front airbag Side airbag Head Remarks

introduction airbag

Driver Passenger Front Rear Front Rear

E34 From 09.93 1 1 1 Please

refer to
Enclosure
5.

E36 From 09.93 1 1 1 Please

refer to
Enclosure
6.

E36/Z3 from series 1 1 1

production

E38 from series 1 1 1 1 1 1

production

E39 from series 1 1 1 1 1 1

production

E46 from series 1 1 1 1 1

production

E52 from series 1 1 1

production

E53 from series 1 1 1 1 1 1

production

E60/E61 up to 08.05 1 1 1
 4/30/2016 4/6

E60/E61 From 09.05 2 2 1

E63 up to 08.05 1 1 1

E63 From 09.05 2 2 1

E64 up to 08.05 1 1

E64 From 09.05 2 2 1

E65/E66 from series 1 1 1

production

E70/71/72 from series 2 2

production

E81/82/88 from series 2 2

production

E83 up to 08.04 1 1 1

E83 From 09.04 2 2 1

E84 from series 2 2

production

E85/86 from series 2 2

production

E87 From 03.05 2 2

E89 from series 2 2

production

E90/91/92/93 from series 2 2

production

R50/R53 up to 06.04 1 1 1

R50/53 From 07.04 2 2 1

R52 from series 2 2

production

R55/56/57 from series 2 2

production

MINI from from series 3 3

R58 production
 4/30/2016 5/6

BMW F- from series 3 3

Series production

BMW i from series 3 3

production

Deactivation/reactivation of acoustic seat belt warning

Deactivate and reactivate the acoustic seat belt warning for the driver and front passenger by conversion as per
the table below.

Note:
Deactivating the acoustic seat belt warning is not permitted in Japan.

With the E53, the deactivation / reactivation of the acoustic seat belt warning on the front
passenger side is only possible with the installation of a Light Check Module (LCM) / light module
(LM) with a coding index 24 or higher (series from April 2005).

Deactivating the acoustic seat belt warning in R50/52/53 is not possible.

Table 2: Deactivating/reactivating the acoustic seat belt warning

Model series Driver and front passenger Front passenger only Remarks

E53 1

E70/71/72 1 only in conjunction with option 230

E60/61/63/64 1

E65/66 1

E81/82/87/88 1

E83 1

E84 1

E85/86 1

E89 1

E90/91/92/93 1

MINI from R55 1

BMW F-Series 1
 4/30/2016 6/6

BMW i 1

Location of documents for deactivating or reactivating the airbag

- Procedure for deactivating and reactivating airbags in the dealer organisation: Please refer to
Enclosure 1

- For how to encode the airbag control unit: Please refer to

Enclosure 2 .

- For notes on documenting the customer's consent and the work carried out: Please refer to
Enclosure 3 .

- Identification of airbag systems Please refer to

Enclosure 4 .

- Deactivating or reactivating the airbags in E34 series vehicles Please refer to

Enclosure 5 .

- Deactivating or reactivating the airbags in E36 series vehicles (excluding Z3) Please refer to
Enclosure 6 .

- Deactivating or reactivating the acoustic seat belt warning Please refer to

Enclosure 7

Note:
Only the airbags listed in the table can be deactivated.

- Deactivating or reactivating the airbags in series See repair instructions

E36/Z3,38,39,46,52,53,60,61,63,65,66,83 (to August 2004), R50,53 (to July RAGRP72-
2004) 7212DEAKTIV-OHNE

- Deactivating or reactivating the front passenger airbag using a key switch in See repair instructions
series E60,61,63,64 (from September 2005) E83 (from September 2004), E87 RAGRP72-
(from March 2005) E85,70,90,91,92,93,R50,53 (from July 2004), R52 7212DEAKTIV-WITH
Parts:

Designation Part number Quantity

Upper front seat belt without belt force See Electronic Parts Catalogue 1
limiter (EPC)

Sets of forms/parts, multilingual (with 01 39 0 028 759 1

warning stickers)
 4/30/2016 1/2

72 12 ... Deactivating front passenger airbags

with key switch

Warning!
The responsibility for deactivation/activation rests with the
customer.
When a child restraint system is used on the front
passenger seat, the front passenger airbags must be
deactivated, otherwise there is an increased risk of injury
for the child in the event of airbag deployment even with a
child restraint system.

The front passenger airbag can only be deactivated in

accordance with the following instructions if the vehicle is
equipped with a suitable key switch!
The key switch for the F series can not be retrofitted if it is
missing and it has not been ordered as optional equipment!
key switch:
 SA 5DA

The following airbags are deactivated simultaneously with the

key switch (1):
 Front passenger airbag
 Side airbag (passenger's side)
 If necessary, knee airbag in US version (passenger's
side)
The airbags can only be deactivated/reactivated while the
vehicle is stationary and with the door open.
Important!
The head airbag remains active.

Deactivation
A Turn key switch with integrated key (1) from the remote key
to the "OFF" position.
Deactivatable airbags on passenger's side out of operation.
Head airbag on passenger's side remains active.
All airbags on driver's side remain active.
 4/30/2016 2/2

Activate
B Turn key switch with integrated key (1) from the remote key
to the "ON" position.
All the airbags in the vehicle are activated and are triggered
in appropriate situations.

Indicator light
When the ignition key is turned in the ignition lock, the function
of the airbag system is checked and the indicator light lights up
for several seconds.
A The indicator light is continuously ON when the front
passenger airbags are deactivated
B The indicator light goes out after a few seconds when the
front passenger airbags are activated
 4/30/2016 1/2

41 01 98 (374)

Dent repairs without damaging paintwork

All

Situation:
Light dents have previously only been repaired through conventional means such as
Multispot and filling followed by repainting.

However, methods of rectifying parking and hailstone damage that do not damage the
paintwork are becoming increasingly common.Vehicle insurers are fully supportive and
endorse this approach.

This procedure involves pressing out damage from the inside of sheet metal panels using
levers followed by polishing. The total outlay is much lower than for conventional dent
repairs with subsequent repair painting. It is to be noted here that some areas of damage
cannot be reached on account of reinforced or bonded body components. For safety
reasons, no additional holes may be drilled to improve accessibility.

The size of the dent should not exceed a diameter of 80 mm.

This procedure can also be used during general workshop repair processes, such as:

- Preparing for painting (reduction in filling work)

- Rectifying any damage following repair painting.
Based on this background as well as environmental aspects and the positive effect on
insurance coverage classification, this method of repairing dents without paintwork
damage is approved for BMW vehicles. This approval only applies to dents that do not
have visible paintwork cracks.
Procedure: Repairing dents without damaging the paintwork requires continuous practice and a high
degree of skill. In order to cater for the relevant situation at all contractual partners, two
application methods for optimum use are offered.

1. In the same way as professional body and paintwork shops are already used, it is
also possible in this case to commission qualified contractors for the purpose of
conducting dent repairs without paintwork damage.

2. Purchase of a BMW pressing-out tool set for dent repairs.

The form and materials of this set have been carefully selected for BMW vehicles. It
consists of a standard set (for approx. 80 % of the outer body skin that can be
reached) and an extension set (for the remaining 20 %).

Training is recommended so that the tool set can be used effectively. This training is
offered by external companies and can be conducted locally (e.g. for Germany the
company Ur-Form).

See Service Information 5 04 98 (328).

Note:
 4/30/2016 2/2

Make sure that the training provider does not conduct training under the
prerequisite of purchasing his particular set of pressing-out tools.
 4/30/2016 1/4

33 41 ... Detaching wheel bearing inner ring from

drive flange (drive flange removed)

Special tools required:

 33 4 409
 33 4 407
 33 4 401
 33 4 403
 33 4 404
 33 4 402
 33 4 400

Important!
Thrust piece 33 4 409 must not be removed!

 
Insert pliers  33 4 407 into special tool 33 4 401.

Position special tool 33 4 401 in conjunction with 33 4 407 on

drive flange.
Important!
Pliers 33 4 407 must be positions in the groove between
the drive flange and wheel bearing inner ring.

Pull special tool 33 4 401 together with rings 33 4 403 and

33 4 404 until the pliers 33 4 407 are fitted flush in the groove
between the drive flange and wheel bearing inner ring.
Unscrew spindle 33 4 402 as far as is possible.
 4/30/2016 2/4

Use special tool, see BMW Workshop Catalogue.

 

- Hydraulic unit - 81 64 2 155 744

- Adapter kit 1 -  81 64 2 155 745

- Adapter kit 2 -  81 64 2 155 746

The following work steps describe pulling off the wheel bearing inner ring:
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 Pressure cylinder of hydraulic unit (1) must be in the initial position.

 Spindle F3 must terminate flush with hydraulic unit (1).
 Assemble special tool, see graphic.
 Turn spindle of special tool 33 4 400 up to limit position.
The following tools are required for detachment, consult graphic for arrangement:
Vehicle components:

I Drive flange hub

II Wheel bearing inner ring

Required components for all models and types:

F3 Spindle M24 (length 270 mm)

1 Hydraulic unit

E3 Washer M24

C1 Holding sleeve

B1 Adapter
 4/30/2016 4/4

33 4 400 Special tool

* Components specific to model and type:

K2 Screws M14 x 1.5
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16 01 02 (890)

Diagnosis of fuel tank systems with fuel tank leak diagnosis module (DMTL)

All US models

Situation:
Since model year 1994, all US models have been equipped with a diagnosis-compatible
system that checks the fuel supply system for leaks.

A leaking fuel supply system causes increased pollutant emissions and, according to
American legislation, must be repaired immediately. The ”Service Engine Soon” indicator
lamp lights up to alert the driver.

Systems for leak detection are tank systems with leak diagnosis pump (LDP) and fuel tank
leak diagnosis module (DMTL). These differ principally in the details listed in Table 1.

LDP DMTL

Diaphragm pump Vane pump

Vacuum line necessary for Compression system

operation of the diaphragm

Leak detection from ∅ 1 mm Leak detection from ∅ 0,5 mm

Leak detection at fuel tank by Leak detection at fuel tank via test
means of external pressure module and/or service function
application
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Figure 1: Block diagram of leak check

A Pressurised components 10 DME control module

1 Tank 11 Fuel evaporation control valve

2 Fuel pump 12 Feed line

3 Expansion tank 13 Return line

4 Activated carbon filter 14 Solenoid valve in DMTL

5 Fuel filter with pressure 15 Dust filter

regulator

6 Injection rail 16 Charge/vent line

7 Intake manifold 17 Fuel tank vent line I

8 Fuel filler cap 18 Fuel tank vent line II

9 LDP / DMTL 19 Fuel tank vent line III

1. Leakage test with leak-diagnosis pump (LDP)

US vehicles have an AKF cutoff valve and a tank pressure sensor that are used by the
tank vent system diagnosis to enable the DME control unit to detect leaks > 1 mm in the
tank and tank vent system.

With this system, a vacuum is formed and used to detect a leak. From Model Year 1998
(US 05.97), the vacuum system was replaced by a compression system.

The depression or compression is generated by a leak diagnosis pump bolted to the

activated charcoal filter and is approx. 25 hPa. Leak diagnosis takes approx. 100 seconds,
depending on the individual vehicle and is performed after nearly every cold start. The air
filter at the LDP inlet is also new.

Note:
If this filter becomes extremely soiled, you may encounter problems when
refuelling the vehicle. Diagnosis is guaranteed on the complete system (fuel
circuit, leak diagnosis pump and reed contact).

1.1 Function description of pressure-leak diagnosis

When the DME control unit performs leak diagnosis, the DME control unit actuates the
solenoid valve in the LDP unit. The intake manifold vacuum not reaches the level of the
upper pump chamber (6, Fig. 2) and pulls the diaphragm (7, Fig. 2) up against the
springs (3, Fig. 2).
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Figure 2: Leak-diagnosis pump (LDP)

1 Vacuum valve 8 Connection to atmosphere

via filter

2 Connection to intake manifold 9 Open/closed valve

vacuum (mechanical)

3 Spring 10 Intake valve

4 Connection to activated 11 Pressure valve

charcoal filter

5 Reed contact 12 Solenoid valve coil

6 Upper pump chamber 13 Electrical connections

7 Diaphragm    

When the diaphragm (7, Fig. 2) is pulled up, a suction or pump effect is created under the diaphragm.
Suction/pressure valves allow the oscillations of the diaphragm to create a pressure of approx. 25 hPa in the
tank vent system, through the activated charcoal filter to the fuel filler cap. The oscillations of the diaphragm,
i.e. the frequency, is measured by the reed contact (5, Fig. 2). The principle of pressure leakage diagnosis is
based on a measurement of the repumping frequency needed by the leak diagnosis pump:
 Repumping frequency greater than nominal value: System leaking
 Repumping frequency less than nominal value: System not leaking

2nd leakage check in OBD II (on-board diagnosis) with fuel tank leak diagnosis module (DMTL)
 4/29/2016 4/10

This test procedure is able to detect leaks as small as > 0.5 mm in the fuel supply system. It thus constitutes a
significant improvement in terms of protecting the environment.

Start criterion Start condition

Engine OFF

Last engine standstill >5h

Duration of current journey > 10 min

Fuel level > 15 % and < 85 %

Ambient temperature > 4 °C and < 35 °C

Altitude above mean sea level < 2500 m

Battery voltage > 11.0 V and < 14.5 V

Table 2: Start conditions for diagnosis

2.1 Function description of fuel tank leak diagnosis module check

Once all start conditions listed in Table 2 are satisfied, the DMTL will automatically start a tank leak
measurement (OBD diagnosis).

The actual tank leak measurement comprises two phases: reference leak measurement and tank leak
measurement.

2.1.1 Reference leak measurement

During the reference leak measurement, the vane pump blows air through the so-called reference leak
(∅ 0.5 mm).

The power intake of the pump is measured and serves as the reference current during subsequent leak
diagnosis. The strength of this pump current is approx. 20 mA to 30 mA.

This initial procedure takes place within the DMTL only and no other parts are affected. This phase serves as a
self-test for the DMTL.

If the current for the reference leak measurement is outside a certain tolerance, the DMTL will be detected as
faulty and the fault memory entry shown in Table 3 will be stored in the DME as an internal DMTL fault.

DME variant Manufacturer Fault in plain text

MS43 Siemens 142 ”Module fault DMTL”

MS45 Siemens 27CD ”Module fault DMTL”

MSV70 Siemens 2A17 ”DMTL system fault”

MSV80 Siemens 2A17 ”DMTL system fault”

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MSD80 Siemens 2A17 ”DMTL system fault”

ME9.2.2 Bosch 2A17 ”DMTL system fault”

MED9.2.2 Bosch 2A17 ”DMTL system fault”

ME9.2.3 Bosch 2A17 ”DMTL system fault”

MSS65 Siemens / BMW 2776 ”DMTL pump”

Table 3: Internal DMTL fault during reference leak measurement

2.1.2 Tank leak measurement

Fig. 1 shows the components of the fuel supply system, to which pressure is applied.

Pressure is applied to the components of the fuel supply system during the tank leak measurement procedure.
 The internal solenoid valve in the DMTL (14, Fig. 1) closes the line to the atmosphere
 The DMTL pump is activated

As a result, the fuel supply system is now a closed system (from the DMTL valve up to the fuel evaporation
control valve) and the pressure is increased in the entire fuel system.

During the tank leak measurement,the pump's current draw is measured. An algorithm in the DME control unit
compares the power intake of the reference leak measurement and of the tank leak measurement.

If the current draw during the tank leak measurement is lower that that recorded during the reference leak
measurement, the fuel supply system is detected as free of leaks. A leak of > 0.5 mm must be present for the
DME to store a fault.

DME variant Minor leak error Major leak error

(engine) > 0.5 mm > 1,0 mm

  (fault in plain text) (fault in plain text)

MS43 8F ”Fuel tank leak diagnosis with DMTL”

MS45 27CC ”DMTL: leak

MSV70 2A16 ”Extremely minor 2A15 ”Minor leak”

leak”

MSV80 2A16 ”Extremely minor 2A15 ”Minor leak”

leak”

MSD80 2A16 ”Extremely minor 2A15 ”Minor leak”

leak”

ME9.2.2 2A16 ”Extremely minor 2A15 ”Minor leak”

 4/29/2016 6/10

leak”

MED9.2.2 2A16 ”Extremely minor 2A15 ”Minor leak”

leak”

ME9.2.3 2A16 ”Extremely minor 2A15 ”Minor leak”

leak”

MSS65 27C3 ”DMTL leak 2779 ”DMTL leak

detection” detection”

Table 4: Fault in tank leak measurement

Note:
Diagnosis will be interrupted if you start refuelling while diagnosis is in progress.

If the faults listed in Tables 2 and 3 are diagnosed twice in succession, an entry will be stored in
the DME. The ”Service Engine Soon” indicator light comes on, prompting the customer to drive to
a workshop for diagnosis and leak detection.

A fault relating to fuel tank leak detection very often occurs in connection with the fuel filler cap not fitted or
closed correctly.

The so-called ”Check Filler Cap” or ”Check Gas Cap” function has been introduced to prompt the customer to
check the fuel filler cap.

3. Check Filler Cap / Check Gas Cap function

The Check Filler Cap / Check Gas Cap function is a prompt to the driver in the event that the fuel filler cap was
not replace or closed properly after refuelling.

This function usually runs after every refuelling and gives a warning message in the instrument cluster. This
gives the driver the opportunity to close the fuel filler cap correctly before the system starts a leak check.

The key difference between this function and the OBD II leak check is that with the CFC / CGC, the MIL
indicator light (or ”Service Engine Soon” indicator light) is not actuated.

Figure 3:

”Check Filler Cap” indicator lamp.

Phase-in September 2001

 4/29/2016 7/10

Figure 4:

”Check Filler Cap I” indicator lamp.

Phase-in September 2003

Figure 5:

”Check filler cap II” indicator lamp.

Phase-in September 2004

Procedure: Case 1. Internal DMTL fault (see Table 3)

Proceed as follows if such an internal DMTL fault is stored in the fault memory:

1. Clear the fault memory

2. Check whether the fuel filler cap is fitted correctly

3. Work through test module:

 Complete vehicle
 Drive
 Engine control
 Fuel tank system test
 Fuel tank leak diagnosis module (DMTL)

This test module carries out a reference measurement and a fuel tank measurement and
simultaneously checks the function of the DMTL pump.

If the fault is stored again in the fault memory after this test module, the DMTL must be
replaced, please refer to Repair Instructions RA 16 13 015.

Important:
On no account open the DMTL!

Note:
Do not use lubricants during assembly.

After replacing the DMTL, clear the fault memory and once again work through the test
module specified above.
 4/29/2016 8/10

If the repair has been carried out correctly, the test module will not store a fault entry.

If, after replacing the DMTL, a leak is detected in the system, it is highly likely that a leak
was caused during the replacement procedure.

Note:
It is recommended to work through the above test module after all repairs to
the fuel supply system.

Case 2. Fault during tank leak detection (see Table 4)

Fuel tank faults indicate a leak in the fuel supply system or incorrect operation of the fuel
filler cap.

Important:
The most common causes of a fuel tank leak fault are:
 Fuel filler cap fitted crooked or not correctly
 Fuel filler cap not turned as far as it will go to the end stop (the end stop
is indicated by a clearly audible ”click”)
 Retaining strap for fuel filler cap trapped between the filler cap itself and
the fuel filler neck

Note:
Also refer to Service Information SI 16 02 99 (501) with regard to the fault
patterns listed above.

Proceed as follows if a tank leak fault is stored in the fault memory:

1. Clear the fault memory

2. Check whether the fuel filler cap is fitted correctly

3. Work through test module:

 Complete vehicle
 Drive
 Engine control
 System diagnosis
 DMTL system test
 For further details, please refer to Repair Instructions 16 00 102 (M54).

If a leak is detected in the fuel supply system on completion of the test module this leak
will be caused by the fuel filler cap not being closed correctly.

Important:
The costs in connection with the above causes are not incurred by any
technical defects in the system and no warranty claims for reimbursement will
be accepted.
 4/29/2016 9/10

A fuel tank leak test must be carried out if the fuel supply system is found to be leaking.

Case 3. Tank leak search

The fuel tank leak test procedure is described in Repair Instructions 16 00 510.

With the ”DMTL pump actuation” service function, the internal solenoid valve (14, Fig. 2) in the DMTL closes
the line to atmosphere and the DMTL pump is subsequently activated.

As a result, the fuel supply system is a closed system and pressure is built up.

The leak can now be found with the aid of a leak detector.

Important:
1. External pressure must not be applied to systems with DMTL because, in this case, the
DMTL valve is not closed and a leak will inevitably be detected.

2. During the above service function, the DMTL pump runs uninterrupted for approx.
15 minutes. After this, the DME switches the DMTL pump off. If necessary, the test module
can be repeated after a short waiting period.

Probable leak points:

 Fuel filler cap screwed on crooked or not up to the stop
(8, Fig. 2)
 Fuel level sensor left or right leaking (replace sealing ring)
 Connection between fuel filler pipe and fuel tank
 Connections of filler vent line or of fuel tank vent lines I and II (16, 17, 18, Fig. 2)

Unlikely but possible leak points:

 DMTL solenoid valve
 Fuel evaporation control valve
 Connection between DMTL and activated carbon filter (19, Fig. 2)
 Pressure relief valve in the fuel filler cap
 Mating between fuel cap and fuel filler neck

Note:
If a repair was previously carried out on the fuel supply system, the leak will probably be at the
repair location.

Important:
1. The pressure relief valve in the fuel filler cap can only be checked as described in Repair
Instructions RA 16 11 130.

2. If the mating between the fuel cap and the fuel filler neck is leaking, the fuel cap and the
fuel filler pipe (both!) must be replaced.

Case 4. Leak detector

 4/29/2016 10/10

The following devices can be used for leak detection purposes:

 Devices that respond to ultrasound
 Devices that respond to hydrocarbon hydrates

Part number of the device recommended by BMW (responds to hydrocarbon hydrates): 81 34 0 144 422.

Important:
Since, during normal vehicle operation, the vent line and the fuel evaporation control valve are
subjected to fuel vapours (fuel residue remains on the line and valve), leaks at the fuel
evaporation control valve cannot be detected effectively with devices that react to hydrocarbon
hydrates.
 4/30/2016 1/2

51 16 992 Disassembling and assembling lock

barrel (lock barrel removed)

Necessary preliminary tasks:

 If necessary, remove lock barrel

Sort supplied retainers (1) according to graphic.

(X) Embossed number on retainer (1)
(Y) Installation position in lock barrel

Insert spring (1) into first position of lock barrel (2).

Note:
Lock barrel version (2) differs according to vehicle.

Insert retainer (1) with lowest stamped number (X) in first

position (Y) in lock barrel (2) so that it snaps into place audibly.
Note:
Number of retainers (1) differs according to vehicle.
 4/30/2016 2/2

Insert ignition key (1) in lock barrel (3) and check whether

retainer (2) is flush with housing.
(A) OK
(B) not OK

If retainer (2) is not OK, press retainer (2) out of lock barrel (3)

with a suitable tool (1).
Repeat work operations with retainer (2) with next higher
number (X) until correct retainer (2) has been found.
Carry out all further positions in lock barrel as described in the
process above.
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17 00 005 Draining and adding coolant (N55)

Special tools required:

 00 2 030

Warning!
Risk of scalding!
The repair work on the cooling system should only be
carried out on an engine that has cooled down!

Important!
Lifetime coolant filling:
Never reuse used coolant!
When replacing and removing components which rely on
the corrosion protection effect of the coolant, it is essential
to change the coolant. The cooling system must therefore
be drained and refilled.
In the case of other removal work involving the draining of
part quantities of coolant, replace these quantities which
have been drained with new coolant.

Installation note:
Use only recommended coolant.
Observe mixture ratio.
 4/29/2016 2/4

Protective measures/rules of conduct:

 Wear safety goggles
 Wear protective gloves
 Observe national/country-specific regulations

Important!
For dirt contamination of the cooling system (e.g. by
engine oil), the cooling system must be rinsed with water
until all dirt contamination is removed!

Important!
Risk of skidding due to coolant on the floor.
Danger of injury!

Catch and dispose of drained coolant in drip tray (1) and if

necessary special tool 00 2 030 (universal hydraulic lifting
equipment).
Recycling:
Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

 Follow notes for carrying out repair work on the cooling
system .
 Remove front underbody protection.
 4/29/2016 3/4

Draining coolant:
Open sealing cap (1) on coolant expansion tank.
Installation note:
Close sealing cap (1) until the arrow marks line up.

Release screws (1).
Remove cover (2).

Release hose clamps (1) and (2).

Pull off coolant hoses from coolant pump and drain coolant.
Installation note:
Note installation position of hose clamps.
 4/29/2016 4/4

Note:
Adding coolant:

Use only recommended coolant.

Observe mixture ratio.
Observe capacities.
Observe bleeding instructions without fail.
Fill and bleed cooling system.
Visual inspection of cooling system for tightness.
 4/29/2016 1/3

16 00 005 Draining and filling fuel tank

Special tools required:

 16 1 080

Important!
Observe country-specific safety regulations.
Ensure adequate ventilation in the workbay!
Connect the exhaust extraction unit to the exhaust tailpipe.
The electric fuel pump must not operate without fuel! After
completing repairs but before starting the engine for the
first time, fill the fuel tank with min. 5 l fuel through the fuel
filler pipe.
Do not damage non-return valve when pulling out suction
hose.

Diesel vehicles:
Before starting the engine for the first time, if the fuel tank has
been run dry or emptied, fill with diesel fuel and turn on ignition
for approx. 1 minute. The fuel circuit is thus filled and vented,
which results in the engine firing more quickly.

Drawing off fuel:

Start engine and allow to run.
 4/29/2016 2/3

The electric fuel pump runs.

In this way, the fuel is re-pumped through the suction jet pump
from the left to the right side of the fuel tank.
Note:
Fuel can be drawn out of left and right sides of tank through fuel
filler neck, leaving only a small residue. The residual amount is
drawn off via the sensor opening.

Insert special tool 16 1 080 into fuel filler neck.

Special tool 16 1 080 has two different diameters for
petrol/gasoline and diesel-engine cars!
Slide suction hose of extractor unit, refer to BMW Service
Workshop Equipment - Planning Documentation, through
special tool 16 1 080 into the fuel filler pipe, turning in the
process if necessary.
Insertion length approx. 125 cm.
Draw off fuel with extractor unit (refer to BMW Service
Workshop Equipment) as far as possible.
Follow drawing off of fuel on fuel gauge in instrument cluster.

Drawing off residual fuel quantity:

Drawing off residual fuel amount is not included in the time
value of this operation.
Important!
Ensure passenger compartment is adequately ventilated.
Catch dripping fuel in a suitable container.

Remove flange cover.

Draw off residual fuel quantity through sensor openings.

Fuel filling:
Insert special tool 16 1 080 into fuel filler neck.
Special tool 16 1 080 has two different diameters for
petrol/gasoline and diesel-engine cars!
Slide suction hose of extractor unit, refer to BMW Service
 4/29/2016 3/3

Workshop Equipment - Planning Documentation, approx. 40 cm

into fuel filler pipe.
Fill fuel from suction extractor unit.

Extracting fuel after a defect in the suction jet pump or fuel

pump:
Draw off right half of tank completely through fuel filler pipe.
Remove flange cover.
Insert extraction hose through service opening in tank, fuel
(also residual quantity) can be drawn off.
 4/30/2016 1/7

64 50 010 Drawing off, evacuating and filling

heating and air conditioning system
(R134a)

Warning!
Only persons in possession of a professional certificate of
competence for the maintenance and repair of heating and
air conditioning systems are authorised to carry out repair
work on the refrigerant circuit. It must be available no later
than 04 July 2010 (applies only to EU countries; follow
country-specific regulations in non-EU countries).
Refrigerant circuit is under high pressure!
 If the protective caps on the filling valves are difficult
to open, there is a danger of injury from leaking
valve inserts.
Repair work may only be carried out on a depressurised
refrigerant circuit!
 Before conducting repairs, check the actual pressure
drop on the pressure gauge of the A/C service
station.
Avoid contact with refrigerant and refrigerant fluid.
 Follow safety instructions for  handling R134a
refrigerant.
 Follow safety information for handling refrigerant oil.

Important!
Risk of damage!
Only BMW-approved R134a refrigerant may be used.
( refer to sourcing reference: Operating Fluids)
Restart engine only when A/C system has been correctly
filled.

Vehicle-specific notes:
E60/E61 M5only:
To access refrigerant line connections, the right intake silencer
housing must be removed.
F01/F02/F03/F04/F06/F12/F13 (N63) only from 07/2012:
 4/30/2016 2/7

To access refrigerant line connections, the right intake port

must be removed.
F02/F03/F04 only:
To guarantee a virtually complete draining of refrigerant from
the automatic rear air-conditioning system or the hybrid battery
cooling system:
In the diagnosis system test module, carry out "draining/filling
refrigerant circuit".
F33 only:
To access refrigerant line connections, the left front end strut
must be removed.
Only F8x:
In order to access the connections of the refrigerant lines, undo
charge air cooler and place to one side.

Note:
On the F01, F02, F10, F11, an additional refrigerant
low pressure connection (2) may be installed specific
to the engine and model year.
This refrigerant low pressure connection (2) is not to
be used in the inspection!
Use exclusively refrigerant connections (1) for
drawing off, evacuating and filling!

Vehicle-specific notes:
BMW I01:

Equipment specification with and without heat pump:

To access the connections for the refrigerant lines,
remove front luggage compartment well.

Equipment specification with heat pump:

Before the drawing off, evacuation or filling procedure,
carry out the following steps:
1. Switch on terminal 15: To do so, press the
 4/30/2016 3/7

Start/Stop button without operating the brake

pedal.
2. Switch off blower at IHKA controls (so that
compressor cannot start up).
3. Switch on low-beam headlight (so that terminal
15 can switch off automatically after a certain
period).
If nec., charge the high-voltage battery (12 V
battery is charged via the high-voltage battery).
4. Pull off connector (1).
This state must be retained for the duration of the
entire drawing off, evacuation and filling procedure.
 
After filling the refrigerant circuit, reconnect
connector (1)!

Equipment specification with and without heat pump:

After filling the refrigerant circuit, delete fault memory!

Important!
Risk of damage!
Comply with SI 08 07 10 (669)!
Carefully move the climate service station!
Comply with the operating instructions and service interval
for the A/C service station!
Make sure that the hoses of the A/C service station are
drained after the drawing off or filling procedure!
The climate service station contains highly sensitive
components, such as scales. These components will be
damaged due to improper handling, such as fast driving
over a bump. This will result in a significant reduction of
the measuring accuracy when drawing off and filling.

Important!
The vehicle must be parked on the floor during all drawing
off, evacuation and filling procedures!
Filling a raised vehicle will result in insufficient filling levels.
 4/30/2016 4/7

Note:
In the event of complaints, perform A/C performance test!
If the system fails the test, draw off, evacuate and fill the
heating and air conditioning system in accordance with the
operating instructions of the relevant service station.

Instructions for drawing off air conditioning:

 
To help separation of refrigerant and refrigerant oil, run engine
at low speed (800-1200 rpm) and with air conditioning turned on
for a few minutes.
The limits the entrainment of refrigerant oil while it is drawn off.
Drawn-off refrigerant oil must be changed and reintroduced via
the A/C service station.
During drawing off, set blower of heating and air-conditioning
unit to middle blower speed. This ensures that drawing off is
more effective since the pressure on the low pressure side
increases.

Recycling:
Dispose of drawn-off refrigerant oil as hazardous waste.
Observe country-specific waste disposal regulations.

Instructions for evacuating off air conditioning:

 
Before each filling, evacuate the refrigerant system.
Observe an evacuation time of at least 30 minutes.
The evacuation procedure removes all traces of ambient air,
water vapour and any other gases present from the heating and
air conditioning system. This enables subsequent system filling
with refrigerant.
If the vacuum does not remain stable when the system is off,
run the procedure for leaks in the refrigerant circuit.
During evacuation, set blower of heating and air-conditioning
unit to middle blower speed. This ensures that evacuation is
 4/30/2016 5/7

more effective since the pressure on the low pressure side

increases.
 

Notes for filling heating and air conditioning system:

 
Before filling with refrigerant, replace the refrigerant oil
entrained during drawing off.
Also top up any lost fluid as indicated in the table:
Loss of R134a refrigerant
Table 1 indicates the permitted loss of refrigerant after a
specific period of time. There is no leak. refrigerant oil may not
be topped up.
Table 2 indicates the amount of refrigerant oil must be topped
up with an unapproved loss of refrigerant due to a leak after a
specific period of time.
Different cases:
a. Loss of refrigerant per Table 1is not exceeded

- Top up lost R134a refrigerant

- It is not permitted to top up the refrigerant oil

 

b. Loss of refrigerant per Table 1 is exceeded

- Top up lost R134a refrigerant

- refrigerant oil must be topped up additionally per

Table 2
 

Table 1: 0- 1- 2- 3-4 4-5

Number of years since 1 2 3
last filling

Permissible loss [g] --> ≤ 30 ≤ 60 ≤ 90 ≤ 120 ≤ 150

Do not top up refrigerant
oil

 
 4/30/2016 6/7

Table 2: R134a loss of Top up quantity

Number of years coolant [g] refrigerant oil
since last filling

0 -1 < 120 0

120 - 150 10

> 150 20

1-2 < 180 0

180 - 210  10

> 210 20

2-3  < 240 0

240 - 270 10

> 270 20

3-4  < 300 0

300 - 330 10

> 330 20

4-5 < 360 10

> 360 20

Follow notes for opening and replacing parts in refrigerant

circuit.
Depending on the type of component replaced on the heating
and air conditioning system, it may be necessary to the top up
the refrigerant oil, even if no measurable losses have occurred
during drawing off. Follow the notes provided by the heating
and air conditioning system manufacturer, taking account of the
tolerances (and inaccuracies) indicated in the operating
instructions of the relevant service station.
Information on the required refrigerant capacity for the entire
heating and air conditioning system is contained on the type
plate (1) in the engine compartment.
 4/30/2016 7/7

If necessary, refer to the Technical Data for capacity.

Installation note:
Reseal refrigerant filler necks on vehicle with sealing caps.
 4/30/2016 1/1

41 00 ... EMC screws

(EMC = Electro‐Magnetic Compatibility)

 

1. Purpose :

- EMC screws are used in the Bonding/Riveting repair method to re-establish bonding transition.

- They assume the function of welded joints, which ensure transition to ground between the individual
components.

- The punch or blind rivets used in the repair do not guarantee permanent bonding transition between the
individual components!

- The EMC screws ensure the operational reliability and safety of the electrical/electronic components
following repairs!

 

2. Procedure, aluminium front end :

- Each welded joint which is opened must be replaced by at least 2 EMC screws.

- Position the 2 screws on the flange on which the weld seam has been separated. In the event of partial
replacement, position the screws in the area of the component overlap.

- In the case of repairs using partial replacement, the number of EMC screws described in the repair
instructions must be fitted.

- Drill holes to a diameter of 4.2 mm and insert screws.

- Seal EMC screws with PU sealing material (risk of corrosion).

 

3. Procedure, steel body :

- Install the number of EMC screws described in the repair instructions.

- Drill holes to a diameter of 4.2 mm and insert screws.

- Seal EMC screws with PU sealing material (risk of corrosion).

 4/29/2016 1/8

Engine identification

Engine number at the marked surface.

Replacement drives are already assigned a number containing
the identification and engine number at the factory.
The old drive number must be imprinted for replacement
crankcases.
Magnesium crank cases feature a label, the engine number
does not need to be embossed.

M47 / M47TU / M47T2

M57 / M57TU / M57T2

M67 / M67TU
 4/29/2016 2/8

N47 / N47S / N47C / N47T / N57 / N57S / N57T

M52 / M52TU

M54
 4/29/2016 3/8

M56

N20 / N26

N40 / N45 / N45T / N43

 4/29/2016 4/8

N42 / N46 / N46T

N51 / N52 / N52K / N52T / N53 / N54 / N55

N62 / N62TU
 4/29/2016 5/8

Position (1) engine number.

Position (2) engine code letters.
N63, N63TU.
S63
N74
S63T0 to engine number 2001 0052 on right side cyl. 1-4.
S63T0 from engine number 2001 0053 on left side cyl.l 5-8.
E72 Vehicles must be imprinted on the left side cyl. 5-8.

N73

S54
 4/29/2016 6/8

S85 / S65

W10 / W11

W17
 4/29/2016 7/8

W20

N12 / N13 / N14 / N16 / N18 / W16

Assemble engine.
4/29/2016 8/8
 4/29/2016 1/4

11 00 300 Engine oil consumption measurement

Important!

This procedure for measuring oil consumption may not be used for the S 85 due to the oil pan design.

Many complaints about oil consumption are caused by the oil level being measured using the wrong method.

The oil consumption should be measured after a distance of 7,500 km at the earliest, as the process of
running in the engine will not have been essentially completed and the engine oil consumption stabilised until
this distance has been covered.

Engine oil consumption that may occur in an engine can only be determined by the customer on the basis of
the refilled engine oil quantity. As soon as the engine oil level falls below the MAX mark on the dipstick, many
customers top up the engine oil without paying attention to a number of basic rules, such as the vehicle must
be standing on level ground, a certain period of time must be left to allow the oil to flow back to the sump. In
such cases, the available container sizes (e. g. 1-litre can) make it easy to top up above the MAX mark. Too
much added engine oil is damaging to the engine and is consumed more quickly due to the splash effect.

It is therefore recommended to allow the engine oil level to the MIN mark and only then to add the required
engine oil quantity. The distance between the marks is equivalent to approx. 1.0 to 1.5 litres.

The procedure for checking the oil level is given in the Owner's Handbook for the vehicle concerned.

The service delegates will only deal with claims made under warranty if exact measurements by weighing are
available (see below).

Measuring oil consumption by weighing:

To assess a warranty or goodwill claim, only the following oil consumption measurement method by weighing
can be accepted (this must have been carried out by a BMW contractual partner):

Note:

The engine must not leak any oil.

Engine oil may only be drained off when the engine is at its normal operating temperature. The
engine oil temperature must be at least 95 °C and read off on the diagnosis system.

Preparation:

1. Eliminate any leaks and traces of oil before measuring the engine oil consumption.

2. Allow the engine to run at idling speed for 5 minutes, during which the engine oil temperature must not
 4/29/2016 2/4

drop below 90 °C.

3. Unscrew the main flow oil filter cover (the engine oil will flow back into the oil sump from the oil filter
housing).

Tightening specifications: O-ring slightly oiled, 1. initial tightening 30 Nm, 2. release oil filter cover 180°,
3. final torque 40 Nm.

4. Unscrew the oil drain plug.

Tightening specifications: Replace sealing ring, tighten 40 Nm.

5. Allow the engine oil to drain off for 15 minutes.

If necessary, remove the fan/fan cowl.

6. Turn the engine once through 360 degrees by the vibration damper.

7. Allow the engine oil to drain off for 15 minutes.

8. Retighten the primary flow oil filter.

9. Pour in the specified engine oil quantity for the engine type in question (with filter change).

10. Drive the vehicle for a distance of at least 1,000 km/500 miles. Increasing the mileage will produce
significantly better measuring results.

Measurement procedure:

11. Check the engine for leaks; if the engine is not tight, the examination will not be meaningful.

12. Prepare the measuring container to be able to capture the oil quantity.

13. Allow the engine to run at idling speed for 5 minutes, during which the engine oil temperature must not
drop below 90 °C.

14. Unscrew the main flow oil filter cover (the engine oil will flow back into the oil sump from the oil filter
housing).

Tightening specifications: O-ring slightly oiled, 1. initial tightening 30 Nm, 2. release oil filter cover 180°,
3. final torque 40 Nm.

15. Unscrew the oil drain plug.

Tightening specifications: Replace sealing ring, tighten 40 Nm.

16. Allow the engine oil to drain off for 15 minutes.

 4/29/2016 3/4

If necessary, remove the fan/fan cowl.

17. Turn the engine once through 360 degrees by the vibration damper.

18. Allow the engine oil to drain off for 15 minutes.

19. Weight the amount of drained engine oil. (Engine oil has a density of about 0.86 g/cm³ at room
temperature.)

Amount of oil added (cm³) ‐ amount of oil drained off (g): 0.86 g/cm³

Engine oil consumption = —————————————————————————————

mileage reading when draining - mileage reading when adding engine oil

Example:

Volume of oil added at mileage reading 44,800: 4.000 cm³

Weight of oil added at mileage reading 45,900: 2.700 g

 

4.000 cm3 - 2.700 g : 0.86 g/cm³

Engine oil consumption = —————————————— = 0.78 cm³/km

45,900 km - 44,800 km

0.78 cm³/km = 0.78 l/1,000 km

Test certificate for engine oil consumption:

Vehicle data: _____________________________

BMW (type): _____________________________

Chassis number: _____________________________

Added oil quantity (in ccm): _________________ at kilometre reading:__________

ccm

less drained off oil quantity (in g) : 0.86 _________________ at kilometre reading:__________
 4/29/2016 4/4

(g/ccm) ccm

=> oil consumption: _________________ => mileage: _____________________

ccm km

Oil consumption [l/1000 km] =

_____________ [ccm] oil consumption _____________ [km] mileage

 

Oil consumption after balancing out: ____________________________ l/1000 km

Oil grade: ____________________________

Oil grade: ____________________________

Viscosity: ____________________________

Cause of damage: ____________________________

 

___________________________________ ___________________________________

Dealer address Signature

 4/29/2016 1/2

11 . . . . . Equipment recoding special tool number of the transverse member for fixing the
engine in the installation location

Equipment recoding from 00 0 200 to 00 6 0 000

 

 

Designation Special tool new Special tool previous

Cross-member, previous --- 00 0 200

Cross-member, new 00 6 000 ---

Mounting bridge 00 6 001 00 0 201

Spindle with hook 00 6 002 00 0 202

Extension 00 6 003 00 0 203

Adapter support 00 6 004 00 0 204

Extension 00 6 005 00 0 205

Chain with hook 00 6 006 00 0 209

Set of supports 00 6 010 00 0 206

Set of supports 00 6 020 00 0 207

Set of supports 00 6 030 00 0 208

Connector 00 6 031 ---

Profile strip (2 x) 00 6 032 ---

Supports (4 x) 00 6 033 ---

Set of supports 00 6 040 ---

Profile strip 00 6 041 00 0 451

Supports (2 x) 00 6 042 00 0 452

Supports, short (2 x) 00 6 043 ---

Set of supports 00 6 050 ---

Profile strip (2 x) 00 6 051 ---

 4/29/2016 2/2

Supports, short (2 x) 00 6 052 ---

Supports, long (2 x) 00 6 053 ---

Support, long 00 6 060 ---

Supports (2 x) 00 6 070 ---

 4/29/2016 1/7

18 02 03 (062)

Exhaust standard EURO 4 and E‐OBD for diesel engines

M47TU, M57TU

Introduction

Exhaust emission standard EURO 4 is mandatory across Europe from 01.01.2005 for newly homologated
vehicle types ('homologation' = registering a production vehicle in the international registrations list). Exhaust
emission standard EURO 4 is mandatory from 01.01.2006 for the registration of all new vehicles. Exhaust
emission standard EURO 4 further reduces the limit values for pollutants in exhaust gas. [more ...]

In addition, in Europe from 01.01.2004 the European on-board diagnosis (E-OBD) is legally required for all
diesel engines in passenger cars. [more ...]

This BMW Service Technology also includes a list of fault codes for the E-OBD. [more ...]
 4/29/2016 2/7

The 4-cylinder diesel engine M47TU is installed in the E46 (RHD since 09/2003, LHD since 03/2004) with
manual gearbox and exhaust emission standards EURO 4. In 03/2004 exhaust emission standards EURO 4
was also implemented in the 6-cylinder engine M57TU. [System overview ...]

On the M57TU the E60/E61 was equipped for the first time with a diesel particle filter. The diesel particle filter
separates out the soot particles in the exhaust gas with a high level of filter performance (> 95 %). The nitrogen
oxide emissions do not affect the diesel particle filter. The nitrogen oxide pollutant emissions are reduced by
measures inside the engine. The new diesel particle filter developed by BMW does not deliver the customer
any disadvantages relating to:

- Scope of maintenance work

- Fuel consumption

- Engine power

- Nose comfort
The diesel particle filter is currently designed for approx. 200,000 kilometres (monitoring by means of Condition
Based Service). The use of a fuel additive in regeneration of the diesel particle filter is not necessary (fuel
additive reduces the ignition temperature of the soot).
Brief component description

To comply with exhaust emission standard EURO 4, the following components in the M47TU/M57TU are new
or have been modified:

- Oxygen sensor

A Lambda oxygen sensor is necessary for compliance with exhaust-gas limit values.

The oxygen sensor is required for the quantity mean value adaptation of the injectors.

The Lambda oxygen sensor measures the fuel&dash;air ratio. In the event of deviations, the DDE adapts
the exhaust-gas recirculation rate to suit the change in air/fuel ratio.

[more ...]

- Injector

The injector characteristic map is adapted to suit the fuel injection rate.

A design change has given the injection system a constant characteristic curve. That means that changes
in the injection period can directly impact changes in the fuel injection rate.

[more ...]

- Charging pressure actuator (electrical actuator drive on the exhaust turbocharger)

The exhaust turbocharger has a variable turbine geometry (VNT = ”variable turbine geometry” from the
English term ”Variable Nozzle Turbine”). To achieve compliance with exhaust emission standard EURO 4
an electrical charging pressure actuator now adapts the variable turbine geometry (previously, an
electromagnetic pressure converter adjusted the variable turbine geometry).
 4/29/2016 3/7

By virtue of the increased adjustment speed and the more rapid response to changes, greater precision is
achieved in respect of charging pressure control.

[more ...]

- Cylinder head and piston

The cylinder head has a geometrically revised swirl port and swirl port.

To improve mixture preparation, the shape of the piston recess has been modified. This has also give rise
to a change in the coolant duct in the piston.

[more ...]

- Exhaust gas recirculation cooler

The exhaust-gas recirculation cooler is now longer. The exhaust-gas recirculation cooler therefore has
increased cooling power. With the new exhaust-gas recirculation cooler, the exhaust-gas temperature is
reduced by approx. 100 °C (in the driving cycle for EURO 4).

[more ...]

- Diesel particle filter (only M57TU in the E60, E61)

The diesel particle filter has a catalytic coating which absorbs soot particles from the exhaust gas.
Continuously, the stored soot particles are incinerated once the exhaust gases reach a temperature of
approx. 350 °C.

Cyclically, the stored soot particles are incinerated once the exhaust gases reach a temperature of
approx. 600 °C.

[more ...]

When the diesel particle filter is used, additional components are required for the Digital Diesel
Electronics (DDE):
 Throttle valve

Under certain operation conditions, the throttle valve throttles the intake air. In combination with 1 to
2 post injections, this leads to an increase in the exhaust-gas temperature (regeneration of the
diesel particle filter). [more ...]
 Exhaust backpressure sensor upstream of the diesel particle filter, exhaust temperature sensor
upstream of catalytic converter and exhaust-gas temperature sensor upstream of the diesel particle
filter

With the exhaust backpressure sensor, the level of load on the diesel particle filter is calculated
when the vehicle is in motion. Whenever the diesel particle filter has built up too many soot
particles, a regeneration cycle is initiated.

As a further parameter, the exhaust-gas temperature is measured upstream of the diesel particle
filter. Measurement of the exhaust back pressure by the exhaust backpressure sensor is not
sufficient in its own right (load-dependency).
 4/29/2016 4/7

From both these signals, the DDE calculates the precise loading for the diesel particle filter.

The exhaust temperature sensor upstream of catalytic converter monitors the exhaust-gas
temperature upstream of the oxidation catalytic converter. Regeneration of the diesel particle filter
cannot take place until an exhaust-gas temperature of approx. 350 °C.

[more ...]
 Leaktight swirl flaps

The M57TU has totally leaktight swirl flaps (electrically activated in the E46, otherwise activated by
vacuum). This does not give rise at the lower end of partial load operation to any leakage around
the swirl flaps, making an increase in swirl possible. In addition, with the electrical activation
function, a tremendously wide variety of intermediate settings on the swirl flap can be achieved.
System functions

Despite component tolerances and influences on components over their operating time (e.g. wear), careful
attention must be paid to these points: The emissions threshold values must be complied with to a sufficiently
large safety distance. More extensive emission-related fluctuations can be anticipated in the first instance from
the following components:

- Injectors

- Hot film air mass meter

- Rail pressure sensor

The tolerances of the components and the influences over the operating time on component must be
compensated for. For compensation on the DDE (Digital Diesel Electronics) the following system functions
exist:

- Injection quantity compensation

- Zero-quantity adaptation

- Mean quantity adaptation

- Regeneration of the diesel particle filter (only M57TU in the E60, E61)
Injection quantity compensation

Injection quantity compensation involves the definition of correction values for pre-injection and main injection
of an injection system. The injection quantity compensation process is conducted at the end of the production
process.

The tolerances given to the injectors on manufacture mean that the actual injected fuel quantity deviates
slightly from the calculated fuel quantity. The extent of this deviation is established after production for every
injector by measurements, conducted across several operating points.

From these measurements, an adjustment value (code) is generated for each injector.

The structure of the alphanumeric code depends on the exhaust emission standard applicable to that engine:
 4/29/2016 5/7

 Exhaust emission standard EURO 3: six-digit (e.g. 78SNGT)

 Exhaust emission standard EURO 4: seven-digit (e.g. 88S66NB)

During vehicle assembly, after installation of the DDE control unit, the adjustment value of each installed
injector is stored in the DDE control unit. The adjustment values are allocated to the individual cylinders
according to the installation of the injectors. With these adjustment values, the DDE control unit corrects the
calculated fuel injection rates slightly and, in this way, it reduces the cylinder-specific deviation of the fuel
injection rate.

Whenever injectors have to be replaced, it must be ensured that the stamped alphanumeric code of each
injector is assigned to the correct cylinder in the DDE control unit.

The BMW diagnosis system has the service function ”Injection quantity compensation”. With this service
function, the code for each cylinder can be changed and stored on the DDE control unit.

For cylinders for which no new adjustment value is entered, the old adjustment value is retained in the DDE
control unit. Injection quantity compensation must also be performed if the DDE control unit is replaced and
communication was no longer possible with the old control unit.

The codes for the injectors installed must be read off and stored in the DDE control unit.
Zero-quantity adaptation

Zero-quantity adaptation is the adaptation process which is used after the running-in phase (approx. 1500 km)
for every single injector to assure the presence of a defined level of pre-injection.

To achieve compliance with exhaust emission standard EURO 4, precise metering of the very small fuel
injection rate is required for pre-injection purposes.

Due to the deviation for the fuel injection rate over the operating time, the zero-quantity adaptation is
performed continuously by the DDE control unit.

For every cylinder in coasting (overrun) mode, a small quantity of fuel is injected. This quantity is then varied
until the desired torque rating is detected by the DDE. To calculate the torque rating, the irregular rotation of
the crankshaft is incorporated in the equation. This irregular rotation is recorded on the crankshaft sensor.

This enables the DDE to detect the activation duration after which the cylinder starts to operate. The quantity
of fuel injected during the zero-quantity adaptation period is used by the DDE as a correction value for the
gearshift map of the pre-injection process.

The zero-quantity adaptation process switches from one cylinder to another in each overrun phase at:
 engine speed 1500 to 2500 rpm (engine at operating temperature)

The zero-quantity adaptation has no impact on fuel consumption because only a small quantity of fuel is
3
injected into each cylinder (approx. 1 mm ).
Mean quantity adaptation

Mean quantity adaptation is the adaptation process at which the air/fuel ratio is corrected (partial load range).
This correction is performed by adapting the amount of air by means of the exhaust-gas recirculation valve.

Whereas no additional components are required for the injection quantity compensation and for the zero-
quantity adaptation, an oxygen sensor is required for the mean quantity adaptation. The oxygen sensor is a
 4/29/2016 6/7

broadband oxygen sensor with a constant characteristic curve.

The mean quantity adaptation is not a rapid control operation, but is instead an adaptive learning procedure.

An oxygen sensor deviation is ”learned” in a characteristic map and stored for a sustained period in the DDE
control unit (EEPROM).

The characteristic map must be reset (deleted) in EEPROM if any of the following components is replaced:
 Hot film air mass meter
 Injector
 Rail pressure sensor

To reset the characteristics map, the BMW diagnosis system offers the service function of ”mean quantity
adaptation”.
Regeneration of the diesel particle filter (only with M57TU in the E60, E61)

The soot load in the diesel particle filter is established by the DDE from the engine operating points.

Regeneration of the diesel particle filter can be continuous and/or cyclical.

 Continuous regeneration:

In operating ranges at which the exhaust-gas temperature exceeds the ignition temperature of the soot
(> 350 degrees Celsius), the soot particles are converted directly. This involves the soot particles being
converted by a process of slow oxidation into carbon monoxide (CO) and carbon dioxide (CO2).

The oxidation agent is the nitrogen dioxide present in the exhaust gas (NO2). This nitrogen dioxide is
formed from the nitrogen monoxide (NO) in the oxidation catalytic converter.

If the exhaust-gas temperature is not hot enough for this process, the soot particles are initially collected
in the diesel particle filter and are then incinerated the next time that the exhaust-gas temperature
increases.
 Cyclical regeneration:

If the driving style does not permit continuous regeneration of the diesel particle filter (e.g. long,
sustained partial load operation in urban traffic and low exhaust-gas temperature), targeted regeneration
is initiated.

This process is controlled by signals from the exhaust backpressure sensor and two exhaust-gas
temperature sensors. Cyclical regeneration runs like continuous regeneration without significant
implications on drivability.

Depending on the load condition of the engine, regeneration can take the form of targeted throttling of
intake air in conjunction with 1 to 2 post-injections. This raises the exhaust-gas temperature to approx..
600 degree Celsius. The residual oxygen in the exhaust gas (O2) enables soot to be burned off. The
regeneration of the diesel particle filter can take several minutes. The interval stages for regeneration
depend on the operating conditions of the vehicle over its last 500 kilometres. At high exhaust-gas
temperatures, there is less soot buildup as a result of continuous incineration of the soot particles.

In addition, every 700 to 2500 kilometres (depending on driving profile), regeneration of the diesel
 4/29/2016 7/7

particle filter can be initiated. In the event of failure of the exhaust backpressure sensor or of one of the
exhaust-gas temperature sensors, the diesel particle filter is regenerated every 500 kilometres.
Notes for Service department

Observe the following information for service:

- General information: [more ...]

- Diagnosis: [more ...]

- Encoding/programming: ---

- Car & Key Memory: ---

No liability can be accepted for printing or other faults. Subject to changes of a technical nature
 4/29/2016 1/3

11 37 ... Fault patterns, valve gear (N20/26 /

N55)

Warning!
The preloading on the throttle return springs increases as
the rotation on the worm gear increases. Danger of injury!
The eccentric shaft may only be twisted on the mounting
flats for protection.
Risk of damage to the eccentric shaft gearing and to the
servomotor worm drive.
The eccentric shaft must not spring back to the minimum
stroke stop. Risk of damage!

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove ignition coil and injector shafts.

Warning!
Heed stop installation instructions.

The eccentric shaft on the mounting flats (2) must only be

turned with an open-end spanner (1) for support.
The eccentric shaft has mounting flats on both sides; if the
engine is installed, the front mounting flat must be used.
Heed the following work instructions.
After the engine stops, the eccentric shaft is in the maximum
stroke position.
If the actuator drive is defective, the eccentric shaft is located in
an undetermined position.

Check throttle return spring (2) for breakage and correct

installation position on intermediate lever (1).
 4/29/2016 2/3

Check roller cam follower (3) for correct installation position.

Check that intermediate lever (1) is correctly seated.

Note:
Graphic does not show sliding block.

Check wear at stop (1) - minimum lift and maximum lift.

Check that stops are securely seated.
Tightening torque: 11 37 5AZ.

Stiff movement in eccentric shaft bearing is excluded.

Stiff movement can occur in worm gear.
 4/29/2016 3/3

Assemble engine.
 4/30/2016 1/6

41 00 ... Frame reference dimension, body

Dimensions in mm.
Dimension tolerances:

- ≤ 1000 mm ± 1.5 mm

- ≥ 1000 mm ± 2.5 mm

The control points shown serve to check the body and the set of attachments.
The specified dimensions always refer to the centrepoint of the bore hole/screw.

Underbody view 1
 4/30/2016 2/6

Underbody view 2
 4/30/2016 3/6

Top view, front end

 4/30/2016 4/6

The specified dimensions refer to removed assemblies.

View of B-pillar (four-door)

 4/30/2016 5/6

Measurement a=1495 mm between screw-on points of door brakes.

View of B-pillar (two-door)

 4/30/2016 6/6

Measurement a=1511 mm between the top screw-on points of the lock striker.

 4/30/2016 1/1

31 00 ... Front axle + steering: wheel/chassis

alignment check must be carried out
after the following work

 
A wheel alignment check must be carried out after the following work:
Release the following screw connections:
 Steering box to front axle support
 Lower wishbone to front axle support
 Track rod end to track rod
Replace the following components:
 Steering box (1)
 Front axle support (2)
 Wishbone, bottom (3)
 Track rod end (4)
 Track rod (5)
 Swivel bearing (6)
 4/30/2016 1/1

31 .. ... Front axle overview

    Safety instructions and general information  

       

1 Anti-roll bar / anti-roll bar link   Testing/adjustment work

2 Trailing link/rubber mount    

3 Swivel bearing    

4 Support bearing    

5 Front axle support    

6 Coil spring    

7 Spring strut shock absorber    

8 Wheel bearing    

9 Wishbone, ride height sensor    

 4/30/2016 1/1

51 01 00 (530)

Front licence plate holder

All models

Situation:
Most BMW dealers use a licence plate backing panel with their company name for fitting
the rear licence plate.

The same backing panel is also frequently used for the front licence plate.
Effect: Fitting such a backing panel to the front bumper is a contravention of licencing regulations
74/483 EEC as it does not meet the specification for protecting pedestrians.

Extract from EC Directive 74/483: "No protruding section of the exterior surface of the
vehicle shall have a rounding-off radius of less than 2.5 mm".

The consequence is the invalidation of the German Federal Vehicle Homologation

Approval and serious disadvantages for the BMW dealer in the event of litigation.

Moreover, the name of the dealership on the licence plate backing panel adjusts the
height of the licence plate, so impeding the cooling air inlet and negatively affecting the
cooling efficiency of the engine at high loads.
Affected All models.
vehicles:
Procedure: Do not install a separate licence plate backing panel on the front bumper. The licence
plate backing panel fitted at the factory corresponds to all requirements regarding safety,
operation and styling.

Important! To prevent rattling noises being caused by the licence plate, the foam-rubber
strips in the by-pack kit must be used as backing and attached double-sided to the licence
plate and to the vehicle.

All necessary securing screws and white or coloured cover flaps can be found in the by-
pack kit.
Parts: Standard licence plate backing panels and mounting components are listed according to
model in the Electronic Parts Catalogue and can be ordered via the customary parts
ordering channels.
 4/30/2016 1/5

41 00 ... Gap dimensions, body

The dimensions specified in this document are

applicable at an object temperature of 20 °C. The aim
of adjustment is to achieve a uniform gap.
Symmetry of the gaps between left and right sides of
the vehicle has top priority.
For door gaps, the maximum deviation between the
front and rear door gaps must be 1.0 mm.
No gap dimension are specified for components which
cannot be adjusted.

Dimensions in mm

1. Panel, bumper, front

2. Engine compartment lid
3. Headlight
4. Front side panel
5. A-pillar
Dimension a increases in size in direction of travel from 0 mm at the front to 1.3 ± 1.6 mm.
 4/30/2016 2/5

1. Front side panel

2. Front door:
3. Rear door
4. Trim panel for entrance
 4/30/2016 3/5

1. Rear door
2. Rear side walls
3. Trim panel for entrance
 4/30/2016 4/5

1. Roof outer skin

2. Rear spoiler
3. Rear side walls
4. Rear window
5. Tailgate
 4/30/2016 5/5

1. Tailgate
2. Rear lamps
3. Trim panel, bumper, rear
 4/30/2016 1/1

32 00 ... General chassis and suspension

definitions

1. Toe 5. Wheel misalignment

2. Camber 6. Camber
3. Caster (with 10° or 20° wheel lock) 7. Rear-wheel position
4. Toe angle difference (with 20° wheel lock) 8. Toe
9. Geometrical driving axis
 4/30/2016 1/1

36 00 ... General information on light alloy disc

wheels

Note:
It is sometimes difficult to distinguish light alloy disc wheels
visually from steel disc wheels.

Identifying features:

- Sticker on light alloy disc wheel. (1) = Indication

”Aluminium”

- Wall thickness of rim dish: approx. 8 mm.

- Light alloy disc wheels are not magnetic.

- Light alloy disc wheels can be identified from their BMW

parts numbers, refer to BMW Parts Department.

Important!
- Use only BMW-approved two-part balancing
weights.

- When fitting two-part balancing weights, always use

specified tools.

- Do not straighten light alloy disc wheels: always

replace damaged light alloy disc wheels.

- Notches in light alloy disc wheels can lead to

cracking.

- Do not lubricate wheel studs.

- When fitting tyres, avoid damaging light alloy disc

wheels, e.g. on sharp-edged retaining claws on tyre
fitting machine.
 4/30/2016 1/1

99 00 ... General instructions on paintwork

General instructions and classification of paint stages are described on the KSD‐CD (notes‐general
information on flat rate unit data, passenger vehicle explanation for FR specifications for paintwork).

 

The marked area serves as reference value for paintwork. This area may differ from the illustration for
technical painting reasons.

Touching-up areas are taken into account.

 

Special procedure for matte paintwork:

Matte paintwork cannot be touched up since the painted surface cannot be polished.

For further information, see also the BMW painting handbook and the Aftersales Assistance Portal.
 4/30/2016 1/3

51 14 ... General notes for labelling with adhesive films

In the event of a repair the adhesive films must be partially or completely replaced. The basic procedure for all
areas of the vehicle is described below.

In addition, vehicle-specific repair instructions are available.

 

1. Preparation:

Wash and dry vehicle. Rework with compressed air as required in area of joints.

Clean complete component surface with glass cleaner (BMW part number 83 12 0 396 775). Also clean the
inside of the component in areas, in which adhesive films are applied.

Only carry out repair work with clean hands!

Important!

Labels can only be applied to recently painted components after a waiting period of 2 weeks. The paint
hardening is only fully completed after this time.

 

2. Procedure for applying labels:

All adhesive films in the repair kit are marked with numbers. Prepare the required plastic films prior to start of
repairs.

The templates included in the repair kit assist orientation. A straight line running over the different
components is the top priority.

Pull off the templates positioning of the adhesive films.

Only throw away templates after completion of all repair work, as some templates are used several times.
 4/30/2016 2/3

Templates are always applied along the light

edge (1). The light edge is the reflection of
the light source in radius (see arrow).

Roughly align the adhesive film using a template.

For large adhesive films, pull off the first 20 cm of protective film and fold back the edge.

Align and lightly press down the adhesive film. Use only one finger for this and not the entire hand so that air
pockets are unable to form under the adhesive film.

Pull off the remaining protective film and press down the adhesive film from front to rear and from inside to
 4/30/2016 3/3

outside.

If faults are made in applying the adhesive film, it can be pulled off and repositioned several times. When no
further corrections have to be made, use a squeegee to press down the adhesive film firmly from inside to
outside.

Lay protruding ends of the adhesive film around the component edge and press down firmly.

Carefully pull off backing film (1) at an acute

angle.
 4/30/2016 1/9

51 31 ... General procedure when dismantling/installing bonded window glass

1 General information

Follow general instructions on window bonding.

Materials needed for window bonding.

The vehicle can be towed away or driven without a windscreen, rear window and side window.

When carrying out dismantling/installation work and during the hardening time, the vehicle must be standing
on its wheels on a level floor.

The windscreen, rear window and side windows are glued to the body. This bonding will increase the torsional
rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the
following.

 

2 Disassembly

The following dismantling methods are applied, according to the version:

- Roll Out 2000

- Oscillating knife (not permissible for vehicles with window bonding on carbon body components)

- Cutting wire with wire pull handles 

- Windscreen removal system "Spider"

Note:

When cutting out the window glass with wire pull handles, there is a risk of damage to the window
glass if the wire is pulled over the window edge.

Unless otherwise described, only use this method when replacing the window glass.

Follow the vehicle-specific repair instructions!

 

3 Installation

3.1 Preparation
 4/30/2016 2/9

Place the front or rear window on the universal work table or fix it onto the tool trolley with a suction lifter.

When placing the window glass on the universal work table, attach two suction lifters to the window glass.

According to its size, fix side and door window glass onto the tool trolley using suction lifters or special tool
51 3 220 and set down on a suitable support.

Always keep the suction faces of the window glass suction lifters dry and clean.

Note:

If accessibility is restricted, insert the window glass on a trial basis.

Bond two yellow plastic adhesive tapes (1) approx. 400 mm in length to the roof.

(A) = 250 mm

Only the yellow plastic adhesive tape may be used to fix the window glass.

The glass will slip down if other adhesive tapes are used.

Window glass slippage will result in leaks and wind noises.

After completing the paint work, the paint must be fully hardened before the plastic adhesive tapes are
applied.

 

3.2 Pre-treatment of bonding surfaces

- Clean window glass and body aperture with cleaning agent R2

Attention! Do not use Sika remover 208 for cleaning in the adhesive area.
 4/30/2016 3/9

- Observe an air drying time of at least 5 minutes (at least 15 minutes when applied to residual adhesive
bead)

- Remove residual adhesive bead from body and window glass (see point 3.3)

- Touch up paintwork damage to body aperture with BMW multibase filler (except for carbon body
components)

- Only for a newly painted body aperture, apply paint activator (blue stick) to paint and then wipe dry with
a paper towel

- Observe an air drying time of at least 1 minute (at least 10 minutes when applied to residual adhesive
bead)

 

3.3 Remove adhesive residue from the body and window glass

Do not remove residual adhesive bead (1) until shortly before bonding.

To remove the residual adhesive bead (1) from the body aperture and when reusing on the window
glass (3), use the pinchweld scraper (2).

Position the pinchweld scraper (2) as shown and detach residual adhesive bead (1) to a thickness of
approx. 0.5 mm.

Attention!

Carbon body components are not to have scratches with a depth greater than 0.2 mm.

Note, comply with life module check!

 
 4/30/2016 4/9

3.4 Installation of spacer (spacer buffer/dual-lock tapes)

Remove all remnants of existing spacers completely before sticking on new spacers.

The exact position of the spacers must be retained (see vehicle-specific repair instructions).

Incorrectly fitted spacers will result in:

- Window glass breakage due to tension

- Leakage (if the spacer is in the adhesive area)

- Wind noises

 

3.5 Add-on part

Depending on the version, attach sealing, expanding foam tape, rain sensor, etc.

Observe Overview of additional work with rain sensor when working with versions including the rain sensor!

Follow the vehicle-specific repair instructions!

 

3.6 Pre-treatment of new window glass

- Apply a thin coat of glass activator (yellow stick); a final wipe is not necessary.

- Observe an air drying time of at least 2 minutes

The glass activator is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin,
homogeneous and continuous line of glass activator must be applied. If the window glass is to be reused with
a cut-back adhesive bead, glass activator is not needed.

It must be guaranteed that a 1 to 2 mm wide line of glass activator is located on the ceramic glass next to the
squeezed adhesive bead.

The adhesive bead may become up to 15 mm wide in compressed condition. The width of the glass activator
is therefore normally a minimum of 17 mm for windscreens and rear windows and a minimum of 9 mm for
side windows.

The glass activator may not be applied in the field of view or the point grid. Fresh glass activator in the field of
view must immediately be wiped off with cleaning agent R2 because hardened glass activator will leave a
haze behind.
 4/30/2016 5/9

 

3.7 Version with inspection glass for vehicle identification number in windscreen

Foam tape (2) must be installed to protect the vehicle identification number (1) against tampering. If
applicable, install foam tape TNR 07 14 7 222 909.

Close off the inspection glass on the windscreen (bottom left) with Sika bonding base VP 206.

Except for:

- All US/GB models

- All models with a black dashboard cover, which means that the vehicle colour cannot be seen through
the inspection glass

 

3.8 Nozzle preparation

 4/30/2016 6/9

When not using standard nozzle C, prepare plastic nozzle(s) for shaping the adhesive bead.

Follow the vehicle-specific repair instructions!

Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside edge of the
window to protect the adhesive bead.

Ceramic glass must not be damaged.

 

3.9 Apply adhesive

Adhesive is applied to the window glass with a cartridge gun.

Glue cartridge must be vertical to window glass.

The almost vertical part of the adhesive bead must be facing the outer window glass edge.

On window glass with guidelines, the adhesive bead must be applied centrally between the guidelines.

On window glass without guidelines, the position of the adhesive bead is specified in the vehicle-specific
repair instructions.

Coat bead joint.

Effect of differing adhesive quantities:

Too little adhesive: Too much adhesive:

- Window glass rests too low in - Window glass rests too high in body aperture
body aperture
- Wind noise may occur
- Insufficient squeezing of adhesive
bead (leaking) - Strains/tensions may occur (window glass breakage)

- Dirt contamination of add-on parts by emerging adhesive

- Adhesive on uninsulated strainer pressure lines of aerial(s)

(interference of reception)

Note on bonding of windscreen:

The adhesive amount specified in the vehicle-specific repair instructions is sufficient if the specified adhesive
bead size is maintained.
 4/30/2016 7/9

If too much adhesive is applied due to application-related variations (manual application), the specified
adhesive amount may not be sufficient. To avoid interrupting adhesive application for longer than the
permitted period, have another glue cartridge ready.

Important!

Once the adhesive bead has been applied, the window glass must be installed within 7 minutes
(depending on air humidity, temperature).

After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.

 

3.10 Mounting the window glass

To prevent a pressure build-up in the passenger compartment when the doors are closed:

- Open a side window

Mount window glass (1) with suction lifter (51 3 010).

 

3.11 Adjusting the window glass

 4/30/2016 8/9

To avoid wind noise, the front and rear windows (1) must be lower than the roof outer skin (2).

Check ride height of the windscreen or rear window using special tool 51 0 010.

Dimension (A) of window glass offset, refer to vehicle-specific repair instructions.

X = measurement stages 1 ... 4 mm

 

3.12 Fixing the window glass

Fix the window glass with yellow plastic adhesive tapes (2).

Immediately remove dirt contamination with adhesive residue using Sika remover 208. Do not press out the
window glass again.

Hardened adhesive can only be removed mechanically.

 
 4/30/2016 9/9

3.13 Label

Depending on version, apply label.

 
 4/30/2016 1/2

41 00 ... Grinding aluminium components

1.0 Recommended tools and equipment

Grinding work on the outer skin:

- To carry out grinding work by hand or machine, you must use the recommended tools and equipment
(refer to Service Information 5 03 03 975).

The workbay can be cleaned with conventional extractor systems (low dust concentration).

Grinding work on the structure (except Z8):

- To carry out grinding work by hand or machine, you must use the recommended tools and equipment
(refer to Service Information 5 03 03 975).

The workbay can be cleaned with conventional extractor systems (low dust concentration).

Z 8 Spaceframe structure:

- To carry out machine grinding on the structure, you must use the recommended device with grinding
dust extractor facility (refer to Service Information 5 01 00 532).

The workbay must be cleaned with the recommended explosion-proof extractor system (refer to Service
Information 5 01 00 532).

High dust concentration, explosion hazard!

 

2.0 Grinding outer skin and structure

Do not use any abrasives (grinding wheels, paper, etc.) which contain iron (risk of corrosion).

Always replace abrasives which have already been used to treat steel (risk of corrosion).

Use stainless steel wire brushes only (risk of corrosion).

Reduce speed of grinding machines. Excessive speeds cause a smearing effect.

Do not use coarse abrasive grains (only ≥ 80).

Do not grind notches into the material (risk of cracking).

 4/30/2016 2/2

Do not grind the material thin.

 4/30/2016 1/1

63 12 ... Headlight fogging fault pattern

Note:
Certain weather conditions can lead to fogging on the inside of
the headlight lens.
This is not necessarily a fault that requires replacement of the
headlight.

(A): Permissible fogging. Headlight does not

need to be replaced.
(B): Impermissible fogging. Replace the
headlight.
 4/30/2016 1/1

64 02 00 (553)

IHKA control panel: LED in A/C button flashes

All models with integrated automatic heating and air conditioning

(option 534)

Complaints:
After a new IHKA control panel has been installed, the LED in the A/C button flashes.

Cause: The flashing of the LED in the A/C button indicates that the automatic air-conditioning
system is in the compressor protection mode. This protective function is intended to
ensure an adequate refrigerant distribution the first time the air conditioner is operated (in
the vehicle factory), before the engine is revved up.

The spare part is identical to the IHKA control panel used in series production. For this
reason, the said protection mode is always active the first time a new IHKA control panel
is installed. The LED in the A/C button will then flash continually until the A/C compressor
has been engaged for about 90 seconds at an engine speed of less than 1500 rpm.
Affected vehicles: All models with integrated automatic heating and air conditioning (option 534)

Procedure: After a new IHKA control panel has been installed, the air conditioner must be run
continually with the engine at idling speed until the LED in the A/C button stops flashing.

Under certain marginal conditions (e.g. very low ambient temperatures), it is possible that
the A/C compressor is not permanently active. In such cases, the LED in the A/C button
can continue flashing for several minutes.
 4/30/2016 1/1

36 0106 (251)

Inflating tyres with nitrogen (N2)

All series

Situation:
The question is regularly asked, whether inflating the tyres with nitrogen instead of air has
any benefit with respect to a ”gradual loss of tyre pressure”. This process is also known as
diffusion (diffusion is the movement of miniscule particles, especially atoms or molecules).

Statement

Some companies regard inflating the tyres with nitrogen as a way of selling the customer
a feature that has no practical benefit whatsoever with respect to diffusion. As nitrogen
has larger molecules, it would indeed be logical to argue in favour of inflating the tyres
with nitrogen instead of with air. However, the improvement achieved is only marginal
because air is anyway made up of about 78 % nitrogen.

Composition of air:
 78 % nitrogen (N2)
 21 % oxygen (O2)
 <1 % inert gases
 0.03 % carbon dioxide (CO2)

The reduced rate in the drop in pressure inside the tyre is just a few hundredths of a bar
over several months. Inflating the tyres with nitrogen does not relieve the driver from his
duty (described in the Owner's Handbook) to check the tyre pressures regularly. Nitrogen
is used in aviation and in motor racing because, in the event of an accident and the
associated risk of fire, no additional oxygen should be fed from the tyres.
Affected All series
vehicles:
Procedure: Recommendation

BMW does not recommend inflating tyres with nitrogen. Should individual customers wish
to have their tyre inflated with nitrogen, their wishes may be accommodated.
 4/30/2016 1/2

0 ... Information for handling the documents: repair instructions, technical data, AZD

The present repair instructions are used for the correct execution of maintenance and repair work for
unmodified standard passenger car products of the BMW Group.

As prerequisite for the execution of the above stated repair work, a completed training is necessary, such as
automotive mechatronics engineer, regular continued education such as system specific courses (e.g. hybrid
car, electric vehicle) are required.

The repair instructions describes installations and removals or replacements of Unified Parts Groups on the
vehicle.

If reference is made in the information to the use of special tools, these tools must be used without fail to
ensure the correct and safe completion of the repair steps. Safety information is to be stringently observed.

Cross references to other repair instructions as well as to ”technical data" and ”AZD" must be observed.

If there are no cross references to AZD in the repair instructions, the extracts from the company standard
BMW Group 90003-2 must be observed.

Cross references to other repair instructions can refer to a complete work scope or only to single, therein
contained operations.

Cross references to other operations or job numbers cannot be consulted as an extension of the job
guidelines.

The organisation of the repair instructions corresponds with the number system of the flat rate manuals (job
number).

In general, in the repair instructions, within the individual operations, only the removal of Unified Parts Groups
are described. The installation takes place in reverse order. If there are special items to be observed during
installation, then as ”installation notes:” they will be brought to attention. In addition to these, for complicated
processes, the removal and installation will be described separately.

Components that are installed on both vehicle sides (e. g. headlights, exterior mirrors or body components)
are described in the repair instructions based on the left side. The procedure are mirrored when applied to
components on the right vehicle side. Exception: The procedure differs on the left and right. In this case, the
steps are also shown for the right side.

(left: in direction of travel, left, right: in direction of travel, right)

The repair instructions describe repair work on left hand drive vehicles. These are, if possible, mirrored when
performed on right hand drive vehicles.

Hybrid technology: Repair work can only be made by specially trained "electrical technicians for high-voltage
systems on intrinsically safe vehicles" or " experts for repair work on high-voltage intrinsically safe vehicles".
 4/30/2016 2/2

In vehicles with high-voltage components, the corresponding safety information must be stringently observed
before work can begin!

Repair work on live high-voltage components is generally prohibited!

Before every step that affects a high-voltage component, the high-voltage system must be de-energised and
locked out against unauthorised start-up.

If improperly used, there is the danger of subsequent damage and the therewith connected safety risks.

Hydrogen technology: Repair work on a Hydrogen 7 (E68) must only be carried out following consultation with
the vehicle-specific registered representative (see owner's handbook for vehicle).
 4/30/2016 1/2

0 ... Information for handling the documents: repair instructions, technical data, AZD

The present repair instructions are used for the correct execution of maintenance and repair work for
unmodified standard passenger car products of the BMW Group.

As prerequisite for the execution of the above stated repair work, a completed training is necessary, such as
automotive mechatronics engineer, regular continued education such as system specific courses (e.g. hybrid
car, electric vehicle) are required.

The repair instructions describes installations and removals or replacements of Unified Parts Groups on the
vehicle.

If reference is made in the information to the use of special tools, these tools must be used without fail to
ensure the correct and safe completion of the repair steps. Safety information is to be stringently observed.

Cross references to other repair instructions as well as to ”technical data" and ”AZD" must be observed.

If there are no cross references to AZD in the repair instructions, the extracts from the company standard
BMW Group 90003-2 must be observed.

Cross references to other repair instructions can refer to a complete work scope or only to single, therein
contained operations.

Cross references to other operations or job numbers cannot be consulted as an extension of the job
guidelines.

The organisation of the repair instructions corresponds with the number system of the flat rate manuals (job
number).

In general, in the repair instructions, within the individual operations, only the removal of Unified Parts Groups
are described. The installation takes place in reverse order. If there are special items to be observed during
installation, then as ”installation notes:” they will be brought to attention. In addition to these, for complicated
processes, the removal and installation will be described separately.

Components that are installed on both vehicle sides (e. g. headlights, exterior mirrors or body components)
are described in the repair instructions based on the left side. The procedure are mirrored when applied to
components on the right vehicle side. Exception: The procedure differs on the left and right. In this case, the
steps are also shown for the right side.

(left: in direction of travel, left, right: in direction of travel, right)

The repair instructions describe repair work on left hand drive vehicles. These are, if possible, mirrored when
performed on right hand drive vehicles.

Hybrid technology: Repair work can only be made by specially trained "electrical technicians for high-voltage
systems on intrinsically safe vehicles" or " experts for repair work on high-voltage intrinsically safe vehicles".
 4/30/2016 2/2

In vehicles with high-voltage components, the corresponding safety information must be stringently observed
before work can begin!

Repair work on live high-voltage components is generally prohibited!

Before every step that affects a high-voltage component, the high-voltage system must be de-energised and
locked out against unauthorised start-up.

If improperly used, there is the danger of subsequent damage and the therewith connected safety risks.

Hydrogen technology: Repair work on a Hydrogen 7 (E68) must only be carried out following consultation with
the vehicle-specific registered representative (see owner's handbook for vehicle).
 4/30/2016 1/2

64 00 ... Information on using cleaning

agent/paints (personal protection
equipment)

Warning!
Use of cleaning agents/paints not compliant with
instructions can cause serious injuries or burns!
Handling cleaning agents/paints can trigger allergic skin
and respiratory reactions!

Important!
Observe following instructions:
 Store cleaning agents/paints only in a secure
cabinet.
 Keep cleaning agents/paints away from naked
flames and other sources of ignition.
 Protect cleaning agents/paints from high
temperatures and direct sunlight.
 Always keep an eye douche on hand, change the
water regularly (once a month).

Important!
Observe following instructions before use:
 Manufacturer's instructions (on container/packaging)
 Hazard warnings (on container/packaging)
 Manufacturer's instructions on package insert
 Material safety data sheet of manufacturer
 Product information in EPC
 National market regulations

Important!
Observe following instructions during use:
 Do not eat, drink or smoke while working with these
products.
 Avoid direct contact with skin and eyes.
 4/30/2016 2/2

 Wear personal protective clothing/equipment.

 Ensure that all enclosed areas are well ventilated or
extract fumes directly.
 Immediately change working clothes soiled with
cleaning agent/paint.
 After finishing work, wash your hands and apply
protective skin cream.

Important!
Follow hazard warnings and wear personal protection
equipment!

First Aid:
 If product comes in contact with eyes, immediately flush
with running water for about 10 - 15 minutes. Seek the
advice of eye specialist.
 In the event of skin contact and where applicable an
allergic skin reaction, clean the affected areas
immediately with soap and water and then apply silicone-
free skin cream. Seek advice of physician.
 If an adhesive product is swallowed, rinse mouth/parts of
mouth thoroughly with running water. Drink 1-2 glasses of
water. Do not induce vomiting. Consult a doctor.
 After inhaling vapours ensure ample supply of fresh air.
Keep calm, keep respiratory tracks clear and call doctor.

Recycling:
Dispose of cleaning agents/paints in a professional
manner!
Observe national/country-specific disposal regulations.
 4/30/2016 1/1

36 00 ... Information/recommendations and repair methods for aluminium wheels

 

Cosmetic repairs of aluminium wheels using ColorSystem

 

Recommendations and repair methods for aluminium wheels are described in the ASAP system under the
following link:

 Aftersales Assistance Portal

 Service/Technology

 ColorSystem

- Repair recommendations for aluminium wheels

 4/30/2016 1/1

51 04 97 (278)

Information sticker exterior paintwork

All Models

Situation:
The information sticker for the exterior paintwork will be affixed manually at the familiar
points in the engine compartment up to the end of 1997. As from January 1998, these
information stickers will be discontinued for vehicles equipped with EC type identification
plates. The information concerning the exterior paintwork will be provided in the bottom
section of the new EC type identification plate with laser inscription.

Effect: The separate identification sticker will still be used for all other
country-specific versions and individual types of paint but now with
laser inscription.
Affected All Models
vehicles:
Procedure: All BMW models from the Munich, Dingolfing, Regensburg and South
Africa production plants will be equipped with the new EC type
identification plate as from January 1998.

Spartanburg will follow at a later date.

 4/30/2016 1/1

36 11 000 Initialising Run Flat Indicator (RPA)

Note:
Checking the tyre pressure is based on speed monitoring of the
wheels in relation to each other. A tyre puncture is detected and
signalled by way of a deviation in specific speed ratios.
The four tyres mounted on the vehicle are monitored while the
vehicle is driving.
Initialisation must be carried out in each case immediately after
tyre pressures have been corrected, after tyres/wheels have
been exchanged and after repair work to the air spring system.

Important!
The Run Flat Indicator does not function when the vehicle
is driven with the compact spare wheel.

Please refer to the relevant Owner's Handbook for details of the

initialisation procedure.
 4/30/2016 1/1

64 12 ... Initialising Telestart hand-held

transmitter

Note:
The Telestart hand-held transmitter must be initialised when:
 Hand-held transmitter is replaced
 Car Access System control unit is replaced
The auxiliary heater is switched on with the hand-held
transmitter and at a preselected switch-on time under an
ambient temperature of approx. 15 °C.
Heating can be activated directly in the Central Information
Display at any ambient temperature. To do so, go to the parking
function menu under direct operation and mark the auxiliary
heating box.

Note:
Initialisation can only be carried out with the BMW diagnosis
system.
Follow instructions and specifications in procedure.
 
Service functions:
 Complete vehicle
 Body
 Air conditioning function
 Telestart transmitter
 Initialisation
 4/29/2016 1/2

11 31 090 Installing and removing/replacing chain

tensioner piston (N55)

Necessary preliminary tasks:

 Remove air duct

Release chain tensioner (1).

Tightening torque 11 31 7AZ.
Important!
Have a cleaning cloth ready. A small quantity of engine oil
will emerge after the screw connection has been released.
Make sure no engine oil runs onto belt drive.

Installation note:
Replace sealing ring.

If the chain tensioner is used again, the oil must be drained out
of the chain tensioner. Place chain tensioner on a level support
and slowly compress.
Repeat process twice.

Assemble engine.
4/29/2016 2/2
 4/30/2016 1/2

63 11 ... Installing headlight repair kit

Necessary preliminary work:

 Remove headlight

Note:
Damaged retaining tabs (I, II, III, IV) can be replaced using the repair kit.
Replacement of headlight is not required!
 
Mount retaining tab from repair kit (I) with clamp (2) as shown. Tighten screws (1).
 4/30/2016 2/2

Remove retaining tabs (II, III, IV) as shown in left-hand image.

Mount retaining tabs from repair kit with retaining clips as shown in right-hand image and screw into place.
After installation:
 Adjust headlights
 4/30/2016 1/3

23 00 041 Installing replacement transmission

(GS6-45BZ/DZ)

Important!
After completion of repair work, check transmission oil
level.
Use only the approved transmission oil.

Failure to comply with this instruction will result in serious

damage to the transmission.

Recycling:
Catch and dispose of escaping transmission oil.
Observe country-specific waste disposal regulations

Necessary preliminary tasks:

 Drain transmission oil at oil drain plug.
Tightening torque 23 00 2AZ.
 Remove transmission.

Transfer gearshift rod joint.

Slide back retaining ring (1) and drive out cylinder pin (2).
 4/30/2016 2/3

Installation note:
Check rubber ring (1) in gearshift rod joint (2) and replace if
necessary.

Convert following components from previous transmission to

new transmission.

- Release bearing and release lever.

- Ball pin and spring wire clamp.

- Studs for clutch slave cylinder.

- Reversing light switch.

 Tightening torque 23 14 1AZ.

- If necessary zero-gear sensor

 Replace screws.
 Tightening torque 23 14 2AZ.

Reassemble the vehicle.

Check oil level.
Installation note:
 4/30/2016 3/3

Observe greasing specification.

 4/30/2016 1/1

64 11 ... Installing servodrive

Installation:
If necessary, align shaft of flap(s) to be actuated to position of
servodrive to be installed.
 4/30/2016 1/1

64 53 ... Instructions for desiccant insert replacement

Special tools required:

 32 1 270

A desiccant insert that is in a correctly functioning, sealed heating and air conditioning system does not have
to be changed at regular service-inspection intervals.

However, the dryer flask or desiccant insert must absolutely be replaced in the event of:

- contamination of the refrigerant with swarf (e.g. when the compressor is clamped).

- With depressurised and/or completely drained refrigerant circuit.

- With a refrigerant circuit, which was closed using special tool 32 1 270 but remains open for more than
24 hours.

The desiccant insert cannot be replaced in the following vehicles:

- 1-Series E8x, 3-Series E9x from 12/2008

- E84, E89

- 1-Series F2x, 3-Series F3x

- BMW i 01 without heat pump

In these vehicles, the condenser for the heating and air conditioning system must be replaced.

- BMW i 01 with heat pump

On this vehicle the low pressure battery must be replaced.

 4/30/2016 1/3

64 52 ... Instructions for opening and part replacement in refrigerant circuit

Special tools required:

 00 9 030

 32 1 270

 

Warning!

 Avoid contact with refrigerant and refrigerant oil

 Follow safety informations for handling refrigerant

 Follow safety information for handling refrigerant oil

 

Attention!

 Always use new O-rings each time A/C connections are opened (refer to Electronic Parts Catalogue)

They must not be coated.

Use special tool 00 9 030 to install sealing rings without damaging them.

 Open the referigerant circuit for as short of a period as possible.

 Close all components and lines in the refrigerant circuit and return parts immediately following the
removals at openings with special tool 32 1 270 to prevent penetration of moisture or foreign objects.

 If the refrigerant circuit was closed at the openings with special tool 32 1 270 but it remains open for
more than 24 h, the dryer insert for the air conditioning must be replaced.

 

I. Part replacement as preliminary work fur further repair work and part replacement based on gradual
 4/30/2016 2/3

leakage.

(minor leak, e.g. hairline crack)

 

Procedure:

 Draw off heating and air conditioning system, then determine drawn-off amount of refrigerant oil

 Carry out part replacement

 Replace removed refrigerant oil and additionally top up with new refrigerant oil according to
components replaced:

- Compressor: refer to Notes on compressor replacement

- Evaporator: 10 ml

- Capacitor: 20 ml

- Desiccant insert / dryer flask: 20 ml

- Each replaced refrigerant line: 10 ml

- Condenser with integrated dryer flask: 40 ml

- Safety pressure switch and gasket: no additional refrigerant oil

- Only I01: Radiator, high-voltage battery unit: 20 ml

 Evacuate and fill air conditioning system

 

II. Part replacement due to sudden leakage

(major leak, e.g. pipe break due to accident)

 

Procedure:

 Draw off heating and air conditioning system, then determine drawn-off amount of refrigerant oil

 Carry out part replacement

 Replace removed refrigerant oil and additionally top up with new refrigerant oil according to
components replaced:
 4/30/2016 3/3

- Compressor: refer to Notes on compressor replacement

- Evaporator: 35 ml

- Capacitor: 35 ml

- Desiccant insert / dryer flask: 55 ml

- Each replaced refrigerant line: 35 ml

- Condenser with integrated dryer flask: 55 ml

- Safety pressure switch and gasket: no additional refrigerant oil

- Only I01: Radiator, high-voltage battery unit: 35 ml

 Evacuate and fill A/C system

 4/30/2016 1/3

32 41 ... Instructions for removing and installing

ear clips

Special tools required:

 32 1 260

Note:
The work steps are show on assorted components.
Ear clip must always be replaced.

To remove an ear clip, place special tool 32 1 260 at right

angles to ear and cut ear open.

The ear clip can be fitted not only axially but also radially after
the hook fastener has been opened.
 4/30/2016 2/3

Attach hook fastener and press ear together with special

tool 32 1 260.

The diagonal cutting pliers of special tool 32 1 260 can be used

in areas which are difficult to access.

Important!
Gap (A) max. 1 mm!
4/30/2016 3/3
 4/29/2016 1/5

17 00 ... Instructions for repair work on cooling

system

Warning!
Risk of scalding. Only carry out repair work on the cooling
system after the engine has cooled down.

Important!
Wear protective gloves and safety goggles.

Important!
Lifetime coolant filling:
Never reuse used coolant.
When replacing and removing components which rely on
the corrosion protection effect of the coolant, it is essential
to change the coolant. The cooling system must therefore
be drained and refilled.
In the case of other removal work involving the draining of
part quantities of coolant, replace these quantities which
have been drained with new coolant.

Important!
Open cooling system only when it has cooled down.
Opening the cooling system while hot can result in air
 4/29/2016 2/5

entering the system.

This can cause overheating with permanent damage to
the engine.

Important!
You must protect the alternator against dirt contamination
before carrying out any repair work on the cooling circuit.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an
alternator malfunction.

Important!
Do not fill coolant expansion tank over MAX level as
overfilling will cause the coolant to overflow. This may give
rise to traces of coolant on the expansion tank or in the
engine compartment and wrongly suggest possible leaks.

Recycling
Catch and dispose of drained coolant.
Observe country-specific waste disposal regulations.
 4/29/2016 3/5

Note:
To disconnect coolant hoses, use commercially available
disconnect tools such as HAZET brand tools (see table).

HAZET no.: Designation

4590-1 Disconnect-pliers, length (mm): 150

4590-2 Disconnect-pliers, length (mm): 180

4590-3 Disconnect-pliers, length (mm): 253

4590 / 2 Disconnect-plier set

4590 / 3 Disconnect-plier set

Note:
Tightening torque for hose clamps

WAF 5 1.0 - 1.5 Nm

WAF 6 2.5 - 3.5 Nm

Instructions for dismantling/assembly of coolant hose quick-

release couplings
 4/29/2016 4/5

Dismantling of quick-release coupling

Pull out lock (1) and (2). Pull off hose.

Installation note:
Check O-rings (1).
Do not coat O-rings (1) with lubricant.

Assembly of quick-release coupling

Press in lock (1) before installing quick-release coupling.
Push on hose.
Quick-release couplings must clearly snap audibly into place.
4/29/2016 5/5
 4/30/2016 1/2

51 31 ... Instructions for repairing stone chip damage on laminated safety glass (clear and
tinted)

Note:

These repair instructions are intended for qualified skilled workers who work conscientiously and
accept full responsibility for their work.

General:

- These instructions are restricted to the repair materials approved by the plant (sourcing reference: BMW
Parts Department), the repair method and related tips to simplify the work involved.

- The instructions can only outline the general work procedure.

- The actual work scope must be adapted to the damage pattern.

- The repair work represents an economical and swift solution which can not rule out visual impairment.

- The repair should be offered to the customer on passing through or for used vehicles and on special
customer request.

- The conditions detailed below for repairing laminated safety glass conform to the legal regulations in
Germany.

- In other countries, the relevant regulations must be observed.

 

Important!
- Repair work may only be carried out outside the field of vision.

- Only damage to the outer area of the windscreen may be repaired.

- The inner window pane and the plastic film between inner and outer window panes must not be
damaged.

- Repairing should be carried out as soon as possible after occurrence of the damage.

- The penetration of moisture or dirt must not be visible in the damaged spot.

- Impact spot cavities must not exceed a diameter of 5 mm.

- Cracks leading away from the impact spot must not be longer than 50 mm.

- Cracks must not end in the rubber window frame trim or decorative strip.
 4/30/2016 2/2

- Visibility through the repaired surface must be clear, transparent and with minimum distortion.

- Cover engine compartment lid and front side panels with protective covers.

- Note processing instructions!

 

Repairing laminated safety glass,

See repair instructions.

 4/30/2016 1/2

64 53 ... Instructions for replacement of air conditioning capacitors and radiator/coolers

Important!

Even when they are correctly installed or due to normal driving, radiators (oil cooler, radiator, charge
air cooler) or air conditioning condensers may show slight impressions or deformations on their discs
(1).

A slight sag with a large radius for the air conditioning condenser is also permissible.

As long as tightness/function are not degraded and an adequate distance of a few mm between the
radiator and capacitor remains, this is not damage in both cases!

Radiators or capacitors are not to be replaced in these cases!

Note:

The deformations shown in Fig. (1) can be bent back with a standard fin comb..

Damage to lines carrying media or on the flat pipe require exchange of the radiator or air conditioning
condenser (2-6).
4/30/2016 2/2
 4/29/2016 1/2

64 53 ... Instructions for replacement of air conditioning capacitors and radiator/coolers

Important!

Even when they are correctly installed or due to normal driving, radiators (oil cooler, radiator, charge
air cooler) or air conditioning condensers may show slight impressions or deformations on their discs
(1).

A slight sag with a large radius for the air conditioning condenser is also permissible.

As long as tightness/function are not degraded and an adequate distance of a few mm between the
radiator and capacitor remains, this is not damage in both cases!

Radiators or capacitors are not to be replaced in these cases!

Note:

The deformations shown in Fig. (1) can be bent back with a standard fin comb..

Damage to lines carrying media or on the flat pipe require exchange of the radiator or air conditioning
condenser (2-6).
4/29/2016 2/2
 4/30/2016 1/3

32 00 150 KDS chassis/wheel alignment check

with vehicle load up to design position

Important!
Carry out wheel alignment with DIN load only:

- If the technical prerequisites for alignment with ride

height input are not fulfilled

- If the vehicle in question is a damaged vehicle

Note:
 Read and comply with General information and
definitions.
 Read and comply with General chassis definition.
 Update KDS data states
 Check compliance with test conditions, repair vehicle if
necessary.

 If necessary, prepare vehicle hoist.

 Drive vehicle onto vehicle hoist.
Note: The front and rear wheels must be positioned
centrally on the rotary and sliding plates.
Note: Rotary plates may vary from illustration depending
on the manufacturer!

Note:
Vehicles with active steering:
Start up active steering prior to wheel alignment!
 4/30/2016 2/3

On vehicles with rear axle slip angle control:

Service function "Moving HSR actuator to centre position" is
included in active steering start-up.

Attach pickup/ride height marks to vehicle (observe

specifications from the various equipment manufacturers).
Important!
Use only quick connectors with poly control pins (1).
Due to excessive measuring inaccuracy, other quick-
clamping units are not permitted!
Illustration of KDS II pickup

 Enter customer and vehicle data

 Identify chassis version and select vehicle
 Enter tyre inflation pressure and tread depth
 Move vehicle into design position

 Install brake tensioner.

 4/30/2016 3/3

 Remove locking pins from both rotary and sliding plates.

 Perform input measurement in accordance with
equipment manufacturer's instructions.
 If necessary, adjust front axle and rear axle
 Perform output measurement in accordance with
equipment manufacturer's instructions.
 Save and print out test record.
 Insert locking pins into both rotary and sliding plates
 Remove chassis/wheel alignment system
 4/30/2016 1/3

32 00 155 KDS wheel alignment check with ride

height measurement without vehicle
load

Important!
Do not perform wheel alignment with the vehicle unladen.

- If the technical prerequisites for alignment with ride

height input are not fulfilled

- If the vehicle in question is a damaged vehicle

Note:
 Read and comply with General information and
definitions.
 Read and comply with General chassis definition.
 Update KDS data states
 Check compliance with test conditions, repair vehicle if
necessary.

 If necessary, prepare vehicle hoist.

 Drive vehicle onto vehicle hoist.
Note: The front and rear wheels must be positioned
centrally on the rotary and sliding plates.
 
Note: Rotary plates may vary from illustration depending
on the manufacturer!

Note:
 Vehicles with active steering:
 4/30/2016 2/3

Start up active steering prior to wheel alignment.

On vehicles with rear axle slip angle control: Service
function "Moving HSR actuator to centre position" is
included in active steering start-up.

Attach pickup/ride height marks to vehicle (observe

specifications from the various equipment manufacturers).
Important!
Use only quick connectors with poly control pins (1).
Due to excessive measuring inaccuracy, other quick-
clamping units are not permitted!
Illustration of KDSII pick-up!

 Enter customer and vehicle data

 Identify chassis version and select vehicle
 Enter tyre inflation pressure and tread depth
 Measure vehicle ride height with tape measure (only
Beissbarth KDSII wheel alignment equipment)
If the ride height is outside the tolerance range (+40/-20
mm), load or unload vehicle accordingly to adjust the
vehicle in this ride-height window

 Install brake tensioner.

 4/30/2016 3/3

 Remove locking pins from both rotary and sliding plates.

 Perform input measurement in accordance with
equipment manufacturer's instructions.
 If necessary, adjust front axle and rear axle
 Perform output measurement in accordance with
equipment manufacturer's instructions.
 Save and print out test record.
 Insert locking pins into both rotary and sliding plates
 Remove chassis/wheel alignment system
 4/29/2016 1/6

13 02 96 (084)

Leaded fuel in vehicles with catalytic converters

All models since MY 86

Situation:
Due to the nature of unrestricted global trade, vehicles with catalytic converters fitted can
find their way into markets in which the BMW Group only sells vehicles without catalytic
converters/”catalytic converter ready” vehicles due to the local exhaust gas legislation or
limited availability of unleaded petrol.

The following measures are required in order for a BMW vehicle with a catalytic converter
to run on leaded petrol (depending on engine type).
Affectedvehicles: All vehicles since model year 86 manufactured as a catalytic converter version (not
”catalytic converter ready” optional equipment) - excluding compressed natural gas
vehicles
Measure: Conversion of vehicle from ”catalytic converter version” to ”catalytic converter ready”
version or ”Gulf States/Tropics” version.

Caution, two restrictions must be observed:

1. Natural-gas powered vehicles (compressed natural gas vehicles) cannot be converted

Natural-gas powered vehicles cannot be converted as no ”catalytic converter ready”

variant is available. If used without prior conversion, the DME adapts the substitute values
that trigger a fault message for CNG components, which then causes the compressed
natural gas system to switch off. The vehicle can then no longer be driven in CNG mode.

2. US models only partially convertible

a) US models with M50 or M52 engine and automatic transmission cannot be converted.
b) For other US models, tyres with the same speed rating as the respective ECE model
must be fitted as per the list below.
Reason:When recoding US models to run on leaded fuel, either the ECE or Gulf States
version of the ”catalytic converter ready” variant must be used due to the lack of a US
"catalytic converter ready" variant. This will delete any top speed limitation stored in the
DME , which means that the vehicle runs faster after conversion without being type-
approved or technically set up for this function.

Since model year 90, all versions of the following US models have been subject to
maximum speed restrictions:

187 km/h limit:From 01/94: E36 318i, E36 318is, E36 318ti, E36 Z3 1.9

196 km/h limit:E30 325i, E30 325ix

206 km/h limit:E34 525i, E34 530i, E34 540i, E36 320i, E36 325i, E36 325is, E36 328i,
E36 328is, E38 740i, E38 750i, E39 528i, E39 540i;until 12/93: E36 318i, E36 318is

220 km/h limit: E36 M3

 4/29/2016 2/6

These US models have also been designed to operate with the maximum speed restriction
in place:- All-season tyres, H tyres, T tyres, depending on the model- Transmission ratio
(4-speed automatic), whose propeller shaft speed reaches its maximum at 206 km/h.
Procedure: On account of the restrictions outlined above, proceed as follows.

a) General measures:
1. The catalytic converter system must always be replaced by a suitable front silencer
without a catalytic converter. This will prevent a foul odour caused by the hydrogen
sulphide that is generated as a result of the higher sulphur content in leaded fuel
(”smell of rotten eggs”).

Note:The method practised up to now (for cost reasons), in which the catalytic
converter and oxygen sensor are left fitted in the vehicle, must no longer be used. This
is due to vehicle performance problems that arise either straight after conversion or at
a later date due to adaptive engine control.
2. Remove the unleaded reduction sleeve from the tank filler neck. If the reduction sleeve
is permanently fitted, contact the Parts Department and order the

PN 16 12 1 150 748
reduction funnel:

PN 16 12 1 150 747
with holder:

From the E36 onwards, the entire tank filler pipe can be replaced with the ”catalytic
converter ready” version.
3. Disconnect the electrical plug connection for the oxygen sensor and tie back the sensor
connector on the engine wiring harness. Apply waterproof insulation to the connector.
4. Remove the oxygen sensor heating relay (if fitted as standard).
5. Set idle CO according to repair instructions.
6. For environmental reasons, the tank ventilation function fitted in all BMW vehicles since
09/88 (using the active carbon canister) should be left fitted in all vehicles - including
"non-catalytic converter vehicles".
 

B. Engine-specific measures:

The respective encoding/programming measures must be carried out using the latest
”Programming” software (on CD-ROM and loaded using DIS or on floppy disk and
 4/29/2016 3/6

loaded using the MoDiC station onto the MoDiC). The correct path to be used is
specified for each engine-specific measure.

Leaded fuel, min. RON 91 / min.

1. M20 B20/B25/B27 (since 09/85) MON 82.5
M30 B30/B35M70

- Recode DME control unit M 1.x to ”catalytic converter ready” or ”Gulf

States/Tropics” (path: ”DME version code”, menu item ”Recode”) to ensure continued
tank ventilation using the carbon canister (AKF).
 

Leaded fuel, min. RON 91 / min.

2. M40 B16/B18 MON 82.5

Leaded fuel, min. RON 95 / min.

M42 B18 MON 85

- Recode DME control unit M 1.x to ”catalytic converter ready” or ”Gulf

States/Tropics” (path: ”DME version code”, menu item ”Recode”) to ensure continued
tank ventilation using the carbon canister (AKF).
- Pull off the electrical plug connection from the tank vent valve (TE valve) and apply
waterproof insulation to the connector at the engine wiring harness end (TE valve is
open and de-energised).
- M40/M42 in the E30:Plug together the single-pin plug connection on the engine wiring
harness in the cable channel on the engine compartment bulkhead to make a connection
with the CO potentiometer in the air-flow sensor (LMM).
- M40 in the E36, until production date 06/91:Plug together the single-pin plug connection
at the DME connector output in the electronics box (LMM as standard with CO
potentiometer in both catalytic converter and catalytic converter ready versions).
- M40/M42 in the E36, production date 07/91 to 09/92:Plug together the single-pin plug
connection at the DME connector output in the electronics box. Exchange LMM for LMM
with CO potentiometer.

Refer to SI 13 02 94 (796)
- M40/M42 in the E34 (M40 only) and E36 from production date 10/92:Exchange LMM for
LMM with CO potentiometer.

Refer to SI 13 02 94 (796)
 
 4/29/2016 4/6

Leaded fuel, min. RON 91 / min.

3. M43 B16/B18 until 03/96 MON 82.5 (knock control)

- Recode DME control unit M1.x to ”catalytic converter ready” or ”Gulf States/Tropics” (path: ”DME version
code”, menu item ”Recode”) to ensure continued tank ventilation using the carbon canister (AKF).
- Exchange LMM for LMM with CO potentiometer.

Refer to SI 13 02 94 (796)

Leaded fuel, min. RON 95 / min.

4. M50 until 08/92 (without variable MON 85
camshaft timing control)

- Replace control unit with an automatic transmission basic control unit

- Use MoDiC to program to ”catalytic converter ready” version or ”Gulf States/Tropics”, path ”DME
programming”Caution:Carry out programming in ”Manual entry” mode only, i.e. when the query ”Is the faulty
control unit still installed in the vehicle? Y/N” appears under the "Identify basic control unit" path, answer with
”No”. Afterwards the relevant ”Basic control unit part number”, vehicle identification number and the
”Programmed control unit for catalytic converter ready part number” or ”Gulf States/Tropics” can be entered.

The basic control unit part number and programmed control unit part number are listed in the Electronic Parts
Catalogue.
- Alternative for leaded fuel, RON 91 / MON 82.5:Program automatic transmission basic control unit using
MoDiC to MNV version (low-compression engine), as well as ”catalytic converter ready” or ”Gulf
States/Tropics”).

Leaded fuel,min. RON 91 / min. MON

5. M50 since 09/92 (with variable 82.5 (knock control)
camshaft timing control)M60M73

- Replace control unit with an automatic transmission basic control unit

- Use MoDiC to program to ”catalytic converter ready” version or ”Gulf States/Tropics”, path ”DME
programming”Caution:Carry out programming in ”Manual entry” mode only, i.e. when the query ”Is the faulty
control unit still installed in the vehicle? Y/N” appears under the "Identify basic control unit" path, answer with
”No”. Afterwards the relevant ”Basic control unit part number”, vehicle identification number and the
”Programmed control unit for catalytic converter ready part number” or ”Gulf States/Tropics” can be entered.
 4/29/2016 5/6

The basic control unit part number and programmed control unit part number are listed in the Electronic Parts
Catalogue.

Leaded fuel,min. RON 91 / min. MON

6. M43 with ASC since 82.5 (knock control)
03/96M44M52M62S50
B32/USS50 B32

- No new control unit required due to flash technology

- Use MoDiC to program to ”catalytic converter ready” version or ”Gulf States/Tropics”, path ”DME
programming"Caution:Carry out programming in ”Manual entry” mode only, i.e. when the query ”Is the faulty
control unit still installed in the vehicle? Y/N” appears under the "Identify basic control unit" path, answer with
”No”. Afterwards the relevant ”Basic control unit part number”, vehicle identification number and the
”Programmed control unit for catalytic converter ready part number” or ”Gulf States/Tropics” can be entered.

"Basic control unit part number" and "Programmed control unit part number" are listed in the Electronic Parts
Catalogue.

Leaded fuel, min. RON 95 / min.

7. S38 B36S70 B56S70/2 MON 85 (knock control)

- Recode DME control unit M 1.x to ”catalytic converter ready” or ”Gulf States/Tropics” (path: ”DME version
code”, menu item ”Recode”) to ensure continued tank ventilation using the carbon canister (AKF).

Leaded fuel, min. RON 95 / min.

8. S38 B38 MON 85 (knock control)

Leaded fuel, min. RON 91 / min.

S50 B30 MON 82.5 (knock control)

- Replace control unit with an automatic transmission basic control unit

- Use MoDiC to program to ”catalytic converter ready” version or ”Gulf States/Tropics”, path ”DME
programming"Caution:Carry out programming in ”Manual entry” mode only, i.e. when the query ”Is the faulty
control unit still installed in the vehicle? Y/N” appears under the "Identify basic control unit" path, answer with
”No”. Afterwards the relevant ”Basic control unit part number”, vehicle identification number and the
”Programmed control unit for catalytic converter ready part number” or ”Gulf States/Tropics” can be entered.
 4/29/2016 6/6

The basic control unit part number and programmed control unit part number are listed in the Electronic Parts
Catalogue.
In accordance with the warranty conditions currently valid, reimbursement for this subsequent conversion
cannot be claimed from BMW AG under warranty/goodwill.
 4/30/2016 1/10

64 50 ... Leak detection with forming gas

Note:
Leak detection with forming gas replaces the leak detection that
is restricted in EU countries using UV.
Observe national regulations in all other countries!

Important!
Compliance with the manufacturer's operating instructions
provided in the equipment case is absolutely mandatory!
Comply with SI 08 08 10 (670)!
Read and comply with the manufacturer's operating
instructions provided with the special tool particularly with
regard to accident prevention, health protection and
environmental protection.
Only the basic procedure is described in the following!

Important!
Wear personal protective clothing/equipment!

Note:
Determine the customer's use behaviour prior to leak detection!
Certain user behaviours can lead to a loss of refrigerant from
the refrigerant circuit even if there is no leak. This may occur if
the customer has not used the air conditioning for a period of
more than six months. This may cause O-rings to harden and
refrigerant may escape. In this case, it will be sufficient to fill the
refrigerant circuit again and switch on the heating and air
conditioning system for approximately 10 minutes while the
engine is running.

Necessary preliminary work:

 If components of the refrigerant circuit are contaminated,
clean the engine compartment. Otherwise, the sensor
 4/30/2016 2/10

head of the leak detector will become contaminated.

Comply with notes and instructions on handling high
pressure cleaner.
 Remove centre fresh air grille
 Remove drive belt from A/C compressor
 Drain off air conditioning system
 Fill the air conditioning system with forming gas
 Set pressure to 5 bar
 
To reach components of the refrigerant circuit with the leak
detector, it may be necessary to remove the following parts,
depending on the vehicle:
 Covers
 Trim panels
 Air duct
 Intake silencer
 Bulkheads
 Parts of the interior equipment (automatic rear air-
conditioning system)
With some vehicles, the air flaps of the automatic air flap control
(LKS) must be opened.

F01 Hybrid, F02 Hybrid, F02, F03, F04:

Before filling the refrigerant circuit with forming gas, perform
test module "Draining/Filling of refrigerant circuit".

Vehicle-specific notesI01:

Equipment specification with and without heat pump:

To access the connections for the refrigerant lines,
remove front luggage compartment well.

Equipment specification with heat pump:

Carry out the following steps before filling the
refrigerant circuit with forming gas:
1. Switch on terminal 15: To do so, press the
 4/30/2016 3/10

Start/Stop button without operating the brake

pedal.
2. Switch off blower at IHKA controls (so that
compressor cannot start up).
3. Switch on low-beam headlight (so that terminal
15 can switch off automatically after a certain
period).
If nec., charge the high-voltage battery (12 V
battery is charged via the high-voltage battery).
4. Pull off connector (1).
This state must last for the duration of the entire leak
detection process!

Equipment specification with and without heat pump:

After filling the refrigerant circuit with refrigerant,
delete fault memory!

Important!
Always perform the leak detection with a pressure of 5 bar
at first!
This is absolutely necessary to find certain leaks, such as
in the area of the O-rings.
If no leak is detected, repeat the leak detection with
10 bar.

Important!
The leak detection may not be performed more than 3 h
after filling the refrigerant circuit with forming gas!
Forming gas consists of 95% nitrogen and 5% hydrogen.
The leak detector will detect hydrogen. If this is leaking
from the refrigerant circuit even though the pressure
remains, the leak detection bears no results.

Important!
Risk of damage!
Maximum approved pressure: 10 bar
Do not start the engine during the entire procedure!
 4/30/2016 4/10

Notes for handling the leak detector:

1. Sensor head must always stand vertical
to the surface to be checked.
2. Sensor head must always be aligned to
the centre of the point to be
checked. Slowly guide the sensor head
around the point (e.g. connection point,
sealing surface, etc.).
3. The optimal distance (A) between
sensor head and surface to be checked
must permanently be approximately 1
mm. 
Maximum distance (B) at points that are
difficult to access approximately 5 mm.
4. Checking speed may not be more than
maximum 2 cm per s.

Note:
If the leak detector displays a leak,
remove the sensor head from the
leak for approximately 10 s.
 4/30/2016 5/10

Then check if the leak is still

displayed at the same point. Repeat
the process up to three times,
to ensure that a leak is actually
present at this point.

Note:
If a leak is detected in the refrigerant
circuit, the remaining points must
also be tested!
Multiple leaks may be present in the
refrigerant circuit.

Note:
Replace the leaking
component. Relieve the pressure
from the refrigerant circuit prior to
replacement.

Important!
Compliance with the
instructions above is absolutely
mandatory!
Non-compliance will
significantly reduce the
efficiency of leak detection!
 4/30/2016 6/10

Note:
The graphic shows the example of
the refrigerant circuit on the F02 with
the automatic rear air-conditioning
system optional equipment .
Refrigerant circuits on other vehicles
may differ from the graphic.

Overview of positions to be checked:

1. Ignition capacitor
2. Connection point between ignition
capacitor and refrigerant line
3. a) Expansion valve, front (vehicles with
and without automatic rear air-
conditioning system)
b) Expansion valve, rear (vehicles
with automatic rear air-conditioning
system)
4. Air conditioning compressor
 4/30/2016 7/10

5. Filler neck high pressure and low

pressure
6. Refrigerant pressure sensor
7. a) Refrigerant line, front (vehicles with
and without automatic rear air-
conditioning system)
b) Refrigerant line, rear (vehicles
with automatic rear air-conditioning
system)
8. a) Evaporator, front (vehicles with and
without automatic rear air-conditioning
system)
b) Evaporator, rear (vehicles
with automatic rear air-conditioning
system)

Note:
Refrigerant line connection points
are identified by arrows.

Checking sequence:
1. Check of components 1, 2, 3a, 4, 5, 6, 7a and 8a of the
automatic front air-conditioning system.
If no fault found:
2. Check of components 3b, 7b, 8b and connection points
of the automatic rear air-conditioning system.

1. Capacitor:
Damage caused by stone chipping, etc. is the most frequent
cause of capacitor leaks (1):
1. Visual inspection in the area of the radiator grille (2) and
air inlet grille, centre (3).
2. Check damaged points first.
3. Check the remainder of the capacitor.
 4/30/2016 8/10

2. Connection point capacitor - refrigerant line

Check the connection point between the connection at the
capacitor (1) and refrigerant lines (2).

3. Expansion valve:
Check the connection point between the expansion valve (1)
and refrigerant lines (2).

4. A/C compressor:
Check the following components on the A/C compressor:
1. High-pressure connection
2. Low pressure connection
3. Pressure relief valve
4. Radial shaft seal of the magnetic coupling: Turn the
magnetic coupling several times by hand during the leak
detection.

5. Filler neck
Blow out the filler neck (1) prior to testing.
 4/30/2016 9/10

6. Refrigerant pressure sensor

Check the sealing surface between the refrigerant pressure
sensor (1) and the refrigerant line (2).

7. Refrigerant lines:
1. Perform visual inspection
2. Check damaged points first.
3. Check bending points at points marked with an arrow.
Leaks occur especially frequently at these points.
4. Check the remainder of the refrigerant line.

8. Evaporator:
Compliance with the following settings is absolutely required:
 Air recirculation function On
 Lowest blower speed
 Lowest temperature
 Set the air distribution to ventilation (air may only flow out
 4/30/2016 10/10

of the centre fresh air grille)

Position sensor head (1) in air duct of middle fresh air grille (2)
as illustrated and move slowly from inside to outside above and
below air flap (3). Carry out this operation on the left and right
fresh air grilles.

Important!
Some vehicles have an expansion valve directly
next to the fresh air intake for the passenger
compartment.
In this case the expansion valve must be
covered!

Following the completed leak detection:

 Evacuate and fill heating and air conditioning system
 4/30/2016 1/4

64 50 ... Leak detection with ultraviolet additives

(UV additives) (BMW leak-testing case)

Important!
In EU countries, only limited UV leak detection is
permitted!
Observe national regulations in all other countries!

Important!
It is absolutely essential to read and comply with the
equipment manufacturer's operating instructions use
provided in the equipment case!
Read and comply with the manufacturer's operating
instructions provided with the special tool particularly with
regard to accident prevention, health protection and
environmental protection.
Use only BMW-approved UV additives (e.g. TRACER).
Only the basic procedure is described in the following!

Important!
UV additives may not be used in vehicles with electric A/C
compressors!

Warning!
Avoid contact with refrigerant.
Follow safety precautions when handling refrigerant.

Important!
Ultraviolet lamp gets very hot in the radiation area!
Do not use the ultraviolet lamp without the filter glass.
Eyes and skin will suffer damage if the ultraviolet lamp is
used without the filter glass.
When using the ultraviolet lamp, wear the safety goggles
provided in the case.

Note:
 4/30/2016 2/4

 Fill the hose system of the hand pump completely with UV

additive PRIOR to use
 The UV additive may be used exclusively for BMW-
approved refrigerant oils
 Do not operate the air conditioning system while the hand
pump is connected or in use
 The air conditioning system must always be filled with an
adequate amount of refrigerant to enable the leak-
detecting agent to be properly distributed

Necessary preliminary tasks:

Before actually testing for leaks, check the entire
refrigerant circuit using the UV leak detection lamp to
ensure that no UV additive is already in the area of the
refrigerant circuit.
Leak areas which have already been detected by UV light
must carefully cleaned with the cleaning agent provided in
the case.

On initial use:
Connect hand pump (1) to additive cartridge (2) and hose piece
(3).

On initial use:
Attach vent valve (1) to quick-release coupling (2).
Turn handle (3) on hand pump to advance the piston until a
small amount of UV additive emerges. This vents the hose
system.
Important!
The entire hand pump with hose system must not be
disassembled again once the filling work has been
 4/30/2016 3/4

completed.

Attach quick-release coupling (1) to low-pressure connection (2)

of air conditioning system.
Turn handle on hand pump (3) until the required amount of UV
additive is added.
The quantity of UV additive to be added is dependent on the
amount of refrigerant in the refrigerant circuit:
 Air conditioning systems with refrigerant filling up to 900
g: one graduation mark (4) on additive cartridge
 Air conditioning systems with refrigerant filling in excess
of 900 g: two graduation marks (4) on additive cartridge
Note:
After filling, remove quick-release coupling (1) and if necessary
use the cleaning agent contained in the special tool case to
clean up the UV additive.

Further tasks:
 Start engine
 Run air conditioning system at highest stage for 5 - 10
minutes in order to ensure adequate distribution of dye in
the system
 Turn off engine.
 Check all air conditioning system components for possible
leaks
 Possible leakage is lit up green when the UV leak-
detecting lamp and UV-absorbing safety goggles are used

Complete accompanying information label (1) with the relevant

 4/30/2016 4/4

data and attach in an easily visible position next to the filling

capacity information label (2).
 4/30/2016 1/5

33 31 503 Lowering/raising rear axle support

(universal lifter)

Special tools required:

 31 5 250
 00 2 030
 31 5 256
 31 5 253
 33 5 206

Warning!
Failure to comply with the following instructions may result
in the vehicle slipping off the lifting platform and critically
injuring other persons.
Load the luggage compartment with a minimum of 100 kg
before lowering/removing the rear axle support. This
prevents the vehicle from tilting or sliding off the vehicle
hoist!
When supporting components, make sure that:
 the vehicle can no longer be raised or lowered
 the vehicle does not lift off the locating plates on the
vehicle hoist.

Important!
Before lowering/removing rear axle support:
 
Observe safety instructions for raising the vehicle
 
In order to avoid damage to vehicle hoist, perform weight
compensation on vehicle.

Necessary preliminary tasks:

 Remove rear wheels.
 Remove exhaust system.
 If necessary, remove rear tension struts.
 4/30/2016 2/5

 Remove propeller shaft at final drive.

 Remove camber arm cover.
 Remove tank cover.
 Remove coil springs.
 Remove both brake-caliper supports and tie up.
 Release shock absorber from camber arm.
 Only on ride-height sensor at left: Disconnect plug
connection and lay cable back toward vehicle.

Release wheel arch panel in rear area.

Unlock clamps, open cover and detach connector. (Left side
identical.)

Detach Bowden cable (1) of parking brake from rear axle

support.

Engage special tool 31 5 250with a 2nd person helping

completely on workshop jack 00 2 030.
Insert special tools 31 5 256 in telescopic supports of a profile
rail pair.
Insert special tools 31 5 253 in telescopic supports of other
profile rail pair.
 4/30/2016 3/5

Note:
In a profile rail pair, two profile rails are connected to one
another by gearing.

Lash rear axle support with tensioning strap 33 5 206 to special

tool31 5 250.

The mounting points on

the right side are
shown.
 
Align special
tools 31 5 250, 31 5 253
and 31 5 256 with rear
axle support.
Support rear axle
support by operating
workshop jack
00 2 030.
Important!
The centre of
gravity of the rear
axle must be
positioned
centrally over the
workshop jack.
 4/30/2016 4/5

Remove compression struts (1).

 
Release screws (2) and remove with thrust washer. (F34 - see
next graphic)
Tightening torque 33 33 1AZ
 
Lower rear axle support.
Installation note:
Check threads for damage; if necessary, repair with Helicoil
thread inserts.
Screw in all screws, first tightening the compression struts (1)
and then screws (2).

F34 only:
Unfasten screws (2).
Tightening torque 33 33 3AZ.
Release screw (1).
 4/30/2016 5/5

Tightening torque 33 33 1AZ.

Remove rear compression strut (3).
 4/29/2016 1/1

00 01 11 (679)

Maintenance work F20

Situation:
The published service intervals are taken over for the F20.

Vehicles concerned: F20

Procedure: Intervals as stated below refer only to the ECE basic interval.

Country specific deviations may apply. For countries with lower-quality fuel grades,
comply with the country-specific intervals.

Change engine oil approximately every 30,000 km/24 months.

 Microfilter => replace at every engine oil change (approx. 30,000 km)
 Air filter => replace every 2nd engine oil change (approx. 60,000 km)
 Petrol engine:

Spark plugs => replace every 2nd engine oil change (approx. 60,000 km)
 Diesel engine:

Fuel filter => replace every 2nd engine oil change (approx. 60,000 km)

Carry out vehicle check => at approx. 60,000 km (every 2nd engine oil service) no later
than after 48 months

 
 4/30/2016 1/3

51 31 ... Materials for bonding window

Special tools required:

 51 3 220

1 Tools

Type Type Order/part number

Electric special cutter SuperCut FSC 1.6Q 81 43 2 296 987

BMW knife set 81 43 9 428 596

Contains:

Knife (U-shape) 24 / 36 / 45 mm

Knife (L shape) 25,4 mm

Knife (straight with stop roller) 16 to 43 mm (adjustable)

14 mm (fixed)

”Roll Out 2000” Wire cutting system 81 62 0 301 768

"Spider" Cutting system with nylon string 81 43 2 357 248

Wire pull handles 81 43 2 326 501

Cartridge gun 81 49 2 213 059

Pinchweld scraper set 81 62 0 410 436

Siphon 81 64 2 184 377

Single suction cup Special tool 51 3 220

Universal work table 81 49 0 151 675

 4/30/2016 2/3

Sourcing reference via BMW Parts Service, Aftersales Assistance Portal (ASAP) - Service/Technology -
Workshop Equipment (Start BMW) - Shop Workshop Equipment or at www.bmwgroup-wep.com.

 

2 Consumables:

Type: Additional info: BMW part number:

Small repair kit 83 19 0 444 141

Contains: Window glass adhesive 300 ml 83 19 0 444 144

Glass activator 83 19 0 444 142

Paint activator 83 19 2 154 458

C nozzle 83 19 2 155 589

Universal nozzle/spacer buffer/paper towel

Large repair kit Like small repair kit, 83 19 0 444 145

plus 1x window glass adhesive 300 ml

Cutting wire Square wire 83 19 2 150 267

Nylon string 81 43 2 344 272

BMW multibase filler

R2 cleaning agent 83 19 0 417 324

Plastic adhesive tape yellow 83 19 9 410 979

Sika remover 208 Adhesive remover 83 19 9 407 780

Sika Activator 205 e.g. for rubber frame on windscreen 83 19 0 030 155

Sika bonding base VP 206 e.g. for inspection glass for vehicle identification number 83 19 9 407 777

Sourcing reference via BMW Parts Service, Aftersales Assistance Portal (ASAP) - Service/Technology -
Workshop Equipment (Start BMW) - Shop Workshop Equipment or at www.bmwgroup-wep.com.

 

Storage of all consumables

Dry at 15°- 25 °C.
 4/30/2016 3/3

 
 4/30/2016 1/1

00 00 ... Microencapsulated screws

Screw securing adhesive is a means of preventing a screwed

connection from being loosened by external influences.
Once the screw has been coated with adhesive, the adhesive
remains inactive until such time that it is activated by the
encapsulation breaking when the screw is inserted and then
cures (hardens) at room temperature.

Installation note:
 Screw connection must be completed within 20 mins.
(start of curing)
 Microencapsulated screws must not be retightened
 Thread of nut must be cleaned beforehand in event of
repeated use
 4/30/2016 1/4

41 03 09 (537)

Min/max tolerance sample catalogue for paintwork and corrosion damage

All

Situation:
Min/max tolerance samples are now available to enable improved assessment of paint
and corrosion damage. They are a supplement to the new BMW Paintwork publication
announced in Service Information 41 01 08 (452) and published in October 2008.

Vehicles that are older than three years after the first registration date may only be
repaired by replacing components if the damage exceeds a defined extent (see min/max
tolerance samples). With immediate effect, certain paint damage patterns attributed to
incipient corrosion may only be repaired by means of spot repairs.

The folded flange seal is now differentiated based on three min/max tolerance samples:
 Paintwork damage with min/max tolerance sample A (critical damage pattern)
 Paintwork damage with min/max tolerance sample B (minor damage pattern)
 Paintwork damage with min/max tolerance sample C (scrape marks)

All customer complaints are to be classified based on these additional min/max tolerance
samples.

1. Min/max tolerance sample A (critical paintwork damage)

General appearance: Rust is visible without scratching the surface.

Sample A1:

Visible rusting on fold and its

seal (1).

Sample A2:

Bubbling on outside (1) of fold seal.

Note:
Formation of bubbles between the
fold seal and outer edge. The fold
 4/30/2016 2/4

seal covers an approx. 5 mm

wide strip at the edge of the
component.

Sample A3:

Bubbling on the inside of the fold

seal (1) is more extensive than the
width.

2. Min/max tolerance sample B (minor paintwork damage)

General appearance: Rust is NOT visible without scratching the surface.

Sample B1:

Bubbling on the inside of the fold

seal (1) is less extensive than the
width. Lengthwise distribution is less
than the width of the fold seal (1).

Sample B2:
 4/30/2016 3/4

Bubbling on the inside of the fold seal (1) is less

extensive than the width. Lengthwise distribution is
greater than the width of the fold seal (1).

3. Min/max tolerance sample C (scrape marks)

Sample C1:

Scrape marks on paint surface caused by plastic panel

(1) on Touring, tailgate (2).

Sample C2:

Scrape marks on paint surface caused by handle (1) on

tailgate (2).

Procedure: The damage patterns on the fold seal are now differentiated based on three min/max
tolerance samples: The following extended warranty applies:

Not for damage Period in years Selection of repair

 4/30/2016 4/4

caused by method
customer

  First registration First registration  

before 1.1.2004 after 1.1.2004

Min/max 6 12 Component
tolerance sample replacement if
A feasible in terms of
time

Min/max 2 3 Component
tolerance sample replacement
B

Min/max From 2 from 3 NO parts

tolerance sample replacement (spot
B repair if necessary)
The local terms of
approval of the
market must be
taken into account

Min/max 2 12 Paint
tolerance sample
C

The paint structure must be built up as specified in the painting manual ColorSystem (pat
number 01 39 0 300 245).

Important!
The repair is only carried out in justified case of customer complaint.

In the case of rusting and paint damage, wherever possible, all add-on parts
must be retained and reinstalled as part of the repair procedure.

In contentious cases, e.g. repeated repairs, the advise of the respective

Warranty department should be sought in order to clarify the procedure.
 4/29/2016 1/2

11 00 Mounting engine on assembly stand

(N55)

Special tools required:

 00 2 300
 11 8 541
 11 8 542

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Remove engine

Use special tool 11 8 541 to mount engine on special tool

00 2 300 .
Mount engine or engine block with special tool 11 8 542 on
 4/29/2016 2/2

11 8 541 .
 4/30/2016 1/5

64 08 00 (645)

Musty odour due to heating and air conditioning system, evaporator cleaning

All model series

Complaint:
When operating the heating and air conditioning system, a musty odour briefly occurs in
the vehicle. This occurs mostly immediately after starting the engine with the heating and
air conditioning system switched on or after switching off the heating and air conditioning
system while driving.
Cause: The cause for the complaint is not a fault in the heating and air conditioning system of the
vehicle. The formation of odour is due to environmental influences during the operating
period of the heating and air conditioning system.

This is caused by the constant condensation of air humidity at the evaporator over a long
operating period of the heating and air conditioning system, creating a favourable
environment for bacteria and other micro-organisms.

Together with dirt contamination brought in by the fresh air, this may cause microbiological
growth on the evaporator and consequently a musty odour.

Regularly changing the microfilter may reduce the entry of dirt contamination and
therefore delay or prevent the development of aforementioned complaint.

Replacement of the evaporator has no continuous effect as microbiological organisms

may redevelop.

Invoicing as warranty is not justifiable as there is no technical fault.

Vehicles concerned: All series with heating air conditioning system (IHKR) or automatic air conditioning (IHKA)

Procedure: 1. Evaporator cleaning with spray lance

The most efficient and lasting method of eliminating the musty odour from the heating and
air conditioning system is to clean the evaporator with the aid of a spray lance. With this
procedure, the disinfectant is sprayed with high pressure directly on the evaporator.

Description of the operations:

For the detailed description of the procedure for the following series, please see the
respective repair instructions:
 E39/E53 with heating and air conditioning system (IHKR): Cleaning evaporator
 E39/E53 with automatic air conditioning (IHKA): clean evaporator (automatic air
conditioning)
 E46 with heating and air conditioning system (IHKR): Cleaning evaporator
 E46 with automatic air conditioning (IHKA): clean evaporator (automatic air
conditioning)
 4/30/2016 2/5

 E65/E66 with heating and air conditioning system (IHKR) or automatic air
conditioning (IHKA): Cleaning evaporator
 E60/E61/E63/E64 with heating and air conditioning system (IHKR) or automatic air
conditioning (IHKA): Cleaning evaporator
 E85/E86 with heating and air conditioning system (IHKR) or automatic air
conditioning (IHKA): Cleaning evaporator
 E81/E82/E87/E88/E90/E91/E92/E93 with heating and air conditioning system (IHKR)
or automatic air conditioning (IHKA): Cleaning evaporator
 E70/E71/E72 with heating and air conditioning system (IHKR) or automatic air
conditioning (IHKA): Cleaning evaporator
 F01/F02/F03/F04/F06/F07/F10/F11/F12/F13/F18 with automatic air conditioning
(IHKA): Cleaning evaporator
 F20/F21/F30/F31/F34/F35 with automatic air conditioning (IHKA): Cleaning
evaporator

2. Cleaning with the evaporator cleaning device "Aircomatic"

As an alternative, the evaporator can be cleaned using the "Aircomatic" cleaning system
made by WYNN’S. For this purpose, use the "Airco-Clean" cleaning agent made by the
same company.

WYNN’S describes this procedure as "Ultrasound procedure".

The cleaning power using the "ultrasound procedure" is lower as compared to cleaning
with a spray lance.

If the "ultrasound procedure" does not bring long-term success due to very severe dirt
contamination of the evaporator, clean the evaporator using a spray lance and the heating
and air conditioning system cleaning agent.

Note:
This procedure is to be used for vehicles for which no spray lance is offered.

Description of the operations:

 Remove microfilter (replace with new filter after cleaning).
 Start the vehicle.
 Switch off heating and air conditioning system.
 Set temperature control to lowest value.
 For automatic air conditioning (IHKA): Switch off automatic air distribution/supply.
 4/30/2016 3/5

 Select the lowest blower speed.

 Set ventilation to upper body area.
 Adjust air supply to air recirculation function.
 Shake the "Airco-Clean" bottle well.
 Place the ultrasound device upside down.
 Screw in the "Airco-Clean" bottle with its opening facing upwards into the device.
 Return ultrasound device to initial position allowing the contents of the bottle to partially flow into the
device.
 Place the ultrasound device in the footwell on the passenger's side.
 Connect the atomisation hose to the device.
 Place the atomisation hose so that the recirculated air system can take in the emitted vapour well.

Do not kink the hose!

 Connect the ultrasound device using the included cable.

Atomisation starts!
 Close vehicle doors and windows.

Note:

No one must remain in the vehicle during treatment!

 
 Treatment is complete after approx. 20 minutes and the ultrasound device stops.
 After treatment, open doors and air the vehicle for approx. 5 minutes.
 After treatment pour out the residual liquid in the ultrasound device.
 Briefly rinse the ultrasound device with water.

 
Parts required: 1. Cleaning with spray lance

Spray lance Order/part number Quantity

- E39/E46/E53/E83 64 1 450 1

- E65/E66/E67 (left hand drive vehicle) 64 1 280 1

- E65/E66/E67 (right hand drive vehicle) 64 1 290 1

- E60/E61/E63/E64 64 1 480 1
 4/30/2016 4/5

- E85/E86 (left hand drive vehicle) 64 1 490 1

- E85/E86 (right hand drive vehicle) 64 1 250 1

- E81/E82/E87/E88/E90/E91/E92/E93 (left hand drive 64 1 260 1

vehicle)

- E81/E82/E87/E88/E90/E91/E92/E93 (right hand drive 64 1 270 1

vehicle)

- E70/E71/E72 (left and right hand drive vehicle) 64 1 300 1

- F01/F02/F03/F04/F06/F07/F10/F11/F12/F13/F18 83 30 2 222 502 1

- F20/F21/F30/F31/F34/F35 83 30 2 344 001 1

Spray gun

SATA spray pistol 81 45 9 429 217 1

Heating and air conditioning system cleaning agent

Heating and air conditioning system cleaning agent 83 19 0 447 911 1

(only for cleaning with spray lance!)

Heating and air conditioning system cleaning agent is used undiluted. No rinsing required.

The spray lance and spray gun can be obtained from the special tools online catalogue,
the heating and air conditioning system cleaning agent directly from the BMW Parts
Department.

2. Cleaning with the evaporator cleaning device "Aircomatic"

(Valid for all series)

Designation Part number Quantity

Set heating and air conditioning system cleaning agent 83 19 2 167 729 1
(consisting of "Aircomatic" cleaning system

and "Airco-Clean" heating and air conditioning system

cleaning agent)

Airco-Clean heating and air conditioning system 83 19 2 167 730 1

cleaning agent (only for "Aircomatic" cleaning system!)

Heating and air conditioning system cleaning agent is used undiluted.

 
 4/30/2016 5/5

The "Aircomatic" cleaning system and "Airco-Clean" cleaning agent can be obtained directly from the BMW
Parts Department.

 
 4/30/2016 1/1

41 01 08 (452)

New BMW paint brochure

All

Presentation of BMW paint brochure:

The existing BMW paint brochure has been thoroughly revised and in its new form provides good reference for
assessing all kinds of paint and corrosion damage.

The examples and detailed descriptions contained in the brochure are intended to find a standard language for
identifying paint and corrosion damage. Unambiguous descriptions of damage mean that misinterpretations can
be largely ruled out when assessing a possible warranty claim. Communication between the customer and the
authorised BMW dealer during assessment on the vehicle is also made greatly easier.

If for example the following damage is unambiguously identified on the paint surface, this will always be
considered to be the responsibility of the customer, and warranty will be ruled out:

- Mechanical influences on the paint surface (e.g. scratches)

- Damage to the paint surface caused by chemical or biological influences (e.g. animal droppings)
The new BMW paint brochure complements the BMW paint handbook when eliminating paint and corrosion
damage. This means that the repair procedures described in the BMW paint handbook are adapted
unambiguously and purposefully to the fault pattern.

Subsequent orders for BMW paint brochure:

The BMW paint brochure can be ordered via the usual parts-related channel under the BMW parts number 01
29 2 148 332.
 4/30/2016 1/3

41 02 09 (521)

New repair methods ”Gluing / Riveting” on steel bodies

BMW/MINI

Situation:
Advance technical developments in the field of glues and equipment technology have
made modified repair methods possible. This procedure has been tested and approved
following exhaustive endurance runs and corrosion tests in the Development division.

Similar to the procedure for the rear cross panel on the F01/F02, the repair methods
"welding/soldering" will change to "gluing/riveting" on various exterior skin and structural
components of steel bodies from the launch of the E89 and R57. This procedure has
already been introduced for repairs on the lightweight aluminium front end (GRAV) of the
E60.

Repairs involving gluing/riveting will be performed, as in the past, by specialist body

technicians supported by a training video.

In the future, this method will also make it possible for MINI and BMW workshops without
specialised body workshops to perform body repairs.

Another positive point of this method is the significantly improved corrosion protection
resulting from the wide-area gluing of the spare part coating (KTL).
Procedure: Essentially, the following components are affected:
 Rear cross panel
 Luggage compartment floor
 Outer roof skin
 Rear side panels
 Engine subframe, parts replacement
 Support beam, parts replacement / complete

Starting with:

- MINI (R55, R56, R57)

- Z4 (E89)

- 7-Series (F01, F02), rear cross panel, outer roof skin

Extending in the course of 2009 to:
 1-Series (E8x)
 3-Series (E9x)
 5-Series (E60, E61)
 4/30/2016 2/3

 5-Series (F07)
 X1 (E84)
 X5 (E70)
 X6 (E71)
 7-Series (F01, F02), remaining areas

Necessary workshop equipment:

 Punch rivet tongs (new)
 Blind rivet tongs (GRAV)
 Cartridge press for body glue
 Universal clamping pliers (for roof ducts)
 See Service Information SI2009-05 01 09 (523)

"New tools and equipment for gluing and riveting"

Parts required:
 Body parts (incl. necessary reinforcement plates)
 Punch rivets
 Blind rivets
 Adhesive
 Cleaner

These parts are available as service repair packs for specific vehicles. Here, the vehicle
identification number is to be entered in KSD2, the corresponding "Packages" button
selected and the required job items selected in construction group 41.

Repair instructions:

The repair instructions have been revised to take account of the new repair methods:

To distinguish between the individual repair methods, a repair stage will be inserted in
brackets into the titles of the repair instructions.
 Repair stage 1: Bolted parts
 Repair stage 2: Glued/riveted parts
 Repair stage 3: Welded parts

In addition, all parts required will be listed together with their part numbers in the
corresponding repair instructions.

Training video:

The new methods, for example "punch riveting", will be described on a training video that
 4/30/2016 3/3

will be distributed to subsidiaries.

Please make sure the training video is made available to the staff who will be performing this work and, should
you not perform body work in your own workshop, to the staff of your specialist body workshop.

Time studies:

Time allowances have been revised to take account of the new repair methods, and shall apply retrospectively.
 4/30/2016 1/2

64 50 ... Note for handling R134a refrigerant

 

Work on the refrigerant circuit may only be carried out by experts!

Avoid all contact with liquid or gaseous R134a. Wear safety goggles and gloves when working on the
refrigerant circuit.

 Follow safety information for handling R134a refrigerant

Warning!

Although R134a at normal temperature is non-toxic, not inflammable and not explosive in air in any
mixture ratio, it is still essential to follow various safety precautions.

As a gas, R134a is colourless, odourless and heavier than air. If it enters the atmosphere, this may result in
an imperceptible danger of asphyxiation or in cardiac palpitations, especially in workshop pits. Ventilate
rooms adequately; if necessary, turn on installed extractor systems.

Store charged refrigerant pressure flasks in a place where they are not exposed to direct sunlight or any other
heat source (max. 45 °C). Also avoid exposing them to mechanical stress (e.g. by dropping).

Do not weld or solder on to filled heating and air conditioning systems or in rooms into which R134a may have
escaped. Exposure to flames or high temperatures (≥ 50 °C) may give rise to toxic decomposition products
(fluorine gas). For this reason, do not smoke either.

In the event of fire, carbon dioxide (CO2), extinguishing powder and a sprayed water jet are deemed to be
suitable extinguishant. Cool reservoirs at risk with a sprayed water jet (risk of bursting!).

If the protective caps on the filling valves are difficult to open, there is a risk of injury from leaking valve inserts
(high pressure).

The filled refrigerant circuit of the A/C system is subject to excess pressure. Before carrying out repairs on the
A/C system, it is absolutely essential to draw off the refrigerant.

 Before conducting repairs, check the actual pressure drop on the pressure gauge of the A/C service
station.

R134a must be drawn off, cleaned and returned to the heating and air conditioning system using an A/C
service station following the relevant operating instructions.

For a properly functioning A/C system, it is essential to have the greatest possible levels of cleanliness when
working on the A/C system and the longest possible evacuation (at least 30 minutes dehumidification from
refrigerant circuit) before each filling of the A/C system.
 4/30/2016 2/2

R134a absorbs very small amounts of moisture. Therefore, seal off opened pipes, condenser, evaporator,
compressor and dryer flask immediately with plugs.

 If an A/C system has been completely drained by leakage, accident or repair, the desiccant insert must
be replaced as excessive moisture may have entered the system.

With exchange parts, the plugs may only be removed immediately before the lines are connected. In the
event of warranty claims, the used parts must be provided with plugs to be able to determine the cause of the
damage.

Installation note:

After each refill of an A/C system, check that the protective caps of the filler valves are hand-tight. They serve
as additional seals.
 4/30/2016 1/3

51 48 ... Notes for bonding sound insulation (SI), doors

Special tools required:

 51 0 300

Important!

Do not pull on the sound insulation in jerks (risk of damage)

General:

Sound insulation is bonded to the inner door panel.

Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.

On-the-job safety:

When working with bonding products (adhesive, cleaning agent, etc.):

- Wear safety goggles, protective gloves and if necessary an apron.

- Ensure rooms are well ventilated.

- Change work clothing contaminated with adhesive immediately.

- Change work clothing contaminated with solvents and swelling agents immediately (keep spare work
clothing on hand).

- Take skin protection measures, provide washing facilities including hot water, use silicone-free skin
creams

- Provide eye douche facilities, change water regularly (once a month).

- Comply with the relevant safety regulations

Handling adhesive area on inner door panel:

 4/30/2016 2/3

Adhesive Cleaning

  a. Cleaning agentR2

a. Butyl bead applied to sound Under no circumstances: paint thinning

insulation with protective
film b. Carry out bonding only after an air drying time ≥ 1 min. Air
drying time may be omitted if the entire bonding surface is
b. Butyl mini-round profile wiped with a dry cloth
∅ 3 mm from the roller
c. After cleaning, the bonding surface may not be touched with
c. Butyl round profile ∅ 6 mm hands or fouled again
from the roller

Repair in area of sound insulation, door:

Repair  Cut the butyl rope between the sound insulation and the inner door panel
with a sharp knife
 
 After the repair is finished, position a new butyl rope ∅ 3 mm directly on the
original adhesive bead

 Heat the butyl bead with a standard hot air blower until the butyl rope strings
when touched slightly. Do not damage the sound insulation in the process

 Press on with special tool 51 0 300. Perform this work extremely carefully

because the increased amount of adhesive requires contact pressure of ≥ 
2 2
20 N/cm (compared to firm thumb pressure ~ 30 N/cm )

 Visually check the adhesive bead and its compression (no capillaries or
broken adhesive bead permitted)

in the event of  In the cases mentioned, the complete sound insulation must be replaced.
damaged sound After removing the sound insulation, removal all butyl remnants from the
insulation or leakage inner door panel. Apply 6 mm ∅ butyl rope to new sound insulation

2

Press on with special tool 51 0 300. Contact pressure ≥  20 N/cm (compare
2
to firm thumb pressure ~ 30 N/cm )

The sound insulation must be bonded watertight below the door lock:

- Flat bonding surface required all round

- No bonding in event of moisture (e.g. condensation, etc.)

 4/30/2016 3/3

- Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents,
greases, oils, paraffins, plastisols, cavity wax, polishing dust residues, etc.)

- Remove the protective film directly before joining (under no circumstances remove earlier, since the
butyl, because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants)

- The sound insulation must be attached with positional accuracy to the inner door panel, because it is no
longer possible to change the position without damaging the butyl bead

- With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of
the sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).

Expiry date of adhesive:

24 months, see label on packaging

Disposal of the cleaning cloth:

Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet)

Disposal of adhesive:

Hazardous waste (see also safety data sheet)

 
 4/30/2016 1/5

64 52 ... Notes for changing the air conditioning

compressor (amount of refrigerant oil of
new air conditioning compressor known)

Special tools required:

 00 9 030

Note:
This procedure only applies if the new air conditioning
compressor has a label with the amount of refrigerant oil.
A different procedure applies for air conditioning compressors
without a label indicating the amount of refrigerant oil.
 

Important!
Risk of damage!
Remove the air conditioning compressor without
damaging and without the use of force!
Air conditioning compressors with plastic belt
pulleys:
 Avoid impacts/knocks to plastic belt pulley
(caused by tools, contact with base).
 Return faulty air conditioning compressors
in their original packaging only and with
sealed connected branches.

Important!
When starting up a new air conditioning
compressor for the first time, it is absolutely
essential to carry out the following breaking-in
procedure:
 Switch on Air conditioning system
 Set all air vents in the dashboard to
"OPEN"
 4/30/2016 2/5

 Start engine and let it stabilise at idle

speed
 Set blower output to min. 75% of max.
blower output
 Switch on heating and air conditioning
system and run for at least 2 minutes at
idle speed
Risk of damage at increased engine
speed!

Important!
In the event of a mechanical air conditioning
compressor failure and the resulting ingress of
chips into the refrigerant circuit, replace the
following parts:
All vehicles except I01:
 air conditioning compressor
 Replace desiccant insert
 Line to the capacitor
 Refrigerant oil
I01 only:
 air conditioning compressor
 Capacitor with desiccant insert/dryer flask
 all expansion valves
Rinse the refrigerant circuit.

All vehicles without I01 with heat pump:

The new air conditioning compressor is filled at the
factory with refrigerant oil.
The amount of refrigerant oil in the new air
conditioning compressor corresponds to the amount
of refrigerant oil for the entire new and unfilled
refrigerant circuit.
 4/30/2016 3/5

 
Only I01 with heat pump:
The new air conditioning compressor and new dryer
flask are filled at the factory with refrigerant oil.
The amount of refrigerant oil in the new air
conditioning compressor and in the new dryer flask
corresponds to the amount of refrigerant oil for the
entire new and unfilled refrigerant circuit.

When replacing the air conditioning compressor it is

absolutely essential to adapt the amount of refrigerant
oil in accordance with the instructions below!
An adaptation is also required for the replacement of
the dryer flask.
An adaptation of the amount of refrigerant oil is not
required in the following cases:
 Replacement of the complete refrigerant circuit.
 If the refrigerant circuit was rinsed (only I01).

When evacuating the heating and air conditioning

system refrigerant oil is also extracted and collected in
the oil separator of the A/C service station.
This amount of refrigerant oil is displayed after the
extraction of the heating and air conditioning system
on the display of the A/C service station.

Take a note of the amount of refrigerant oil displayed on the

display of the A/C service station (= amount of refrigerant oil 1).

Example:
30 nm read on the display of the A/C service station.
Amount of refrigerant oil 1 = 30 ml

Transfer the refrigerant oil remaining in the previous air

conditioning compressor via the oil filler plug completely into a
measuring cup.
 4/30/2016 4/5

Read the amount of refrigerant oil at the measuring cup. Add at

least 10 ml extra to the amount of refrigerant oil read, but note
an overall total of 50 ml (= amount of refrigerant oil 2).

Example:
20 ml read at measuring cup:
20 ml + 10 ml extra = 30 ml < 50 ml
Amount of refrigerant oil 2 = 50 ml

Turn the belt pulley during the filling process.

This allows more refrigerant oil to flow out of the
previous air conditioning compressor.

Determination of the amount of refrigerant oil to be filled in the

refrigerant circuit:

Amount of refrigerant oil to be filled = amount of refrigerant

oil 1 + amount of refrigerant oil 2

Example:
Amount of refrigerant oil to be filled = 30 ml + 50 ml = 80 ml

Open oil filler plug. Drain the following amount of refrigerant oil
from the new air conditioning compressor into a clean
measuring cup:

Amount of refrigerant oil to be drained = amount of refrigerant

oil of new air conditioning compressor - amount of refrigerant
oil to be filled

Example:
Amount of refrigerant oil of new air conditioning compressor:
150 ml
Amount of refrigerant oil to be drained = 150 ml -
 80 ml = 70 ml
70 ml must be drained from the new air conditioning
 4/30/2016 5/5

compressor.

Installation note:
Replace sealing rings.
Use special tool 00 9 030 to mount sealing rings
without damaging them.
Tightening torque 64 52 2AZ.

The drained new refrigerant oil can be filled into the

expansion tank of the A/C service station after
draining.

On account of its hygroscopic properties, refrigerant

oil must not be stored in open containers.

If the new, drained refrigerant oil is not filled straight

away into the expansion tank of the A/C service
station, it must be disposed of properly.

The refrigerant oil drawn off from the oil separator of the A/C
service station and from the previous air conditioning
compressor must not be reused and must be correctly disposed
of.
Observe country-specific waste disposal regulations.

Installation note:
If the refrigerant circuit is open for longer than 24 hours:
 Replace desiccant insert
 4/30/2016 1/5

64 52 ... Notes for changing the air conditioning

compressor (amount of refrigerant oil of
new air conditioning compressor not
known)

Special tools required:

 00 9 030

Note:
This procedure only applies if the new air conditioning
compressor does not have a label with the amount of
refrigerant oil.
A different procedure applies for air conditioning compressors
with a label indicating the amount of refrigerant oil.
 

Important!
Risk of damage!
Remove the air conditioning compressor without
damaging and without the use of force!
Air conditioning compressors with plastic belt
pulleys:
 Avoid impacts/knocks to plastic belt pulley
(caused by tools, contact with base).
 Return faulty air conditioning compressors
in their original packaging only.

Important!
When starting up a new air conditioning
compressor for the first time, it is absolutely
essential to carry out the following breaking-in
procedure:
 Switch on Air conditioning system
 Set all air vents in the dashboard to
 4/30/2016 2/5

"OPEN"
 Start engine and let it stabilise at idle
speed
 Set blower output to min. 75% of max.
blower output
 Switch on heating and air conditioning
system and run for at least 2 minutes at
idle speed
Risk of damage at increased engine
speed!

Important!
In the event of a mechanical air conditioning
compressor failure and the resulting ingress of
chips into the refrigerant circuit, replace the
following parts:
All vehicles except I01:
 air conditioning compressor
 Replace desiccant insert
 Line to the capacitor
 Refrigerant oil
 
I01 only:
 air conditioning compressor
 Capacitor with desiccant insert/dryer flask
 all expansion valves
Rinse the refrigerant circuit.

All vehicles without I01 with heat pump:

The new air conditioning compressor is filled at the
factory with refrigerant oil.
The amount of refrigerant oil in the new air
 4/30/2016 3/5

conditioning compressor corresponds to the amount

of refrigerant oil for the entire new and unfilled
refrigerant circuit.
 
Only I01 with heat pump:
The new air conditioning compressor and new dryer
flask are filled at the factory with refrigerant oil.
The amount of refrigerant oil in the new air
conditioning compressor and in the new dryer flask
corresponds to the amount of refrigerant oil for the
entire new and unfilled refrigerant circuit.

When replacing the air conditioning compressor it is

absolutely essential to adapt the amount of refrigerant
oil in accordance with the instructions below!
An adaptation is also required for the replacement of
the dryer flask.
An adaptation of the amount of refrigerant oil is not
required in the following cases:
 Replacement of the complete refrigerant circuit.
 If the refrigerant circuit was rinsed (only I01).

When evacuating the air conditioning system, refrigerant oil is

also extracted and collected in the oil separator of the A/C
service station.
After evacuation, the refrigerant must be filtered in the A/C
service station as the oil separator could still contain a liquid
refrigerant/oil mixture. The refrigerant completely gasifies
through the cleaning operation. Only the prior bound refrigerant
oil remains in the oil separator. Measure and note down this
quantity of refrigerant oil.
 Refer to "Drawing off air conditioning system"

Transfer the refrigerant oil remaining in the previous air

conditioning compressor via the oil filler plug completely into a
measuring cup.
 4/30/2016 4/5

Measure the amount of refrigerant oil collected from the

previous air conditioning compressor.

Open oil filler plug and pour entire contents of air conditioning
compressor into a clean collecting vessel.
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to mount sealing rings without
damaging them.
Tightening torque 64 52 2AZ.

From the new air conditioning compressor, pour the same

amount of refrigerant oil (as drained from the previous air
conditioning compressor) + 10 ml extra into a clean measuring
cup and pour again into the new air conditioning compressor. At
least but a total of 50 g.
Remaining refrigerant oil can be poured into A/C service station
tank.
 4/30/2016 5/5

 Refer to "Evacuating air conditioning system" .

Otherwise the excess refrigerant oil must be disposed of
correctly.
On account of its hygroscopic properties, refrigerant oil must
not be stored in open containers.

The refrigerant oil drawn off from the oil separator of the A/C
service station and from the previous air conditioning
compressor must not be reused and must be correctly disposed
of.
Observe country-specific waste disposal regulations.

After installing the new air conditioning compressor, it is

essential before filling the heating and air conditioning system
to pour the same amount of the previously drawn off refrigerant
oil into the system again.
 Refer to "Filling air conditioning system"

Installation note:
If the refrigerant circuit is open for longer than 24 hours:
 Replace desiccant insert
 4/30/2016 1/1

63 99 ... Notes for handling bulbs / bulb light

sources (exterior lights)

Warning!
Xenon headlight: Danger to life due to high voltage!
Work on the entire xenon lighting system (ignition device,
control unit and bulb) may only be carried out by qualified
personnel.

Warning!
Halogen bulbs are under pressure:
To avoid injury, wear protective goggles and gloves.

Warning!
LEDs are potentially dangerous due to their dazzling
effect:
Do not look directly and unprotected into the light radiating
from the LED.

Important!
To avoid short circuits:
Disconnect bulbs / light sources from the voltage supply
before changing them (lighting system and ignition off).

Do not touch glass bulbs with bare hands, as even the smallest
amount of contamination will burn in and reduce bulb service
life.
Only touch light bulbs with clean gloves or a clean cloth.
Do not expose light bulbs to mechanical vibrations.
Use only recommended light bulbs.
Follow the light bulb manufacturer's notes without fail.
 4/30/2016 1/1

63 99 ... Notes for replacing the protective cap of

the headlight

Important!
Risk of damage!
Damaged seals on the protective caps will lead to
moisture penetration into the headlight.
This will in turn cause porous cable insulations and
malfunctioning of the headlight.

When working on the headlight system, check the protective

cap seals.
Replace the protective cap in the event of damage!

Example: screwed protective cap

Seal (1) on protective cap (2).

Example: latchable protective cap

Seal (1) on protective cap (2).
 4/30/2016 1/2

51 00 ... Notes on component bonding adhesive tape

Unless specified otherwise in vehicle-specific or component-specific instructions, the following notes apply.

1. General notes

- Bonding at room and object temperature of >+18 °C.

- Newly painted parts may only be bonded after a drying time of at least 24 hours.

- Optimal bonding/attachment to the background surface is achieved after approx. 48 hours.

Components must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).

- Do not touch bonding area.

- It is not the length of time that pressure is applied but rather the force of pressure applied that is
crucial.

- Detaching the adhesive tape after pressing destroys the adhesive layer.

- After being pressed on gently, adhesive tape can be pulled off again up to 3 times.

 

2. Auxiliary materials and tools

- Cleaning agent R1 or cleaning agent R2 (sourcing reference: BMW Parts Department)

- Fluff-free cleaning cloths

- Pressure roller

 

3. Preparations

- Remove all adhesive residue or clean new part thoroughly

- Clean the areas to be bonded immediately before bonding to remove silicone and grease residues.

Note:

Observe air drying time ≥1 minute.

 
 4/30/2016 2/2

4. Bonding
4.1 Components without pre-fitted adhesive tape

- Pull off liner* from adhesive tape

- Position adhesive tape on component and stick on

- Press down adhesive tape over entire adhesive area

- Continue with Point 4.2

* Liner is the protective film on the adhesive tape.

 

4.2 Components with pre-fitted adhesive tape

- Pull off liner* from adhesive side (if adhesive area is large, do not pull off liner completely)

- Align component in correct position on vehicle

- Press down component over entire adhesive area

Minimum contact pressure ≥ 15 N/cm² (firm thumb pressure reaches approx. 30 N/cm².)

* Liner is the protective film on the adhesive tape.

 4/30/2016 1/2

51 00 ... Notes on fitting window guide seals

 

1. Work safety when handling lubricant G13*

- Wear safety goggles, protective gloves and if necessary an apron.

- Do not eat, drink or smoke in the area of processing/application

- Ensure rooms are well ventilated.

- Keep heat and ignition sources well away

- In event of skin contact: Wash areas of skin affected with soap and water immediately, change work
clothing which has been fouled with lubricant immediately (keep spare work clothing in reserve)

- In event of eye contact: Rinse eyes immediately with plenty of water and seek medical advice

- Observe safety data sheet (see Aftersales Assistance Portal (ASAP) ‐ Service/Technology ‐ Safety
Data Sheet ‐ 7‐digit part number)

 

2. General notes

- Use only the BMW-approved lubricant for fitting

- Application only at room and object temperatures between 18 and 25 °C

- Lubricant dries at different rates depending on the quantity, temperature and ventilation and
becomes sticky

- Lubricant can only be used for fitting and not for fault elimination (e.g. grating)

- Newly painted parts may only be brought into contact with the lubricant after cooling

- Optimal bonding/attachment to the background surface is achieved after approx. 48 hours. The
window guide seal must not be exposed to mechanical strain beforehand (car wash, strength test,
etc.).

Important!

To avoid grating noises, do not use soapy water (low-surface-tension water with washing-up liquid) or
lubricant containing silicone
 4/30/2016 2/2

 

3. Auxiliary materials and tools

- Cleaning agent R1 or cleaning agent R2, cleaning cloth, plastic scraper, needle

- Lubricant G13* (manufactured by Zestron) part no. 83 23 0441 032

(*sourcing reference: BMW Parts Service)

 

4. Preparations

- Heat and remove anti-friction agent residues with a hot air blower or clean new part thoroughly

- Immediately prior to fitting, clean the work area in order to remove silicone and grease residues

Note:

Air drying time approx. 1 minute

 

5. Installation

- Apply a thin coating of lubricant to the reverse side of the window guide seal only

- Perform fitting within 30 minutes of applying lubricant

- Lubricant dries after fitting and becomes sticky

 4/30/2016 1/2

61 00 ... Notes on handling wiring harnesses and

cables

The following applies in general:

To avoid damage, observe the following instructions:
 Avoid compressive and tensile loads
 To ensure professional repairs, perform repair work only
with BMW-approved or recommended special tools and
spare parts
 Make sure cables are laid without kinks or abrasions
 Ensure non-contacting routing at sharp-edged body parts;
use edge protection if necessary
 Secure additionally laid cables/leads with cable ties
 
The following additionally applies
Shielded cables
Joins in the shield can cause problems with regard to noise
radiation and interference immunity. Consequently, distinctions
have to be drawn between the following types:
Coaxial cable
 Shielded RTK031 coaxial lines may only be repaired
using special crimping tools.
CVBS cables
 CVBS cables may not be repaired.
 CVBS cables must be replaced in their entirety.
HSD cables
 HSD cables may not be repaired.
 HSD cables must be replaced in their entirety.
 
Fibre-optic cables:
Note:
Fibre-optic cables are coloured differently as follows:

 Green = MOST (Media OrientedSystems Transport)

optical fibre
 Yellow = ISIS (Intelligent Safety Integration System)
optical fibres
 Orange=repair fibre-optic cables
 4/30/2016 2/2

Important!
 Optical fibres are permitted to show only one
junction point (bridge). Replace optical fibres if
necessary
 Smallest permissible bending radius is 25 mm
 Avoid effects of heat ≥ 85 °

Treating cables and fibre-optic cables

 
FlexRay:
It is possible to repair the FlexRay. In the event of damage, the
cables can be joined with conventional butt connectors and
heat-shrink tubing.
Note:
 FlexRay lines may only reveal one separation point
(bride); renew complete line if necessary.
 The cable is a twisted cable. If possible, maintain twisted
cable after repair.

 
Airbag lines:
Repairing airbag cables
 4/30/2016 1/1

67 31 ... Notes on initialisation of electric seat

actuator drives

Note:
Initialization is carried out at the adjusting switch of the relevant
seat.

In this process, the end positions of the relevant electric seat

actuator drive are recorded and stored.
An initialisation must be performed:
 After replacing a drive unit for seat adjustment.
 After replacing/programming control unit for seat
adjustment.

Operating procedure for initialisation:

Move corresponding seat actuator drive(s) into both end
positions.
 4/30/2016 1/3

67 62 ... Notes on initializing power windows

Note:
Initialisation is performed on the power window switch of the
relevant door.
Initialisation comprises:
 Normalisation
 Learning characteristic curve
With normalisation, the mechanical end stops of the power
window regulator are recorded and stored.
The characteristic curve is learnt immediately after
normalisation.
When the characteristic curve is learnt, the mechanical closing
forces of the power windows are recorded and stored for
correct operation of the anti-trapping mechanism.
Initialisation, i.e. normalisation and learning of characteristic
curve, is performed in a continuous operation.

Note:
An initialisation must be performed:

 In the event of malfunctions, e.g. no one-touch function,

no opening or no convenience function possible.
 After the power windows drive or door module has been
replaced.
 After work is carried out on the power windows
mechanism.

Warning!
There is no anti-trap mechanism during initialisation.
 4/30/2016 2/3

Necessary preliminary work:

 Vehicle stationary
 Sufficient battery voltage available / connect charger
if necessary
 Terminal ”15” switched on
 All doors closed
 F12 up to 02/2012 soft top open, from 03/2012 soft
top closed

Operating procedure for initialisation (manual):

Deleting the initialisation:
 Move side window into lower end position.
 Press and hold switch in ”Open one-touch function”
position (second switch position) for between 15 and
25 seconds.
Note:
Deletion of initialisation was successful if toll function and anti-
trap mechanism have been rendered inoperative.

Performing initialisation:
 Move side window to upper end position
 Pull and hold switch in ”Close one-touch function” (2nd
switch position) during the entire process.
Note:
Re-initialisation was successful if toll function and anti-trap
mechanism function flawlessly.
 4/30/2016 3/3

Alternatively, initialisation of the power window regulation can

also be carried out via the Service function in ISTA.
Selection via:
- Body
- Locking and security functions
- Power window regulator
- Initialise power window regulators
 4/30/2016 1/2

24 34 ... Notes on mechatronics (GA8HP45Z)

Special tools required:

 24 2 390

Important!
- Do not let skin come in contact with transmission oil
and do not inhale fuel vapours.

- Wear protective gloves.

- Ensure adequate ventilation.

Important!
After completing work:

- Load specific data status with the BMW diagnosis

system.

- Check transmission oil level.

- Use only approved transmission oil.

Failure to comply with this requirement will result in
serious damage to the automatic transmission!

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).
 4/30/2016 2/2

Unscrew connector (1) and disconnect.

Insert special tool 24 2 390 in sealing sleeve (1).

 4/30/2016 1/1

66 01 07 (394)

Notes on radio-operated system (vehicle access, radio-operated opening, radio-

operated closing)

All

Situation:
With some functional procedures and unintended activations, use of the radio-operated
systems for vehicle access, radio-operated opening and radio-operated closing leads to
faulty interpretations and thus to complaints.
Procedure: The known complaint cases are described in the following appendices. Each case is
presented with its causes and any necessary measures.

Enclosure 1: Self-locker

Enclosure 2: Range problem

Enclosure 3: Selective unlocking

Enclosure 4: Convenient access/convenient opening

Enclosure 5: Radio remote control failed/poor radio reception

Enclosure 6: Self-opener
 4/30/2016 1/2

72 12 ... Notes on scrapping vehicles with gas generators (airbag system)

The gas generator is a pyrotechnical component and is for the most part permanently mounted on the
following components:

- Airbag module

 Driver's/passenger airbag

 Side airbag

 Head airbag

 Knee airbag

- Automatic electric reel

- Belt end fitting tensioner

- Belt buckle tensioner

- Safety battery terminal

- Active head restraint

In accordance with accident prevention regulations and specific national regulations, gas generators must be
rendered unusable before they are scrapped. This is necessary because pyrotechnical objects can cause
injury if improperly activated (e.g. scrapping with flame cutters).

With vehicles which are scheduled for scrapping, it is always essential prior to draining and further stripping
work to ensure that all the gas generators in the vehicle are fired. The fired gas generators can then be
scrapped together with the vehicle.

Gas generators that have not fired constitute a hazard (also to the environment)!

 

Firing failure:

If correct firing is not possible, the relevant components must be removed and disposed of by special waste
disposal companies!

Comply with safety regulationsfor handling airbag system components .

If a triggering operation has failed:

 4/30/2016 2/2

- Disconnect the triggering device from the battery and

- Wait a few minutes before approaching the vehicle

 

The components of an airbag system must always be disposed of. Such components must not be sold on as
used parts.

 

Firing:

Triggering of the gas generators may only be carried out by expert personnel and under the supervision of a
responsible person. Other standard accident prevention regulations (safety goggles, ear defenders etc.) must
also be observed.

The gas generators must be fired from the outside in this vehicle which has been earmarked for scrapping. In
this process

- the doors must be closed

- the rear lid must be open

- the side windows must be open and

- the sunroof must be open

To fire the gas generators, use the firing device with the appropriate cables (follow instructions).

Warning!

Once gas generators have been fired, observe a ventilation period of 10 minutes with the doors
opened. Only then is it permitted to continue work inside the vehicle.

Wear protective goggles and protective gloves when handling a fired gas generator!

The burning of solid fuel will heat up the airbag unit - danger of burning hands!

Wash skin with water after contact with fired gas generators!
 4/30/2016 1/1

41 00 ... Notes on the water drain hose of the slide/tilt sunroof

The water drain hoses for the slide/tilt sunroof are partially permanently integrated in the body and cannot be
replaced individually.

These water drain hoses can only be completely replaced with extensive body repair work (e. g. after an
accident).

Component Vehicle Individually replaceable

Water drain hose, front All BMW No

All MINI

Rear water drain hose E60 No

E61 Yes

E84, E92 Yes

F01, F02, F04, F06, F07, F10, F11, F18 Yes

F25, E70, E71 Yes

F20, F21, F30, F31, F34, F35 Yes

R55, R56, R60, R61 Yes

 

An individual solution is required for damage that was not caused by an accident.

Contact national hotline.

 4/30/2016 1/4

51 31 ... Notes on window bonding repair kit

Small repair kit 83 19 0 444 141 contains the following separate component:

Contents Part number

Window adhesive 300 ml 83 19 0 444 144

Glass activator 83 19 0 444 142

Paint activator 83 19 2 154 458

C nozzle 83 19 2 155 589

Plastic nozzle, spacer buffer and paper towel

Large repair kit 83 19 0 444 145 contains an additional window glass adhesive 300 ml.

Important!

Before working with the consumables, note the following information.

- Country-specific safety and industrial safety regulations

- Material safety data sheet of manufacturer

- Processing instructions on the packaging

 

1 Storage and processing of all consumables

Dry at 15 ° - 25 °C.

 

2 Expiry date of adhesive:

Repair kit and glue cartridges are marked with a date (expiry).

Date (1) refers to the calendar week and year (KW/JJJJ).

The adhesive cannot be used after this date (1).

 4/30/2016 2/4

3 Hardening of adhesive:

The adhesive hardens by reacting with air humidity at room temperature.

Important!

Once the adhesive bead has been applied, the window glass must be installed within 7 minutes
(depending on air humidity, temperature).

After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.

At ambient temperatures above 23 °C and 50 % relative air humidity (hot countries), the adhesive open time
is shortened to approx. 5 minutes (skin formation time).

A relative humidity of < 30% significantly slows hardening.

The adhesive hardening process is interrupted completely at ambient temperatures below 5 °C. In this event,
there will be no increase in the strength of the bonded connection.

 

3.1 Minimum hardening time:

Minimum hardening time is reached beginning at 22 °C and 38 % relative air humidity.

- 1 hour, vehicles without front passenger airbag (after which vehicle can be moved)

- 2 hours, vehicles with front passenger airbag in countries without mandatory seat belt usage
Note:
 4/30/2016 3/4

In vehicles with front passenger airbag in countries without mandatory seat belt usage:

The vehicle can be transferred to the customer after a 1-hour hardening time with the following
warning:

Once the windscreen glass has been bonded, all occupants must travel with their seat belts attached
for 1 hour.

Important!

If the minimum hardening time is not adhered to, an accident can cause the passenger together with
the windscreen to fall out of the vehicle after the front passenger airbag deploys.

During the minimum hardening time of 1 hour, the vehicle must not be subjected to load on one side such as
e.g.:

- one wheel on kerb

- vehicle hoist

- etc.

Manoeuvring inside garage/workshop:

- only permitted on level ground

- do not under any circumstances drive over approach ramps, e.g. into multi-storey car parks

Do not remove adhesive tapes until after hardening time.

If the minimum hardening time of 1 hour is undercut, leaks and wind noises may occur at the window glass.

 

4 Disposal of adhesive:

Hardened adhesive is disposed of as normal waste.

Non-hardened adhesive, glue cartridge and mixtures of adhesive and solvents and the like must be disposed
of as hazardous waste.

The adhesive is disposed of in paper sacks so that it can react with moisture.

 
 4/30/2016 4/4

5 Glass/paint activator (bonding agent):

Warning!

Wear cut resistant gloves when breaking the glass ampule.

Prepare glass activator and paint activator for application by shaking and snapping (breaking glass ampule).

Apply glass activator by pressing gently. There is no need for final wiping. Air drying time approx. 2 minutes.

Apply paint activator by pressingly gently. Then wipe dry with a paper towel (included in the set).

 

6 Expiry date of bonding agent:

Repair kit and bonding agent are marked with a date (Best Before).

- The bonding agent may only be used up to this date (if not already opened previously).

- After opening, keep only for one week even if the expiry date has not yet been reached.

 

7 Disposal of bonding agent:

Bonding agent must not be disposed of in household trash.

Bonding agent must be disposed of as hazardous waste.

 
 4/30/2016 1/2

64 11 .. Overview of actuator drives on

heater/air conditioner

1 Actuator drive, 7 Actuator drive,

blending flap, ventilation flap,
left right

2 Actuator drive, 8 Actuator drive,

ventilation flap, fresh
left air/recirculated air
flap

3 Actuator drive, 9 Actuator drive,

air mixing flap, blending flap, right
left

4 Actuator drive,
rear
compartment
flap

5 Actuator drive,
air mixing flap,
 4/30/2016 2/2

right

6 Actuator drive,
defroster flap
 4/30/2016 1/1

65 20 ... Overview of aerial diversity

1. Back‐up aerial
2. Interference suppression filter
3. Roof aerial
4. Aerial amplifier
5. Wave trap
 4/30/2016 1/1

65 13 ... Overview of audio components

1 Tweeters in the dashboard 8 Amplifier

2 Tweeter mirror triangle 9 Mid-range speaker, rear left

3 Mid-range speaker, door, front 10 Central bass, driver's side

4 Central bass, passenger's side 11 Mid-range speaker, door, front

5 Mid-range speaker, rear right 12 Tweeter mirror triangle

6 Rear right tweeter 13 Mid-range speakers in dashboard

7 Rear left tweeter

 4/30/2016 1/1

34 32 ... Overview of brake lines

1 Brake hose, front 3 Brake hose, rear

2 Brake pipes
 4/30/2016 1/1

34 31 ... Overview of brake master cylinder /

brake booster

1 Expansion tank 4 Brake servo

2 Brake master cylinder 5 Vacuum hose

3 Non-return valve 6 Bleed braking system

 4/30/2016 1/1

34 00 ... Overview of brakes

0 General Information

1 Front brake 2 Brake master cylinder / brake servo

3 Hydraulic unit 4 Electrical components

5 Parking brake 6 Brake, rear

7 Adjustment work 8 Testing

 4/30/2016 1/1

51 00 ... Overview of consumables (Electronic Parts Catalogue)

Designation, repair Designation, Electronic Part number, Electronic Parts Remarks

instructions Parts Catalogue Catalogue

Cleaning agent R2 Cleaning agent R2 83 19 0 417 324 500 ml

Lubricants G13 Lubricants G13 83 23 0 441 032 900 ml / Notes

Yellow plastic Adhesive tape 83 19 9 410 979 A = 66 mm;

adhesive tape B = 50 mm

Masking tape Masking tape 81 22 9 400 181 L = 50 mm /

W = 19 mm

Masking tape Masking tape 81 22 9 400 388 L = 50 mm /

W = 30 mm

Eraser disk Scotch Brite eraser disk 51 91 0 402 946 with shaft

Cutting cord Cutting cord 81 43 2 344 272 Notes

Adhesive set K6 Adhesive set K6 83 19 2 317 925

Profile rubber 83 19 2 232 322

adhesive

 
 4/30/2016 1/1

34 52 ... Overview of electronic components

1 ICM control unit 3 Pulse sensor, rear

2 DSC control unit 4 Pulse sensor, front

5 Start-up of ICM control unit

 4/30/2016 1/1

22 Overview of engine/gearbox mounting

  Engine mounting:     Gearbox mounting:  

1 Engine support arm (left / right) 3 Gearbox cross member

2 Engine mount (left / right) 4 Gearbox mount

Transmission mounting bracket

 4/30/2016 1/1

34 11 ... Overview of front brake

1 Brake disc 4 Brake guard plate

2 Brake pad 5 Brake pad wear sensor

3 Brake calliper   6 Checking brake pad thickness  

 4/30/2016 1/1

25 11 ... Overview of gearshift mechanism for

manual gearbox

1 Gearshift arm 6 Support bearing (gearshift arm bearing)

2 Ball socket (gearshift lever bearing) 7 Gearshift lever

3 Gearshift lever cover (gaiter) 8 Gearshift rod

4 Gearshift lever knob 9 Gearshift rod joint

5 U-type bellows 10 Bearing bush

 4/30/2016 1/1

34 41 ... Overview of handbrake

1 Handbrake lever 4 Brake shoe expander

2 Guide tube 5 Handbrake Bowden cables

3 Handbrake shoes 6 Adjusting handbrake

 4/30/2016 1/1

64 00 .. Overview of heater - A/C system

components

1 Heater/air conditioner with add-on 4 Capacitor for heater - A/C system

parts

2 Remove fan for heater - A/C 5 Dryer flask for heating and air conditioning system (included in
system the capacitor)

3 Compressor for A/C system 6 Expansion valve

 4/30/2016 1/1

26 11 ... Overview of propeller shaft (rear

flexible disc)

1 Complete propeller shaft 3 Centring mount

2 Flexible disc 4 Centre mount

 4/30/2016 1/1

33 .. ... Overview of rear axle final drive/output

shafts

       

    Safety instructions & general information  

     

1 Rear axle final drive  

2 Radial shaft seal for drive flange  

3 Output shaft (left/right)  

4 Radial shaft seal for output shafts  

5 Lid (incl. cover gasket)  

 4/30/2016 1/1

33 .. ... Overview of rear axle support with

rubber mounts

       

    Safety instructions & general information  

       

1 Rear axle support  

2 Rear differential rubber mount, front  

3 Rear axle final drive rubber mount, rear  

4 Rear axle support rubber mount, front  

5 Rear axle support rubber mount, rear  

 4/30/2016 1/1

34 21 ... Overview of rear brake

1 Brake disc 4 Brake guard plate

2 Brake pad 5 Brake pad wear sensor

3 Brake calliper 6 Checking brake pad thickness

 4/30/2016 1/1

33 32 ... Overview of steering links

Adjusting procedure

1 Trailing arm 4 Wishbone

2 Traction strut 5 Camber arm

3 Camber arm cover 6 Toe arm

 4/30/2016 1/2

23 00 ... Overview of transmission housing

(GS6-45BZ/DZ)

Complete transmission, oil change, transmission designations

0 General information

 
1 Drive shaft

 
2 Guide tube

For transmission input shaft

3 Radial shaft seal

 
4 Transmission housing, front section

 
5 Internal components

 
 4/30/2016 2/2

6 Reversing light switch

 
7 Zero-gear sensor

shafts, gear wheels, gearshift components

8 Transmission housing, rear section

For gearshift shaft

9 Radial shaft seal

 
10 Gearshift shaft

 
11 Output shaft

 
12 Output flange

For output flange

13 Radial seal
 4/30/2016 1/6

61 13 ... Overview, rain sensor (additional work when replacing the windscreen / sensor
replacement)

- 5-Series: E60, E61

- 6-Series: E63, E64

- 7-Series: E65, E66:

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required

necessary

all types No Yes Yes Yes

square
60 x 40 mm

all types No Yes Yes Yes

approximately ø (new replacement

50 mm optics required,

refer to Electronic
Parts Catalogue)

 

- X5: E70, E71, E72

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor Encoding / Initialisation required
replacement programming required
required
necessary

RLPSS (Rain, light and Yes Yes Yes Yes

 4/30/2016 2/6

precipitation solar sensor)

(Designation is located on
the back of the sensor)

approximately ø 50 mm

RLSS (vehicle without No Yes Yes Yes

HUD)
(new replacement
(Designation is located on optics required,
the back of the sensor)
refer to Electronic
approximately ø 50 mm Parts Catalogue)

RLSS (vehicle with HUD) Yes Yes Yes Yes

(Designation is located on
the back of the sensor)

approximately ø 50 mm

 

- 1-Series: E81, E82, E87, E88

- 3-Series: E90, E91, E92, E93

- X1: E84

- X3: E83

- Z4: E85, E86

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required

necessary

all types No Yes Yes Yes

square
60 x 40 mm
 4/30/2016 3/6

 

- 5-Series: F10, F11, F18

- 5-Series GT: F07

- 6-Series: F06, F12, F13

- 7-Series: F01, F02, F03, F04

- X3: F25

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required

necessary

all types No No Yes Yes

approximately ø
35 mm

all types Yes Yes Yes Yes

approximately ø
50 mm

 

- X5: F15

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required

necessary

all types No No No No

approximately ø
 4/30/2016 4/6

35 mm

 

- 1-Series: F20, F21

- 2-Series: F22, F23

- 3-Series: F30, F31

- 3-Series GT: F34

- 4-Series: F32, F33

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor Encoding / Initialisation required
replacement programming required
required
necessary

all up to 03/2014 except No No Yes Yes

SBS (01)

(Designation is located on
the back of the sensor)

approximately ø 35 mm

SBS (01) No No No No

(Designation is located on
the back of the sensor)

approximately ø 35 mm

All as of 03/2014 No No No No

approximately ø 35 mm

 

BMW i:
 4/30/2016 5/6

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required

necessary

all types No No No No

approximately ø
35 mm

 

MINI (all):

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required

necessary

all types No Yes Yes Yes

square
60 x 40 mm

all types No No No No

approximately ø
35 mm

 

Rolls-Royce (all):

Sensor type/ With windscreen With sensor With sensor Connecting the
replacement replacement replacement diagnosis system
Sensor shape
Sensor replacement Encoding / Initialisation required
required programming required
 4/30/2016 6/6

necessary

all types No Yes Yes Yes

square
60 x 40 mm

all types No No Yes Yes

approximately ø
35 mm

all types Yes Yes Yes Yes

approximately ø
50 mm
 4/30/2016 1/2

34 11 667 Precision-turning both front brake discs

on both sides

Important!
Always precision-turn both sides of both brake discs on
one axle.
Maximum machining dimension per friction ring side is
0.8 mm!
Minimum brake disc thickness (MIN TH)
Brake discs of M models (Compound brake discs) must
not be machined!
Only one brake pad set may be used up on brake discs
which have been lathe-turned to minimum thickness (MIN
TH).

Stationary brake disc lathe:

Important!
Only BMW-approved brake disc lathes may be used!

In the case of stationary brake disc lathes, the brake disc must
be removed.
Please refer to the equipment manufacturer's operating
instructions for the exact procedure.

Mobile brake disc lathe:

Important!
Only BMW-approved brake disc lathes may be used!

In the case of mobile brake disc lathes, the brake caliper and
the brake anchor plate must be removed.
The brake discs remain on the vehicle.
Please refer to the equipment manufacturer's operating
instructions for the exact procedure.

After fine-grinding the brake discs, measure the thickness

 4/30/2016 2/2

difference inside the braking surfaces at 8 points with an caliper

gauge.
 4/30/2016 1/6

33 21 ... Pressing output shaft out of drive flange

and drawing in

Necessary preliminary tasks:

 Remove rear axle final drive.

If necessary, remove visual protection cap (1).

Important!
Expand anti-twist lock sufficiently to avoid damaging
thread when releasing collar nut (1).

Activate parking brake.

Unfasten collar nut (1).

Use special tool, see BMW Workshop Catalogue.

 

- Hydraulic unit - 81 64 2 155 744

 4/30/2016 2/6

- Adapter kit 1 -  81 64 2 155 745

- Adapter kit 2 -  81 64 2 155 746

- Adapter - 81 64 2 318 661

 Secure output shaft against falling out.

The following work steps describe pressing out the output shaft:
 4/30/2016 3/6

The following tools are required to press out the output shaft from the drive flange, see graphic for
arrangement:
Vehicle components:

I Drive flange hub

II Wheel carrier

Required components for all models and types:

1 Hydraulic unit

E3 Washer M24

F3 Spindle M24 (length 270 mm)

C1 Holding sleeve

B1 Adapter

* Components specific to model and type:

K* Wheel bolts
 4/30/2016 4/6

The following work steps describe drawing in the output shaft:

The following tools are required to fit the output shaft in the drive flange, see graphic for arrangement:
Vehicle components:

I Drive flange hub

II Wheel carrier

III Output shaft

Required components for all models and types:

1 Hydraulic unit

E1 Holding sleeveM24

D1 Washer

F2 Spindle M24 / M20 (length 335 mm)

* Components specific to model and type (thread diameter, output shaft):

 4/30/2016 5/6

G2 Adapter M24 x 1.5 to M20

Installation note:
Lightly oil gearing of the output shaft and insert in drive flange.

Important! Risk of damage!

Due to the technical requirements, the special tool used, sleeve G,* is relatively thin-walled. To ensure that the
load limit of the tensioning sleeve is not exceeded when drawing in the output shaft, it is essential to use
adapter 81 64 2 318 661 in combination with a torque wrench.
 
Fit adapter with torque wrench to hydraulic unit (see graphic).
Set torque wrench to 20 Nm.
Draw in output shaft with hydraulic tool until the torque wrench is activated.

Tighten collar nut (1), activate parking brake for this purpose.
Tightening torque 33 41 1AZ.
Secure collar nut (1) by positive peening at flat areas of output
shaft.
Installation note:
No oil permitted on thread of shaft journal or collar nut.
Renew collar nut (1).
4/30/2016 6/6
 4/30/2016 1/5

72 12 ... Procedure after airbag deployment as result of an accident

Check and/or replace following components after airbag deployment:

Satellites (control unit + sensor)

- Components

 Satellite, A-/B-pillar, left/right

 Satellite, front door

 Satellite, rear seat

 Satellite, driver's/passenger's side

 Satellite, vehicle centre

- Procedure

 Inspect visually for mechanical damage

 Read fault memory

 Disconnect battery and observe waiting period

 Rectify faults

 Connect battery and observe waiting period (at least 10 seconds)

 Delete fault memory

 Turn off ignition and wait at least 2 minutes (no consumers may be switched on during this period
such as e.g. interior lights, radio, etc.)

 Switch on ignition (wait at least 10 seconds)

 Clear fault memory and if necessary rectify faults

 

Cables and connectors

- Components and procedure

 4/30/2016 2/5

 Check cables and connectors for damage, replace if necessary.

(e. g. corrosion, correct engagement, bent pin)

 

Seat belt system

- Components

 Automatic reel

 Belt buckle tensioner

 Seat belt height adjustment

 Anchor fitting tensioner

- Procedure

 Check components, replace if necessary

 

Seats

- Components

 Seat

 Airbag module

 Active head restraint

- Procedure

 Check seats (function check of seat mechanism), replace if necessary

 Check seat screw/bolt connections

 Replace gas generator, active head restraint system

 

If the severity of the crash has not caused any other damage to the seat, only the triggered gas
generator needs to be replaced.
 4/30/2016 3/5

External feature: The triggered head restraint is folded forwards and engaged.

The repair work can be carried out in the vehicle with the rear panel removed. The entire system
can be pushed back into its original position and the new gas generator installed.

The gas generator can be replaced up to 5 times.

 Replace airbag module and seat cover with upholstery

 

Driver's airbag

- Components

 Airbag module

 Steering Wheel

 Steering column (if damaged)

- Procedure

 Check components, replace if necessary

 Replace steering wheel

 

Front-passenger airbag

- Components

 Airbag module

 Dashboard trim panel (must be replaced!)

 Supporting tube (if damaged)

- Procedure

 Check components, replace if necessary

 

Side airbag, front/rear

 4/30/2016 4/5

- Components

 Airbag module

 Door trim panel

 Door in white

 Seat

- Procedure

 Check components; replace if necessary

 

Head airbag

- Components

 Airbag module

 Cover, A-pillar

 Roofliner

 Cover, B-pillar (if damaged)

 Cover, C-pillar (if damaged)

 Connection/mount (on side frame)

- Procedure

 Check components, replace if necessary

 

Knee airbag

- Components

 Trim panel (driver's side)

 Lower section of glove box

 4/30/2016 5/5

 Knee protection (driver's and passenger's sides)

- Procedure

 Check components, replace if necessary

 

Passive knee protection

- Components

 Trim panel (driver's side)

 Glove box incl. knee protection (passenger's side)

- Procedure

 Check components for damage, replace if necessary

 Check retaining element

 4/29/2016 1/1

00 .. ... Raising vehicle with trolley jack

Observe the following trolley-jack-related instructions:

1. Only trolley jacks sold or approved by BMW, with a
rubber plate on their mounting, may be used!
2. Trolley jacks must be regularly serviced and always
checked for functional reliability before they are used!
3. Check the rubber plate on the trolley jack prior to each
use, replacing if necessary.

Warning!
The vehicle may be raised with a trolley jack only at the
following mounting point!
 

1 Car jacking point

Note: When raising, the underbody panelling is pressed
against the front axle support.
 
2 Side car jacking points
 
3 Rear axle final drive
Note: It is not permitted to raise the vehicle at the rear
differential cover!

Risk of damage!
Jacking point (1) must be present!
Align the rubber plate on the trolley jack to the jacking
point (1) in such a way that there is no contact to adjacent
components and that they are therefore not damaged.
 4/30/2016 1/1

36 11 503 RDC resetting

Note:
RDC monitors the tyre pressure in the four wheels.
Each tyre incorporates an Wheel electronics module, which
constantly monitors the tyre pressure.
The system signals when the tyre pressure drops in one or
more tyres.
Resetting must be carried out in each case immediately after
tyre pressures have been corrected, after tyres/wheels have
been replaced and after repairs to the air spring system.

Please refer to the relevant Owner's Handbook for details of the

resetting procedure.
 4/30/2016 1/1

33 .. ... Rear axle layout

    Safety instructions & general  

information

       

1 Overview of rear axle final drive/output 8 Coil spring

shafts

2 Overview of rear axle support 9 Anti-roll bar link

3 Tension strut 10 Wheel carrier

4 Overview of steering links 11 Adjustment

work

5 Wheel bearing / drive flange 12 Testing

6 Shock absorber    

7 Anti-roll bar    
 4/30/2016 1/2

REP-UEB-RAF2033-3300_VERM_NACH   Rear axle: wheel/chassis alignment check must be carried out

after the following work

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

33 00 ... Rear axle: wheel/chassis alignment

check must be carried out after the
following work

 
A wheel alignment check must be carried out after the following work:
 Release the following screw connection:
 Wishbone to rear axle support (2)
 Toe arm on rear axle support (4)
 Toe arm to wheel carrier (4)
 Camber arm on rear axle support (5)
 Camber arm to wheel carrier (5)
 
 Replacement of following parts:
 4/30/2016 2/2

 Rear axle support (1)

 Wishbone (2)
 Wheel carrier (3)
 Toe arm (4)
 Toe arm (5)
 Ball joint in wheel carrier
 Rubber mount in wheel carrier
 4/30/2016 1/2

36 00 ... Recommendation for heating tyres before removing or installing

Recommendation for heating cold tyres to minimum installation temperature +15 °C:

 

To ensure injury-free tyre fitting, in particular the upper side wall and the upper tyre bead must have a
temperature of at least 15 °C on the inside.

To ensure easier tyre installation, a temperature of 20° to 25° C is recommended.

This internal temperature is called the core temperature.

Rubber is a poor conductor of heat. For this reason, a cold tyre must rest for a sufficient length of time in a
warmed-up environment until the inner rubber layers have warmed up to at least 15 °C.

The surface temperature of the tyre during the warm-up phase is not a measure of the internal temperature!

The room temperature is normally measured and read off at eye level. At 19 °C at eye level the temperature
on the floor is approx. 16 °C. In other words, do not lay tyres directly on a cold floor to warm up; instead, lay
them at least on an insulating surface, such as a pallet, or even higher.

To ensure that cold tyres absorb the heat from the ambient air as quickly as possible, they should not be
stacked but rather stored individually so that they are thoroughly ”immersed” in the warm ambient air.

Do not under any circumstances place tyres in front of a radiant heater or a hot air blower as harmful surface
temperatures are very quickly reached in this situation. Apart from heating with warm water or with warm
recirculated air (max. 50 °C, no hotter), there is no other way of heating a tyre without damaging the tyre!

If a cold tyre (under 0 °C) is introduced into a warm environment (over 0 °C), a layer of frost will form
immediately on the tyre surface. This frost layer shows that the tyre is absorbing heat intensively from its
surroundings through condensation of the moisture in the air. When the frost layer has melted, condensation
water forms; dry off this water with a cloth so that the subsequent warming-up process is not slowed down by
latent heat.

 

Summary:

Starting from a min. room temperature of 19°C:

- Tyres at initial temperature of 0 °C and higher: store for at least 2 hours

- Tyres at initial temperature below 0 °C: store for at least 2.5 hours

Recommendations for heating:

 4/30/2016 2/2

- Store on an insulating surface - a pallet or similar ‐ at as high a level as possible

”Upper” bead facing upwards

- Position tyres individually so that they can be thoroughly ”immersed” in warm air

- Wipe off condensation water

- Do not point heaters at tyres

 4/30/2016 1/5

41 00 ... Reinforcement plate (bonded)

In the case of a partial replacement piece, a body component is

cut at a point described in the repair instructions.
A reinforcement plate is bonded in to ensure sufficient strength.
Observe notes on repair stage 2 .
 
Note:
The following graphics serve as general illustrations of
reinforcement plate repair work. They apply to sectional repairs
to the structure.

Mark component in accordance with measurement a and cut.

Preparation of new part:

Cut new part (1) in accordance with cut on vehicle and if

necessary adjust to fit with straightening attachment or
universal mount.
 4/30/2016 2/5

Make reinforcement plate (1) from trim of new part (2).

Length of reinforcement plate is 80 mm.

Slide reinforcement plate (1) half-way into component on body

and fasten with 2 self-tapping screws (2).

Adjust new part (1) to fit and set 4.3 mm dia. bore holes (2).
Remove new part again.
Release self-tapping screws (3).
Remove reinforcement plate.
Drill out bore holes (3) for screws to 4.3 mm dia.
Deburr all bore holes.
 4/30/2016 3/5

Important!
Do not grind new part and body in area of bonding
surfaces.

Installing reinforcement plate

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive (1) to reinforcement plate bonding surface.
Carefully slide reinforcement plate half-way into body
component (2).
Important!
When joining reinforcement plate, make sure there is
sufficient adhesive on bonding surfaces.
 4/30/2016 4/5

Rivet reinforcement plate (1) up to half-way with blind rivets N3

(2).

Apply adhesive (1) to reinforcement plate bonding surface.

Install new part (1) with straightening attachment or universal

mount and rivet with blind rivets N3 (2).
After adhesive has hardened, flatten adhesive area and seal
blind rivets.
4/30/2016 5/5
 4/30/2016 1/2

61 35 270 Remove and install (replace) control unit

Front Electronic Module (FEM)

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point
 Remove side trim panel from footwell on right A-
pillar

Release screw (1) and remove cover (2).

Important!
Risk of damage to positive battery cable connector!

 
Unlock the positive battery cable connector:
1. Loosen lock (1) in direction of arrow.
2. Unlock top positive battery cable connector (2) in
direction of arrow.
3. Disconnect battery positive lead (2).

Unlock plug connections·(1) and disconnect.

Release bolt (2) and remove control unit (3).
Tightening torque 61 35 5AZ.
Installation note:
Make sure all plug connections are correctly latched.
 4/30/2016 2/2

Replacement:
The front electronic module (FEM) makes functions available
from the former control units FRM, CAS, JBE and ZGM. After
the FEM is replaced, it is therefore necessary to start up the
integrated central gateway module (ZGM); during this process,
the configuration of the vehicle and the connection in FlexRay is
learned in again. An adjustment also needs to be performed on
the electronic transmission control (EGS) and electric steering
lock (ELV) after the FEM is replaced. In this case, the FEM
transfers the individual code to the EGS or ELV. After the FEM
is replaced, it is absolutely essential for all ID transmitters
(ignition keys) to be re-initialised.
Carry out vehicle programming/coding.
 4/30/2016 1/1

61 35 275 Remove and install (replace) control unit

Rear Electronic Module (REM)

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point
 Remove right luggage compartment wheel arch
panel.

Unlock plug connections·(1) and disconnect.

Unlock and disconnect positive battery cable (2). (Note removal
instructions below)
Unscrew nuts (3).
Tightening torque 61 35 4AZ.
Remove control unit (4).
Installation note:
Make sure all plug connections are correctly latched.

Important!
Risk of damage to positive battery cable connector!

 
Unlock the positive battery cable connector:
1. Loosen lock (1) in direction of arrow.
2. Unlock top positive battery cable connector (2) in
direction of arrow.
3. Disconnect battery positive lead (2).

Replacement:
Carry out vehicle programming/encoding.
 4/30/2016 1/2

61 21 010 Remove and install or replace battery

Warning!
Observe safety informations for handling vehicle battery.

To ensure the correct safety and convenience functions, install

only the original battery (battery size and type) stored in the
vehicle order. Observe note on battery replacement.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Open cover (1) and release nut (2) below it.

Tightening torque 61 21 1AZ.
 
Important!
Do not under any circumstances pull or lever off safety
battery terminal (3) by force.

Remove safety battery terminal (3) towards top, lay to one side

and fix in position.

Unscrew nuts (1).

Tightening torque 61 21 5AZ.
Remove retaining brackets (2).
Release vent hose (3).
Remove battery crash pad (4) towards top.
 4/30/2016 2/2

Release screw (1) and remove holder (2).

Tightening torque 61 21 5AZ
Remove battery.
 
Installation note:
Make sure battery is correctly seated in mounting.

Replacement:
 Register battery replacement
 4/30/2016 1/5

36 10 300 Remove or install front or rear wheel

Special tools required:

 36 1 300
 81 25 2 344 011
 36 1 335
 36 1 010

Note:
From 02/2013 vibration absorbers (1) are installed on vehicles
with rear-wheel drive and run-flat tyres!

Important!
Wheel was balanced electronically.
Observe safety information on raising the vehicle.
Adhere to the instructions on initializing the Run Flat
Indicator (RPA).
When fitting all four wheels (e.g. when changing from
summer to winter wheels), check the tyre pressure.
To avoid tyre damage, advise the customer to check the
tyre pressures on a regular basis (see operating
instructions).

Observe the following procedure to prevent clamping errors and

imbalance:
 4/30/2016 2/5

- Loosen wheel studs.

- Wheel positioned with valve facing down.

- If several wheels are simultaneously removed, mark

installation position of wheels on tyres (e.g. with a piece
of chalk).

- Mark out wheel to wheel hub.

- Mark out lockable wheel stud in relation to wheel.

- Unscrew wheel studs. Remove wheel.

Important!
Contact surfaces between:

- brake disc and disc wheel,

- brake disc and wheel hub,

must be clean and free from grease.

Remove dirt, grease residues and corrosion from contact

surface with a drill and special tool81 25 2 344 011.
Important!
Do not operate special tool 81 25 2 344 011 with an
impact screwdriver!

Note:
Degrease contact surface with universal cleaner, refer to
BMW Parts Department.

Note:
If there are grease residues in the area of the wheel stud
hole, the brake disc must be removed and cleaned.

Remove dirt, grease residues and corrosion from contact

surface (1) with a drill and special tool 81 25 2 344 011.
 4/30/2016 3/5

Important!
Do not operate special tool 81 25 2 344 011 with an
impact screwdriver!

Note:
Degrease contact surface with universal cleaner, refer to
BMW Parts Department.

Check brake disc retaining bolt (1) for tight fit.

Important!
Mounting bolt (1) must not under any circumstances
protrude over contact surface (2) between brake disc and
disc wheel.

Tightening torque brake disc retaining bolt:

 Front axle 34 11 1AZ
 Rear axle 34 21 1AZ

Apply a thin coat of grease to wheel centring (1) in disc wheel.

Note:
To release and tighten lockable wheel bolts, use a
matching adapter from special tool 36 1 300, 36 1 335 or
36 1 010.
 4/30/2016 4/5

Clean wheel studs and check threads for damage, replace, if

necessary.
Replace rusty wheel studs.
Important!
Do not apply oil to wheel studs.

Important!
Under no circumstances use pneumatic or electric
screwdrivers to install and tighten the wheel studs.

Important!
Disc wheel must rest uniformly against brake disc.
In the case of non-original BMW wheel studs/rims it may
be necessary to retighten the wheel studs on account of
setting properties (refer to manufacturer's documents).

Fit wheel studs and evenly tighten crosswise by hand in order

 4/30/2016 5/5

to centre the disc wheel.

Tighten down wheel studs in crosswise sequence with a
calibrated torque wrench to prescribed tightening torque
36 10 1AZ.
 4/30/2016 1/1

52 15 403 Remove or install/replace cover left or

right thigh support from/on the front seat
(sport/manual)

Unlock and move thigh support (1) as far forward as possible.

Lift out welt of seat cover (2) from thigh support.

Lever out cover welt in marked area (1).

Detach trim wire in marked area (2) from thigh support.
Remove cover with upholstery.

Pull cover (1) off upholstery (2).

 4/30/2016 1/7

51 31 ... Remove windscreen with "Roll Out

2000"

Special tools
required:
 2 150 267

Windscreen removal system "Roll Out 2000"

 4/30/2016 2/7

1 Wire starter 8 Extension (short)

2 Parabolic tool 9 Extension (long)

3 Plastic washer 10 Reversible ratchet

4 Wire cutting roller 11 Plastic wedge

5 Suction cup lifters 12 Guide needles

6 Protective gloves 13 Suction cup lifter with double spool

7 Safety goggles    

Note:
Both paint and ergonomic and health-endangering damage is
minimised with the "Roll Out 2000" system.
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical -
Workshop Equipment (Start BMW) - Shop Workshop
Equipment or at www.bmwgroup.com
 4/30/2016 3/7

Warning!
Follow safety instructions for working on vehicles with
airbag systems (risk of injury).

Important!
Take care when handling sharp-edged tools and cutting
wire (risk of damage to head airbag and window glass).

Important!
Always keep both suction cups dry and clean to ensure
their optimum adhesion on the windscreen.
Suction cup may not be applied at the damaged point
(crack in window glass).
Lubricate spool if lock rattling becomes too loud.
Always wear safety goggles and protective gloves for your
own safety.

Mounting suction cup lifters on windscreen or rear window:

 4/30/2016 4/7

- Secure position of lifting jacks as shown (view from outside):

1. Suction cup lifter with double spool
2. Suction cup lifter with single spool (as deflecting point)
3. Window
4. Cutting wire
Note:
Optimum cutting is guaranteed when the cutting wire is at an acute angle to the adhesive bead. There is a risk
of the cutting wire breaking if the angle is too obtuse.
The suction cup lifter (2) is used as the deflection point to achieve the corresponding angle.
Depending on the window glass version and the effort applied during cutting, it may be necessary to change
the deflection point during cutting.
The suction cups without a spool can even be used as the deflection point.
 4/30/2016 5/7

Preparatory work:

- Cut off required cutting wire length:

Length approximately = 6 x window glass diagonal

- The cutting wire loops must lie on top of each other in area (B).
They must not get caught up in each other. (Otherwise no possibility of cutting the adhesive bead/wire will
break.)
Overlapping of cutting wire loops approx. 10 cm.
Distance from right window edge approx. 30 cm.

Pulling cutting wire into vehicle:

- Grip wire with pliers

(If accessibility is bad, stick wire with wire
starter 2 150 267 through adhesive bead.)

- Wire end (1) must be bent towards window glass.

- Heat wire end (1) and use it to pierce adhesive bead (2).

- Pull the wire approximately 1.5 m into the passenger

 4/30/2016 6/7

compartment

Using wire starter:

Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive
bead, wire end (bent part) must be positioned on window glass.

Laying cutting wire around window glass:

- Starting from pull-in point, lay wire eyelet created on the

outside around the window glass

- Pull excess wire into passenger compartment

Important!
Make sure the cutting wire is located at all four corner
points below the window glass.
Check that the cutting wire is not caught on clamps or
body.
Secure window glass on outside with adhesive tape
against sliding.

Note:
Window glass (1) with installed seals (3) or moulded-on
surrounds:

- Moisten cutting wire (4) and seals (3) on window glass (1)

with water

- Insert cutting wire (4) in bend (without kinking) between

window glass(1) and body aperture (2)
 4/30/2016 7/7

Protect the passenger compartment:

- To avoid damage and possible dirt contamination, protect

A-pillars, roof and dashboard trim panel (3) by means of
plastic washer (1)

- Always carry plastic washer (1) between respective

wire (2) being tightened and trim panels

Attaching wire in hoisting winch with double coil:

- Bend over cutting wire end (1) approximately 10 mm and

insert into slot of spool (2)

- Repeat process with other end of wire (1) and second

spool (2)

- Wind cutting wire (1) onto spools by hand until cutting

wire (1) is under slight tension

Starting the dismantling:

Note:
Spools can only be rotated in one direction.

- Make sure the wire is always situated in the guide

channel of the suction cup lifter (1)

- Fit reversible ratchet onto top spool shaft (2) and tighten
wire

- Start by cutting lower adhesive bead

- At the end of the cutting process, the two wire loops join
up at the lifting winch (1)

- Remove "Roll Out 2000"

- Remove window glass

 4/29/2016 1/2

17 11 150 Remove, fit/replace additional oil cooler

(N55)

Warning!
Risk of scalding!
Only perform this repair work after engine has cooled
down.

Important!
Wear safety goggles and protective gloves.

Recycling:
Engine oil escapes when engine oil pipes are released.
Collect any escaping engine oil using a suitable vessel
and dispose of it.
Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

 Remove the right front section of the wheel arch
cover.
 4/29/2016 2/2

Release screw (1).
Tightening torque 17 22 5AZ.
Remove engine oil pipe from engine oil cooler flange.
Replace sealing rings.
Unfasten screws (2).
Tightening torque 17 22 3AZ.
Catch and dispose of emerging oil.
Remove engine oil cooler (3).

Note:
After completing the repair work, check the oil level in the
engine; top up if necessary.
 4/29/2016 1/2

13 71 170 Removing air duct (N55)

Necessary preliminary tasks:

 Remove intake silencer housing.
 Remove fan cowl.
 Remove front underbody protection.
 Release coolant expansion tank and place to one
side, do not drain coolant.

Unlock connector (1) and remove.

Release screw (2).
Pull off engine vent line (3) from air duct.

Release screw (1).
Tightening torque 13 71 2AZ.
Slacken nut (2).
Tightening torque 13 71 3AZ.
Pull off air duct (3) from exhaust turbocharger, feed out and
remove.

Assemble engine.
4/29/2016 2/2
 4/30/2016 1/2

34 41 000 Removing and installing / replacing

handbrake lever

Special tools required:

 32 1 030

Necessary preliminary tasks:

 Remove centre console.

Note:
If the parking brake lever is replaced, the handbrake lever grip
must also be replaced.

Lock adjustment unit (ASZE).

Actuate parking brake lever. Connect special tool 32 1 030.
Press limit position (1) of adjusting spring back to such an
extent that retaining hook (2) engages in limit position (1).
Installation note:
Unlock adjustment unit (ASZE).
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from limit position (1) of
adjusting spring.

Press retainer (1) in balance arm (2) forward in direction of

arrow.
Detach parking brake Bowden cables (3) from balance arm (2).
 4/30/2016 2/2

Disconnect cable (1) from handbrake check switch.

Unclip cable clip (2) from parking brake lever.
Release nuts and remove parking brake lever (3).
Installation note:
Replace self-locking nuts.
Tightening torque 34 41 1AZ.
Parking brake lever and adjustment unit (ASZE) are only
exchanged completely as a single unit.
 4/30/2016 1/2

34 31 505 Removing and installing / replacing

master brake cylinder for DSC

Special tools required:

 32 1 270

Necessary preliminary tasks:

 Read and comply with General Notes.
 Remove expansion tank.

After completing repair work:

 Bleeding brake system with DSC.
Important!
Before beginning work, fully press the brake pedal several
times to reduce the vacuum pressure in the brake servo.

Important!
Do not bend brake lines.

Unfasten brake lines (1).

Installation note:
Tightening torque 34 32 1AZ.

Close off brake lines and brake master cylinder with seal plugs
 32 1 270 .
Release nuts (2) and feed brake master cylinder out of brake
booster.
Installation note:
Replace self-locking nuts.
Tightening torque 34 31 1AZ.
 4/30/2016 2/2

Installation note:
Replace sealing ring.

Installation note:
When inserting the brake master cylinder (2) into the brake
booster (1), make sure the pressure rod of the brake booster
and that of the brake master cylinder meet each other on one
level.
 4/29/2016 1/9

11 31 028 Removing and installing / replacing

exhaust camshaft (N55)

Special tools required:

 00 9 120
 11 4 350
 11 4 461
 11 7 100
 11 8 550
 11 8 552
 11 8 553
 11 9 000

Important!
It is absolutely essential to follow an exact procedure for
removing and installing the exhaust camshaft.
Risk of damage!
The upper and lower bearing strips must be preloaded
with a total of six special tools 11 8 550.

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove all ignition coils and injector shafts.
 Remove exhaust camshaft adjuster
 Adjust valve timing.

Position special tool 11 7 100 on cylinder 2.

Hand-tighten special tool 11 7 100 with special tool 11 8 552.
 4/29/2016 2/9

Note:
Graphic without bearing strip.

Screw in roller cam follower at 2nd cylinder using spindle nut of

special tool 11 7 100 to end stop.

Release screw connection on bearing strip in sequence from 15

to 1.
Remove upper bearing strip (1).
Note:
The upper and lower bearing strips (1) can also be lifted out
completely with exhaust camshaft.

Remove exhaust camshaft (1) from bearing strip in direction of

arrow.
Set down exhaust camshaft (1) on special tool.
 4/29/2016 3/9

Important!
Marks of intake and exhaust camshafts are different.
Mixing up the intake and exhaust camshaft will result in engine
damage.
A = Exhaust camshaft.
E= Intake camshaft

Metal plain rectangular compression ring:

Important!
Plain rectangular compression rings (1) can easily break.

Only replace plain rectangular compression rings (1) when they

are broken.
The plain rectangular compression rings have catches at the
joint.
Press plain rectangular compression rings (1) apart upwards
and downwards and removed towards front.
Make sure plain rectangular compression rings (1) can move
freely.
Installation note:
When exhaust camshafts are inserted, no joint must point to a
separating joint.
 4/29/2016 4/9

Plastic plain rectangular compression ring:

Installation note:
The plastic plain rectangular compression ring is maintenance
free and does not have to be replaced.

Insert plastic rectangular compression ring (1) into groove of

exhaust camshaft (2) (see arrow).
Lightly oil plastic rectangular compression ring (1) and rotate in
direction of arrow until compression ring (1) is positioned on the
exhaust camshaft.

Check plastic plain rectangular compression ring (1 and 2) for

freedom of movement.

Important!
Removal on engine:
Set engine to ignition TDC at cylinder No. 1.
Removed cylinder head:
When using special tool 11 9 000, it will be necessary to
remove the aluminium strip.

Installation note:
Before mounting the exhaust camshaft, ensure the correct fit of
the rocker arm (1) on the hydraulic valve clearance
compensating element and the valve.
See "Removing and installing/replacing all roller cam followers".
 4/29/2016 5/9

Mounting bearing strip:

Pre-install special tool 11 7 100 on cylinder no. 2.
Important!
Special tool 11 8 552 is a special screw.

Press down rocker arms (3) on cylinder no. 2 with spindle

nut (2) of special tool 11 7 100 .

Position lower bearing strip (1) with exhaust camshaft (2) on

rocker arms.
Align exhaust camshaft (2).
Cylinder nos. 2 and 4 are at valve overlap.
Cams (3) on cylinder no. 1 point upwards at an angle.
Part number (4) on mounting flats of exhaust camshaft (2)
points upwards.

Insert exhaust camshaft so that none of the latching

mechanisms for the plain rectangular compression rings (1)
point to a bearing cap joint.
Centre latch mechanism of the plain rectangular compression
rings with the bearing cap.
 4/29/2016 6/9

Insert exhaust camshaft so that the data code (1) on the

mounting flats faces up.
Note:
Graphic of intake camshaft.

The cam (1) at cylinder 6 points downward at an angle.

Important!
There must be no oil residues in the cylinder head
threaded holes.
Clean threaded holes.

Fit upper bearing strip (1).

 4/29/2016 7/9

Insert bolts dry.

Join exhaust camshaft to lower and upper bearing strips (1)
with torque wrench (2) to 8 Nm in sequential order from 1 to 15.
Release all screws of upper bearing strip (1) from outside
inwards by 90°.

Installation note:
Upper and lower bearing strips must be aligned to each other at
ground surfaces (1 and 2).

Make sure that the synchronising key and the shanks of special
tools 11 4 461 rest on the milled surfaces.

Note:
Schematic diagram of special tool 11 8 553 at upper bearing
strip (1) and lower bearing strip (2).
Preload all special tools 11 8 553with special tool 11 4 350 only.

Important!
Tighten screw (3) on synchronising key to 2 Nm. Risk of
damage!

Position special tool 11 8 553 over screw connection of bearing

strips.
Make sure that the shanks rest exactly on the ground surfaces
of the upper bearing strip (2) and lower bearing strip (1).
 4/29/2016 8/9

Initially tighten screw of special tool 11 8 553 to ground

surfaces of upper bearing strip (1) and lower bearing strip (2).
Important!
Tighten screws on synchronising key to 2 Nm. Risk of
damage!

Important!
Set special tool 11 8 553 to 2 Nm.
Preload all special tools 11 8 553with special tool 11 4 350
only.

Mount special tools 11 8 553 to inside of cylinder head with

pressure bolt.
Mount special tool 11 8 553 on cylinder no. 2 with pressure bolt
facing outward.
Position special tools 11 8 553 so that screw connections (2) of
bearing strip are easily accessible.
 4/29/2016 9/9

Tighten top and bottom bearing strip with special tool 00 9 120.
Tightening torque 11 31 1AZ.
Important!
Remove special tool 11 8 553 only when exhaust
camshaft screw connection is completed.

Assemble engine.
 4/30/2016 1/2

34 31 181 Removing and installing / replacing

expansion tank for hydraulic brake
control

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove cover in engine compartment, left.

After completing repair work:

 Bleed braking system

Note:
Extract brake fluid out of expansion tank. Use a suction bottle
used exclusively for drawing off brake fluid.
Do not reuse drawn out brake fluid.

Pull off supply hose (1) of clutch hydraulic system if necessary.

Unfasten plug connection (2) and disconnect.

Loosen the lock screw (1).

Installation note:
Tightening torque: 34 31 2AZ.

Pull expansion tank in direction of arrow vertically out of brake

master cylinder.

Important!
Check rubber plug in brake master cylinder for damage
and replace if necessary.
Push the expansion tank vertically onto the master brake
cylinder.
4/30/2016 2/2
 4/30/2016 1/6

REP-REP-RAF2033-3353000   Removing and installing / replacing rear left or right coil spring

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

33 53 000 Removing and installing / replacing rear

left or right coil spring

Special tools required:

 33 5 010
 33 5 013
 33 5 014
 33 5 015
 33 5 016
 33 5 017
 33 5 020
 2 241 786
 2 241 788
  3 5 013
 2 41 786

Important!
Both coil springs on the relevant axle must be replaced in
the event of corrosion breakage.
The spring pads at the top and bottom must also be
renewed when replacing the coil springs.
Avoid damaging the coil spring coating.

Note:
The coil spring is allocated in the Electronic Parts
Catalogue (EPC) under the item "Spring table" after the vehicle
identification number has been entered and the optional
equipments of the car have been selected.

Warning!
Before using the special tool 33 5 010 take care to read
 4/30/2016 2/6

through the Owner's Handbook!

All the safety precautions and instructions contained in the
Owner's Handbook must be strictly observed!
Failure to observe these safety precautions and
instructions increases the risk of serious physical injury,
damage to your health and damage to property and
equipment!

Important!
1. Prior to each use, check the special tools for
defects, modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the
special tools!
4. These special tools are intended solely for the
purpose of tightening and relieving cylindrical and
tapered suspension springs.
5. Keep special tools dry, clean and (down to the
spindle) free from grease.
6. Impact screwdrivers are prohibited!
7. Do not compress coil spring to full extent.

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Necessary preliminary tasks:

 Remove rear wheel.
 4/30/2016 3/6

Removal:
Insert lower spring cup 2 241 786 centrally into coil spring and
turn to lowest winding.
Guide spindle 33 5 013, 33 5 014, 33 5 015 from below through
the camber link and the lower spring cup 2 241 786.

Insert top spring cup 2 241 788 sideways into coil spring and

turn to the uppermost winding.
Important!
Make sure spindle (hexagonal) is correctly seated in upper
spring cup 2 241 788!

Pull spindle 33 5 013 down.

Warning!
Danger of injury!
Make sure coil spring is correctly positioned in spring
cups.
 4/30/2016 4/6

Important!
Centre special tools 2 241 786, 2 241 788, 33 5 013,
33 5 014, 33 5 015 to achieve the greatest possible
contact surface with the coil spring.

Check installation position of special tools 2 241 786,

2 241 788, and  3 5 013, 33 5 014, 33 5 015, correct if
necessary.

Tighten coil spring using special tools 33 5 016 and 33 5 020,

gripping the spindle of the spring tensioner with special
tool 33 5 017.
Remove coil spring upwards.

Important!
Replacement:
Relieve tension on coil spring.
Insert spring tensioner in the new spring and position
spring tensioner in the new spring so that the bottom end
of coil spring (1) is flush with the opening of spring
 4/30/2016 5/6

cup 2 241 786 (see drawn line)!

Check spring pad for damage, renew if necessary.

Insert spring pad in camber control arm so that plastic tab (1) is
positioned in outer bore hole of camber control arm.

Installation:
Place top spring pad (1) on coil spring.
Note:
Upper spring pad (1) must come into contact with end of coil
spring.

Important!
Observe the following when installing and relieving tension
on coil spring:

- Lower spring pad must be positively seated in the

designated receptacle in the camber arm
Note: Otherwise there is a risk of the coil spring
 4/30/2016 6/6

jumping out sideways.

- Lower spring pad must come into contact with end of

coil spring (see arrow)

- Lower spring pad must rest flush on last coil (see

broken line)

Firstly insert coil spring in camber link.

Press wheel carrier slightly towards bottom by hand with
second person and install coil spring with fitted spring pad at
top in spring cup.
Check fitting of coil springs in spring pads (top and bottom), if
necessary again align and relieve tension.
Remove special tools 2 241 788, 2 41 786 and 33 5 013,
33 5 014, 33 5 015.

After installation:
 Check headlight adjustment, correct if necessary.
 4/30/2016 1/1

65 13 188 Removing and installing/ replacing rear

left or right mid-range speaker

Necessary preliminary tasks:

 Remove luggage compartment wheel arch panel

Release screws at marked points.

Disconnect plug connection (2).
Remove mid-range speaker (3) downward from luggage
compartment capping (1).
 4/30/2016 1/1

52 26 005 Removing and installing / replacing rear

seat

Unclip rear seat on left and right towards top.

Installation note:
Feed seat belt buckles (1) into recesses in rear seat.

Release screw (1) from seat belt end fitting (2), centre.

Tightening torque 72 11 22AZ.
Feed out the end fitting from the rear seat.
Lift out rear seat.
Installation note:
End fitting is coded against incorrect assembly.
 4/30/2016 1/2

65 83 020 Removing and installing (replacing) Car

Information Computer (CIC)

Important!
Risk of damage!

A hard disk is installed in the Car Information Computer (CIC).

Carry out mechanical work on the CIC and adjacent
components with care.
Avoid subjecting the CIC to vibration / shocks.

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Note:
Comply with notes and notes on handling optical fibres.

Necessary preliminary tasks:

 Disconnect negative battery cable (F03: disconnect
both negative battery cables).
 Remove radio and IHKA controls

Note:
Picture for example purposes only!

Unfasten screws (2).
Pull CIC (3) out of guide.
Installation note:
Make sure CIC (3) is correctly seated in guide lugs (1).

Unlock plug connections (2) and (3) and disconnect.

 4/30/2016 2/2

Remove CIC (1).

Only for US models with satellite radio:

When replacing the CIC unit, additional work is required!
 Refer to document Replacing satellite tuner, as of
09/2009.

Replacement:
Carry out vehicle programming and encoding.
 
Load additionally for following vehicles' service history:

- 1-Series F2x, 3-Series F3x from series introduction

- F01, F02, F03, F07, F10, F11 with production date from
07/2013

- F06, F12, F13 with production date from 03/2014

- F15, F16 from series introduction

- F18 with production date from 09/2013

- F25 with production date from 04/2014

- F26 as of series introduction

 
Load service history:

- 05 Maintenance and Pre-Delivery Check

- Service history
 4/30/2016 1/1

66 53 180 Removing and installing (replacing)

control unit for reversing camera

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove luggage compartment wheel arch panel on
left.

Unscrew nuts (2).

Pull the control unit (1) forwards by approx. 5 cm.

Unlock plug connections (2) and disconnect.

Remove control unit (1).

Replacement:
 Carry out programming/encoding.
 Calibrate reversing camera
 4/30/2016 1/1

51 16 145 Removing and installing (replacing)

decorative trim at centre console

Special tools required:

 00 9 327

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Loosen cover (1) with special tool 00 9 327 from clamps (2).

If necessary, unlock associated plug connections and
disconnect.
Feed out cover (2) to the top/rear.

Installation note:
Clamps (1) and guide (2) must not be damaged or missing.
Feed guide (2) correctly into centre console.
 
Replacement (depending on version):
Modify controller (3).
 4/30/2016 1/1

51 45 067 Removing and installing (replacing)

decorative trim of control panel

Operation is identical to:

Removing and installing/replacing light operating facility.
 4/30/2016 1/4

51 11 156 Removing and installing (replacing) front

bumper panel

Remove gasket (1).

Release screws (1).
Tightening torque 51 11 1AZ.

Release screws (1) on wheel arch cover (2) on left/right.

Lift out wheel arch cover (2) at side.
Installation note:
Make sure wheel arch cover (2) is in correct position.

Unlock and remove cover (1).

 4/30/2016 2/4

Release screws (1) on left/right.

Tightening torque 51 11 11AZ.

Installation note:
Guide (1) of bumper panel (2) must not be damaged.
Guide (1) of the bumper panel (2) must be aligned correctly in
the side wall (3).

Height adjustment, see  body gap dimension.

Release retaining elements (1) on bumper panel (2).

 4/30/2016 3/4

Release screws (1).
Feed out trim panel (2) and detach plug connection for outside
temperature sensor.
Note:
Carry out work on the right side in the same way as for the left
side illustrated here.

Press bumper panel toward the rear and lift out latch
mechanism (1) in direction of arrow.
Note:
In versions with the M Aerodynamic package, the latch
mechanism (1) is at the bottom and must be released in the
direction opposite to the arrow.

Note:
The following tasks must be carried out with a second person
assisting:

Pull bumper panel (1) forwards a little.

Unlock associated plug connections and disconnect.
 4/30/2016 4/4

If necessary, unlock the hose pipe for the headlight cleaning

system and route upward.
Remove bumper panel (1) towards front with the aid of a
second person.
Installation note:
Bumper panel (1) must engage correctly in all clamps (2).

Only F20/F21 with version up to 08/2013:

Due to the different versions, the holder (1) must if necessary
be replaced if the Z-support is faulty.
Grind welding spots (2) and remove holder (1).
Coat new holder (1) in marked area with adhesive set K6.
Stick holder (1) in bumper.
Also apply adhesive in area of ground welding spots (2).

Replacement:
 Attach plate
 Remount middle front radiator grille
 Remount ornamental grille for bumper panel (centre)
 Remount ornamental grille for bumper panel (side)
 Remount support for number plate
 Fog lights remounting and adjusting
 Remount washer jets
 Remount ultrasonic sensor
 4/30/2016 1/5

51 41 000 Removing and installing (replacing) front

left or right door trim panel

Special tools required:

 64 1 020
 00 9 325

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Necessary preliminary tasks:

 Remove cover on door handle

Important!
Do not under any circumstances pull on map pocket.
 4/30/2016 2/5

Pull out inside door handle (1) and hold open so that catch (3)
on handle recess (2) can be released (see next operation).

Working edge (1) of special tool 64 1 020 points upwards and

levers out latch mechanism (2) in direction of arrow.
At the same time, lift up handle recess (3) slightly at rear so that
it doesn't snap back in again.

Detach handle recess (1) from latch mechanisms (2) with

special tool 64 1 020 and remove.

Installation note:
Guide (1) and latch mechanisms (2) must not be damaged.
For version with handle recess lighting:
Optical fibre (3) must not be missing or damaged.
 4/30/2016 3/5

Release screws (1).
Tightening torque 51 41 1AZ.

Important!
Risk of damage!
Do not pull on map pocket. Door trim panel lower section
may separate from door trim panel upper part.

Mask front door and door trim panel in working area with plastic
adhesive tape.
Detach door trim panel with special tool 00 9 325 in area A-
pillar/mirror triangle starting at clips (1).
Pull off door trim panel from clamps (2).

Disengage Bowden cable (1) for release lever first at counter

support (2) and then at door lock (3).
Installation note:
Perform function check for door inside handle with door open
and rotary striker lock closed.
 4/30/2016 4/5

Feed out door wiring harness from all brackets.

Unlock and disconnect all plug connections, then remove door
trim panel.

Installation note:
Rubber buffers (1) must not be missing or damaged.
Replace clips (2 and 3) after each removal.
Make sure the installation location of clips (2 and 3) is correct.
(2) Clips, natural
(3) Clip, beige

Replacement:
 Modify speaker trim (1)
 Modify switch cover (2)
For version without light package:
 Install cover (3) for footwell light aperture
For version with light package:
 Modify footwell light (3)

Installation note:
After assembling the door trim panel proceed as follows:

- Open side window

- Lock with ignition key

 4/30/2016 5/5

- Check for ease-of-movement on locking button linkage

- If necessary, align linkage

 4/30/2016 1/2

51 16 150 Removing and installing (replacing) front

storage compartment

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Necessary preliminary work:

 Remove centre console cover

Unlock plug connection (1) and disconnect.

Unfasten screws (2).
Feed the storage compartment (3) out of the guides (4) and
disconnect the plug connection from the power socket (5).
Installation note:
Make sure guides (4) are correctly seated.

Installation note:
Guides (1) must not be damaged.
 
Replacement:
 4/30/2016 2/2

- Modify charging socket (2)

- Modify storage trays (3)

- Modify aerial (4)
 4/30/2016 1/2

65 12 315 Removing and installing (replacing) HU-

H)

Important!
Risk of damage!

There is a hard disk installed in the headunit.

Carry out mechanical work on the headunit and adjacent
components with care.
Avoid subjecting the headunit to vibration/shocks.

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Note:
Comply with notes and notes on handling optical fibres.

Necessary preliminary tasks:

 Remove radio and IHKA controls
 Disconnect battery earth lead (F03: Disconnect both
battery earth leads).

Note:
Picture for example purposes only!

Unfasten screws (2).
Pull headunit (3) out of guide.
Installation note:
Make sure headunit (3) is correctly seated in guide lugs (1).

Set the protective nonwoven material (1) aside as shown.

 4/30/2016 2/2

Unlock plug connections·(2) and disconnect.

Remove headunit (3).

Only for US models with satellite radio:

When replacing the headunit, additional work is required!
 Refer to document Replacing satellite tuner, as of
09/2009.

Replacement:
Carry out vehicle programming and encoding.
 
Load additionally for following vehicles' service history:

- 1-Series F2x, 3-Series F3x from series introduction

- F01, F02, F03, F07, F10, F11 with production date from
07/2013

- F06, F12, F13 with production date from 03/2014

- F15, F16 from volume production launch

- F18 with production date from 09/2013

- F25 with production date from 04/2014

- F26 as of series introduction

 
Load service history:

- 05 Maintenance and Pre-Delivery Check

- Service history
 4/30/2016 1/1

51 16 142 Removing and installing (replacing)

insert in centre armrest storage
compartment

Special tools required:

 64 1 020

Unclip insert (1) with special tool 64 1 020 in upward direction.

Unlock and disconnect the plug connections of the connecting
socket (2).
Remove insert (1).
Replacement:
Modify connecting socket (2).

Installation note:
Catches (1) on storage compartment (2) and corresponding
counter-pieces on the insert must not be damaged or missing.
 4/30/2016 1/2

63 12 010 Removing and installing (replacing) left

(Xenon) headlight

Warning!
Version with xenon lighting system:
Danger to life due to high voltage! Therefore disconnect all
components from voltage supply before removal.
Work on the entire xenon lighting system (ignition device,
control unit and bulb) may only be carried out by qualified
personnel.

Necessary preliminary tasks:

 Remove front bumper panel

Unlock and remove cover (1).

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.
 4/30/2016 2/2

 
Unfasten plug connection (1) and disconnect.
Unfasten screws (2).
Tightening torque 63 12 1AZ.
Release screw (3).
Tightening torque 63 12 1AZ.

Release screw (1).
Tightening torque 63 12 1AZ.
Carefully remove headlight (2) in direction of arrow.

Installation note:
Correctly install headlight (1) relative to holder (2).
Adjust headlight.
 

Replacement:
 Modify Xenon control unit
 Modify ignition unit with bulb
 Modify headlight driver module
 Modify LED module daytime driving lights
 4/30/2016 1/1

65 77 720 Removing and installing (replacing) left

B-pillar sensor

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Warning!
Note airbag safety regulations!
Incorrect handling can activate airbag and cause injury.

Necessary preliminary tasks:

 Disconnect battery earth lead and cover
 Remove trim panel for door post (bottom)

Unfasten plug connection (1) and disconnect.

Release screw (2).
Tightening torque 65 77 3AZ.
Remove sensor (3).
 4/30/2016 1/2

63 12 003 Removing and installing (replacing) left

headlight

Necessary preliminary tasks:

 Remove front bumper panel

Unlock and remove cover (1).

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.

 
Unfasten plug connection (1) and disconnect.
Unfasten screws (2).
Tightening torque 63 12 1AZ.
Release screw (3).
Tightening torque 63 12 1AZ.

Release screw (1).
Tightening torque 63 12 1AZ.
Carefully remove headlight (2) in direction of arrow.
 4/30/2016 2/2

Installation note:
Correctly install headlight (1) relative to holder (2).
Adjust headlight.
 

Replacement:
 Convert bulbs if required, note bulb types
 4/30/2016 1/3

63 21 260 Removing and installing (replacing) left

rear light

Important!
Risk of paint damage!
 

Tape off the entire area (1).

Release latch mechanism (1) and remove cover (2).

Slacken nut (1).

Tightening torque 63 21 1AZ.
 4/30/2016 2/3

Important!
The rear light is secured in the body with two latch
mechanisms!
To prevent damage to the rear light and paint, the
instructions below describe how the two latch mechanisms
can be released separately in sequence.

Step 1: Inner latch mechanism

 Counter-hold the rear light (2) with the left hand in the
direction of the arrow.
Loosen the rear light (2) with your right hand in the
direction of the arrow from the latch mechanism (1).
Installation note:
Catch (1) must not be damaged.
Make sure that rear light (2) is correctly locked.

Step 2: outer latch mechanism

 Detach the rear light (2) in direction of arrow from the
latch mechanism (1).
Unlock associated plug connection and disconnect.
Remove rear light (2).
Installation note:
 4/30/2016 3/3

Catch (1) must not be damaged.

Make sure that rear light (2) is correctly locked.

Replacement:
If necessary, remove bulbs.
 4/30/2016 1/2

32 33 010 Removing and installing (replacing) M

sports steering wheel

Note:
Chassis / wheel alignment is not necessary after the steering
wheel has been removed and installed or replaced.

Necessary preliminary tasks:

 Remove airbag unit

Move wheels/sports steering wheel into straight-ahead position.

Disconnect and detach plug connections (1).
Release screw (2) and remove sport steering wheel.
Installation note:
Make sure connecting line(s) is/are correctly laid.
Tightening torque 32 33 1AZ.

Installation note:
Before fitting sports steering wheel on steering column, ensure
correct cable routing.
Align sports steering wheel by way of marking (1) to steering
 4/30/2016 2/2

column marking (2) and attach.

Replacement:
 Modify shift paddles
 Modify both multifunction steering wheel switches
 Modify design cover for sports steering wheel at front and
rear
 Modify steering wheel module control unit
 If necessary modify lane departure warning engine
electrical system
 4/30/2016 1/1

51 11 183 Removing and installing (replacing)

ornamental grille for bumper panel (side)

Special tools required:

 00 9 325

Note:
Tape off painted surfaces in working area and protect against
damage.

Disengage ornamental grille (1) with special tool 00 9 325 along

line (2).

Installation note:
Retaining lugs (1) must not be damaged or missing.
 4/30/2016 1/1

51 33 000 Removing and installing (replacing)

power window regulator in left or right
front door

Note:
Disengage, but do not remove, the door window and secure in
the door window frame.

Necessary preliminary tasks:

 Release door window at front

Unfasten plug connection (1) and disconnect.

Release cable from holder in area (2).
Release nuts (3) and feed out power window regulator (4).
Tightening torque 51 33 2AZ.
Replacement
Swap over flat motor for power window regulator.
 4/30/2016 1/6

33 10 016 Removing and installing (replacing) rear

axle differential

Special tools required:

 33 5 206
 33 5 200
 33 5 124
 2 240 465
 33 5 121
 33 5 122
 33 5 123
 2 240 265
 2 240 464
 33 5 125

Warning!
Rear axle final drive must be lashed with tensioning
strap 33 5 206 to prevent it falling out when the output
shafts are forced off.

Important!
When reinstalling the current rear axle differential, both
radial shaft seals of the output shafts must be replaced!
 
The circlips on both output shafts must be replaced!

Necessary preliminary tasks:

 4/30/2016 2/6

 Remove vibration absorber at screw connection of rear of

rear axle differential.
 If necessary, remove rear tension struts.
 Remove propeller shaft from rear axle differential.

- Disconnect propeller shaft at rear axle differential.

- Release centre mount.

- Tie up propeller shaft to underbody.

Note:
Bending the propeller shaft by an excessive angle
can cause premature damage to the joint/propeller
shaft!

Position special tool33 5 200 on workshop jack.

Support rear axle final drive33 5 200 with special tool .
Lash rear axle final drive with tensioning strap 33 5 206 to
special tool33 5 200.
Important!
Tensioning strap 33 5 206 must be pass through between
output shafts and rear axle final drive cover!

Important!
Insert special tools 33 5 124 or 2 240 465 into the all-
round slot (1) of the output shaft!

Left output shaft only:

Press out the output shaft from the rear axle differential with
 4/30/2016 3/6

jerky movements using the following special tools.

Complete special tools depending on the motorisation.

- N13, N20B20: 33 5 121, 33 5 122, 33 5 123, 2 240 465

- N47, N20B28, N55,

N57: 33 5 121, 33 5 122, 33 5 123, 33 5 124
The thrust piece of the screw 33 5 122 must be in contact with
the rear axle differential.

Release screws (1).
Tightening torque 33 17 1AZ
Installation note:
Adhere to the installation sequence at the end of the document
in order to prevent distortion of the rear axle final drive during
installation and thereby avoid potential complaints about noise.

Release nut (1) and push screw towards rear to the limit

position.
Tightening torque 33 17 2AZ.
Installation note:
Replace nut.
Adhere to the installation sequence at the end of the document
in order to prevent distortion of the rear axle final drive during
installation and thereby avoid potential complaints about noise.

Lower rear axle final drive with special tool33 5 200.

 4/30/2016 4/6

Press (tilt) rear axle final drive on right upwards.

Feed out left output shaft in downward direction and tie up.
Swing rear axle final drive towards left side.

Right output shaft:

Press out the output shaft from the rear axle differential with
jerky movements using the following special tools.
Complete special tools depending on the motorisation.

- N13, N20B20: 33 5 121, 33 5 122, 33 5 123, 2 240 265

- N47, N20B28, N55,

N57: 33 5 121, 33 5 122, 33 5 123, 33 5 124
The thrust piece of the screw 33 5 122 must be in contact with
the rear axle differential.
 
Feed out output shaft and tie up.
Remove rear axle final drive.

Important!
High installation forces indicate that the output shaft spline
teeth are damaged or deformed!
 4/30/2016 5/6

Check gearing and replace components if damaged.

Check dust plate (1) for damage, renew if necessary.
Circlip (2) must be renewed!
Coat highlighted contact surface (3) of output shaft with
approved final drive oil.

Installation note:
Insert output shaft into rear axle final drive.
Pull out assembly protection ring at lug (1) until one of the two
predetermined breaking points gives.

Press the output shaft into the rear axle differential using the
following special tools (depending on motorisation) and a
rubber mallet.

- N13, N20B20: 2 240 464

- N47, N20B28, N55, N57: 33 5 125

Installation note:
The output shafts must audibly snap in place on the rear axle
differential.

Assembly sequence:
1. Insert the rear axle final drive into the rear axle support
using the workshop jack and special tool33 5 200.
2. Insert screws (1) (do not tighten).
3. Insert bolt from rear and replace nut (2) (do not tighten
down).
 4/30/2016 6/6

4. Release tensioning strap and lower special tool33 5 200

and move away.
5. Tighten down screws (1).
Tightening torque 33 17 1AZ
6. Tighten nut (2).
Tightening torque 33 17 2AZ

After installation:
 Check transmission oil level, correct if necessary.
 4/30/2016 1/2

51 12 156 Removing and installing (replacing) rear

bumper panel

Important!
Risk of damage!
The rear lights must be removed to remove the bumper
panel!

Necessary preliminary tasks:

 Remove both rear lights.
 Remove both number plate lights

Release screws (1) on wheel arch cover (2) on left/right.

Fold back wheel arch cover (1).

Release screw (2).
Tightening torque 51 12 4AZ.

Release screws (1).
 4/30/2016 2/2

Important!
Bumper panel (1) is locked on sides and must be unlocked
for removal purposes (risk of damage).

Removing:

- Starting from area (2), carefully disengage individual

guide tabs on left and right

- Repeat process for area (3)

- Pull bumper panel (1) straight towards rear with aid of a

2nd person

- If necessary, disconnect plug connections

Installation note:
Latch mechanisms and guides (1) must not be damaged or
missing.
If necessary, replace faulty sheet metal nuts left/right.

 
Replacement (depending on version):
 Remount the cover for the towing eye
 Remount the number plate
 Remount the ultrasonic sensor
 Remount the reversing camera
 Remount the trim strip
 Remount the lower cover (M Aerodynamics package)
 4/30/2016 1/5

51 42 000 Removing and installing (replacing) rear

left or right door trim panel

Special tools required:

 64 1 020
 00 9 325

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Necessary preliminary work:

 Remove cover on door handle

Important!
Do not under any circumstances pull on map pocket.
 4/30/2016 2/5

Pull out inside door handle (1) and hold open so that catch (3)
on handle recess (2) can be released (see next operation).

Working edge (1) of special tool 64 1 020 points upwards and

levers out latch mechanism (2) in direction of arrow.
At the same time, lift up handle recess (3) slightly at rear so that
it doesn't snap back in again.

Detach handle recess (1) from latch mechanisms (2) with

special tool 64 1 020 and remove.

Installation note:
Guide (1) and latch mechanisms (2) must not be damaged.
For version with handle recess lighting:
Optical fibre (3) must not be missing or damaged.
 4/30/2016 3/5

Release screws (1).
Tightening torque  51 42 1 AZ.

Important!
Risk of damage!
Do not pull on map pocket. Door trim panel lower section
may separate from door trim panel upper part.

Mask rear door and door trim panel in working area with plastic
adhesive tape.
Detach door trim panel with special tool 00 9 325 in area B-
pillar starting at clips (1).
Pull off door trim panel from clamps (2).

Disengage Bowden cable (1) for release lever first at counter

support (2) and then at door lock (3).
Installation note:
Perform function check for door inside handle with door open
and rotary striker lock closed.
 4/30/2016 4/5

Feed out door wiring harness from all brackets.

Unlock and disconnect all plug connections, then remove door
trim panel.

Installation note:
Rubber buffers (1) must not be missing or damaged.
Replace clips (2 and 3) after each removal.
Make sure the installation location of clips (2 and 3) is correct.
(2) Clips, natural
(3) Clip, beige

Replacement:
Modify rocker switch for side window operation.

Installation note:
After assembling the door trim panel proceed as follows:

- Open side window

- Lock with ignition key

- Check for ease-of-movement on locking button linkage

 4/30/2016 5/5

- If necessary, align linkage

 4/30/2016 1/1

61 31 008 Removing and installing (replacing)

steering column switch cluster

Important!
Move wheels into straight-ahead position and do not alter
this position during the repair work.
Do not under any circumstances turn the steering column
switch cluster when the steering wheel is removed.

Necessary preliminary tasks:

 Remove steering wheel

Unclip steering column shroud upper and lower sections (1).

Unfasten screws (2).
Tightening torque 61 31 3AZ.
Remove steering column switch cluster (3) in direction of arrow.
Installation note:
During installation, take care to position the anti-twist lock
correctly on the coil spring cassette!

Disconnect plug connection (1).

Remove steering column switch cluster (2).
 4/30/2016 1/2

84 10 810 Removing and installing (replacing)

Telematic Communication Box

Important!
Read and comply with notes on protection against
electrical damage (ESD protection).

Comply with notes and instructions on handling optical fibre.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.
 
Remove luggage compartment floor trim panel (1) in direction of
arrow.

Unlock and disconnect all plug connections in area (1).

Unscrew nuts (2).
Tightening torque 84 10 1AZ.
Remove Telematic Communication Box (3).
Installation note:
Note colour coding of plug connection.
 4/30/2016 2/2

Note:
 
When replacing the TCB, check whether the faulty TCB is equipped with an emergency battery:

- if no, then the new part is installed without an emergency battery!

 

- if yes,, then the new part should be equipped with a new emergency battery (ordered
separately, TCB is supplied without an emergency battery!)

Replacement:
 Carry out vehicle programming/encoding.
 4/30/2016 1/2

63 11 560 Removing and installing (replacing) the

headlight driver module

Warning!
Version with xenon lighting system: Danger to life due to
high voltage! Therefore disconnect all components from
voltage supply before removal.
Work on the entire xenon lighting system (ignition device,
control unit and bulb) may only be carried out by qualified
personnel.

Necessary preliminary tasks:

 Remove headlight

Release screws (1).
Remove headlight driver module (2).

Installation note:
Gasket (1) must not be damaged and must be installed free
from grease.
 4/30/2016 2/2

Replacement:
Teach in headlight driver module (1) via vehicle diagnosis.

- Service functions

- Body

- Lights

- Initialise the headlight driver module and teach in LEDs in

headlight
 4/30/2016 1/1

61 35 001 Removing and installing (replacing)

trailer module

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove right luggage compartment wheel arch
panel.

Pull trailer module (1) out of holder (2).

Unfasten plug connection (3) and disconnect.
Remove trailer module (1).

Replacement:
Carry out vehicle programming/encoding.
 4/30/2016 1/1

61 42 050 Removing and installing (replacing)

voltage transformer

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Note:
Voltage transformer is only installed depending on equipment.

Necessary preliminary tasks:

 Remove right luggage compartment wheel arch
panel.

Unfasten plug connection (1) and disconnect.

Pull voltage transformer (2) out of holder (3).
Installation note:
Make sure plug connection (1) is correctly seated.
Make sure voltage transformer (2) is correctly seated in holder
(3).
 4/30/2016 1/1

61 31 362 Removing and installing (replacing)

wireless remote control

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove trim panel for roof pillar at rear (C-pillar)
right

Note:
Similar to graphic.

Unfasten plug connection (1) and disconnect.

Release screw (3) and remove control unit (2).
Installation note:
Position control unit (2) so that positioning pin on rear side
engages in associated bore hole.

Replacement:
Carry out vehicle programming/encoding.
 4/29/2016 1/2

11 12 040 Removing and installing all ignition coils

and injector wells (N55)

Necessary preliminary work:

 Remove cylinder head cover.
 Remove all injectors.

Release screws (1).
Tightening torque: 11 12 8AZ.

Check fitting bushes (1) for damage.

Installation note:
Replace gasket (2).

Assemble engine.
4/29/2016 2/2
 4/30/2016 1/2

35 11 000 Removing and installing complete

bearing support for foot pedal

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism.
 Detach the air duct for footwell ventilation and
slightly push it up.

Release screws (1).
Push the locking bolts (2) out.
Installation note:
Pipe remains connected.
Replace the locking bolts (2).
Replace self-locking nuts.
Tightening torque 21 52 2AZ.

Pull the retaining clip (1) off the brake pedal and pull out the
locking pin.
Unscrew nuts (2).
Installation note:
Replace self-locking nuts.
Tightening torque 35 11 1AZ.

Disconnect plug connection (1).

Loosen the nut (2) and swivel out the bearing support (3).
Installation note:
 4/30/2016 2/2

First, tighten the nuts on the screw connection to the brake

booster and then tighten the nut (2).
Replace self-locking nuts.
Tightening torque 35 11 1AZ.
 4/29/2016 1/4

18 00 020 Removing and installing complete

exhaust system (N55)

Special tools required:

 31 2 220

Warning!
Risk of burning!
Only perform this repair work after engine has cooled
down.
Danger of injury!
Removal of the exhaust system must be carried out with
the assistance of a second person.

Necessary preliminary tasks:

 F21, F22, F31, F32, F33, F34 only:
Remove rear trailing link.
 F31, F34 only:
Remove right trailing link.

Support exhaust system with jack and special tool 31 2 220 or

with a suitable lever and secure against falling out.
 4/29/2016 2/4

Release clamp (1).

Tightening torque 18 31 1AZ.

Release screws (1).
Tightening torque 18 20 2AZ.

If fitted:
Release screws (1).
Tightening torque 18 31 3AZ.
Remove reinforcement plate (2).
 4/29/2016 3/4

Unfasten nut.
Tightening torque 18 20 3AZ.

Unlock connector from exhaust flap and pull off.

Slacken nut (2).
Tightening torque 18 20 3AZ.
Lower and remove exhaust system with assistance of a second
person.

Installation note:
Check rubber mount for damage.
If necessary, replace damaged rubber mounts.
Check exhaust system for leak tightness.
4/29/2016 4/4
 4/30/2016 1/3

54 12 211 Removing and installing complete glass

slide/tilt sunroof

Special tools required:

 2 354 941

Necessary preliminary tasks:

 Remove headlining
 Remove all holders for the grab handles

Important!
The assistance of a second person is required when
removing the glass slide/tilt sunroof.

Important!
Risk of damage!
Removed glass slide/tilt sunroof must only be placed on a
level support.
Do not place glass slide/tilt sunroof on cross member.
Place glass slide/tilt sunroof broadly across side frame.

Warning!
During the following work the head airbag must not be
damaged.
A damaged head airbag exhibits an impaired protective
function and in extreme cases loses its protective function
altogether.
A damaged head airbag must be replaced.
 4/30/2016 2/3

- Unfasten plug connection (1) and disconnect.

- Detach water drain hoses

- Helper must hold glass slide/tilt sunroof to prevent it falling out.

- Release screws in marked area and carefully lower glass slide/tilt sunroof
Tightening torque 54 12 02AZ.
Important!
Do not damage any surrounding components when removing the glass slide/tilt sunroof.
Remove glass slide/tilt sunroof fully:
F20: Tailgate, rear
F30: Rear door

Installation note:
If necessary, remove fabric adhesive tape.
To stop groaning noises, secure all screws (1) prior to
installation with plastic washers (2).
If the standard screws can no longer grip, use ”repair
screws” (have larger threads).
 4/30/2016 3/3

Important!
Do not crush any cables when installing the glass slide/tilt
sunroof.

Installation note:
To align glass slide/tilt sunroof to body aperture, insert the
screws and tighten loosely.
Glass slide/tilt sunroof must still be able to move in the body
aperture.
On account of leaks, glass slide/tilt sunroof must be exactly
aligned to body aperture.
Insert special tool 2 354 941 into centring bore up to limit
position in glass slide/tilt sunroof and body.
Tighten down screws.
Tightening torque 54 12 02AZ.
Initialise glass slide/tilt sunroof.
 4/30/2016 1/3

31 31 000 Removing and installing complete left or

right spring strut shock absorber

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Necessary preliminary tasks:

 Remove front wheel.
 Remove front brake disc.
 Remove anti-roll bar link from spring strut.
 Disconnect plug connection for pulse sensor and
expose cable up to holder on spring strut.
 Disconnect plug connection for brake pad wear
sensor and expose cable up to brake caliper.

Only on ride-height sensor at left:

Release link at wishbone.

Slacken wishbone bolt connection on front axle support in order

to prevent wishbone rubber mount from being damaged.
Remove wishbone from swivel bearing.
Remove track rod end from swivel bearing.
 4/30/2016 2/3

Remove trailing link from swivel bearing

Unlock closures (1).
Press clamps (2) together and lift.
Remove cover (3).
Installation note:
Make sure closures are correctly locked.

Warning!
Danger of injury!
Secure spring strut against dropping.

Release screw (1) on suspension cross-brace.

Tightening torque 51 61 1AZ.
Release screws (2) and remove spring strut with swivel bearing
towards bottom.
Tightening torque 31 31 1AZ.
Installation note:
 4/30/2016 3/3

Replace screws (1) and (2).
Clean inside contact surface at spring strut dome.
Align spring strut with boreholes on spring strut dome using
centring pins and push up.
Important!
While screwed in, the screws (2) must be sealed with BMW part
no. 83 42 0 428 190 cavity preservation/spray sprayed from
above onto the spring strut dome in order to prevent moisture
penetration between the screw head and spring strut dome and
thus prevent corrosion.

Installation note:
Check sealing washer (1) for damage, renew if necessary.

After installation:
 Carry out wheel alignment procedure.
 4/30/2016 1/2

33 31 000 Removing and installing complete rear

axle support

Warning!
Failure to comply with the following instructions may result
in the vehicle slipping off the vehicle hoist and critically
injuring other persons.
Load the luggage compartment with a minimum of 100 kg
before lowering/removing the rear axle support. This
prevents the vehicle from tilting or sliding off the vehicle
hoist!
When supporting components, make sure that:
 the vehicle can no longer be raised or lowered
 the vehicle does not lift off the locating plates on the
vehicle hoist.

Important!
Before lowering/removing rear axle support:
 
Observe safety information for raising the vehicle
 
In order to avoid damage to vehicle hoist, perform weight
compensation on vehicle.

Necessary preliminary tasks:

 Detach parking brake Bowden cable from brake
shoe expander.

Note:
 4/30/2016 2/2

The subsequent procedure is described in the document

”Lowering/raising rear axle support”.
 4/30/2016 1/2

64 11 377 Removing and installing control panel of

heater/air conditioning system

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Carry out installation in a dust-free workshop area only.
To avoid damage, do not touch or dirty the display field.

Necessary preliminary tasks:

Remove centre fresh-air grille

Release screws (1).

Unlock locking wedges (1) with a suitable tool (e.g. screwdriver

- 3 mm blade) in upward direction.
Installation note:
Locking wedges (1) must be felt to engage.
Make sure locking wedges (1) are securely seated.

Unlock associated plug connection and disconnect.

Remove control panel for heater - air conditioning system (2).
 4/30/2016 2/2

Installation note:
Locking wedges (1) must not be damaged.
 4/30/2016 1/2

64 11 377 Removing and installing control panel of

heater/air conditioning system

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Carry out installation in a dust-free workshop area only.
To avoid damage, do not touch or dirty the display field.

Necessary preliminary tasks:

Remove centre fresh-air grille

Release screws (1).

Unlock locking wedges (1) with a suitable tool (e.g. screwdriver

- 3 mm blade) in upward direction.
Installation note:
Locking wedges (1) must be felt to engage.
Make sure locking wedges (1) are securely seated.

Unlock associated plug connection and disconnect.

Remove control panel for heater - air conditioning system (2).
 4/30/2016 2/2

Installation note:
Locking wedges (1) must not be damaged.
 4/29/2016 1/6

11 12 100 Removing and installing cylinder head

(N55)

Special tools required:

 11 0 320
 11 4 420
 11 4 430
 11 4 471
 11 4 472
 11 8 580

Important!
Fit new cylinder head bolts.
Do not wash off bolt coating.
Lightly oil washer on the contact surfaces (both sides).
There must be no coolant, water or engine oil in the blind
holes.
Risk of cracking and corrosion!

Necessary preliminary tasks:

 Remove exhaust system.
 Drain coolant.
 Drain engine oil.
 Remove engine.
 Mount engine on assembly stand.
 Remove intake plenum.
 Remove exhaust turbocharger with integrated exhaust
manifold.
 Detach coolant hoses from cylinder head.
 Remove intake and exhaust camshaft adjusters.
 4/29/2016 2/6

Important!
If the timing chain is stowed in the gear case, the
crankshaft must no longer be rotated.

Release screws (1).
Unclip timing chain module (2) at separation point (3) and
remove towards top.
Set down timing chain.
Note:
Graphic shows N52.

Note:
Bolt (2) can only be released when the timing chain module is
pressed forward slightly.

Release screws (1).
Tightening torque 11 12 3AZ.
Release screw (2).
Tightening torque 11 12 3AZ.
 4/29/2016 3/6

Release cylinder head bolts in sequence 14 to 11 with special tool 11 4 420.
Release cylinder head bolts in sequence 10 to 1 with special tool 11 8 580.
Note:
Picture shows intermediate lever and exhaust camshaft removed.

Secure special tool 11 0 320 with bolts (1).

Tightening torque 11 12 4AZ.
Important!
Removing and install cylinder head with a second person
helping.
Weight of cylinder head with add-on parts is approx.
40 kg.
Do not rest cylinder head on sealing surface. Risk of
damage to valves!

Note:
Graphic shows N52.

Insert 11 4 430 special tool into bore holes.

 4/29/2016 4/6

Remove coarse residues on sealing surfaces with special tool

11 4 471 from cylinder head and crankcase.
Important!
Do not use any metal-cutting tools.

Remove fine residues on sealing surfaces with special tool

11 4 472 from cylinder head and crankcase.
Important!
Do not use any metal-cutting tools.
There must be no coolant, water or engine oil in the
pocket holes.
Risk of cracking and corrosion!

Clean all blind holes.

Replace cylinder head gasket.
 4/29/2016 5/6

Fit new cylinder head bolts.

Insert cylinder head bolts (1 to 10) with special tool 11 8 580.
Tightening torque 11 12 1AZ.
Insert cylinder head bolts (11 to 14) with special tool 11 4 420.
Tightening torque 11 12 2AZ.
Note:
Picture shows intermediate lever and exhaust camshaft removed.

Insert bolts (1).
Tightening torque 11 12 3AZ.
Insert bolt (2).
Tightening torque 11 12 3AZ.

Assemble engine.
4/29/2016 6/6
 4/30/2016 1/1

51 45 370 Removing and installing decorative strip

on left dashboard

Special tools required:

 00 9 325

When working on trim panel components, make sure that the sensitive surfaces are not
scratched or damaged.

Lever out decorative strip (2) at retaining points (1) with special

tool 00 9 325 and remove in direction of arrow.
 4/30/2016 1/1

51 45 380 Removing and installing decorative strip

on right dashboard

Special tools required:

 00 9 325

Note:
When working on trim panel components, make sure that the
sensitive surfaces are not scratched or damaged.

Carefully unclamp decorative strip (1) with special tool 00 9 325

at marked points.
Remove decorative strip (1) with fresh air grille.
 4/30/2016 1/1

41 51 ... Removing and installing door

Important!
Do not damage adjoining body components.

The graphics are schematic representations and are to be

applied to the relevant vehicle type.
Open door.

Pull the lock (1) up and disconnect plug connection.

Note:
Secure door against closing.

Release screw (1) on door stop.

Front door:
Tightening torque 51 21 3AZ.
Rear door:
Tightening torque 51 22 3AZ.
Open door up to limit position.

Release screws between both hinge elements at top and

bottom.
Front door:
Tightening torque 41 51 1AZ.
Rear door:
Tightening torque 41 52 1AZ.
Unhinge door by moving upwards and placing it on a suitable
surface.
Installation note:
If necessary, adjust door.
 4/29/2016 1/6

11 00 050 Removing and installing engine (N55)

Special tools required:

 11 0 000
 11 7 310
 11 8 680
 13 5 281
 13 5 282

Necessary preliminary tasks:

 Disconnect negative battery lead.
 Move engine compartment lid into service position.
 Remove intake plenum.
 Remove cowl panel cover.
 Remove clean air pipe.
 Remove left charge air duct.
 Remove right charge-air duct.
 Remove expansion tank.
 Remove thermostat.
 Remove rear ignition coil cover.
 Remove air conditioning compressor.
 Remove the catalytic converter.
 Remove transmission.
 Remove front output shaft (all-wheel drive vehicles only).
 Remove radiator.
 Detach all coolant hoses from engine.
 Detach vacuum line from brake booster.

To remove or install the engine, the towing hook 72 

15 8 108 670 is required.
 4/29/2016 2/6

Pull off rubber mount (1) and slightly raise service cover (2) until
lock of cover (3) is accessible.
Unlock lock and remove cover (3).

Slacken nut (1).

Tightening torque 12 42 3AZ.
Remove positive battery cable from battery positive terminal.

Unlock and pull off all connectors (1) from power distribution

module.
Remove cover (2).
Release nut beneath it and set positive battery cable aside.
Tightening torque 12 52 7AZ.
Release lock (3) in direction of arrow.
 4/29/2016 3/6

Feed out and remove power distribution module.

Unlock and pull off the connector (1) from the power distribution
module and cable holders.
Release the clamp (2) and expose the wiring harnesses.

Note:
Hot-climate version
Release screw (1).
Remove oil pipes (2) from oil filter unit.
Release oil lines on cylinder head cover.

Unscrew nuts (1).

Remove power protective plate (2).
Release fuel lines from protective plate.
 4/29/2016 4/6

Unlock and disconnect fuel tank ventilation line (1).

Unlock and disconnect fuel delivery line (2).

Close off fuel line (3) with special tool 13 5 281.

Close off fuel line (2) with special tool 13 5 282.

Attach special tool 11 8 680 to rear lifting eye (gearbox side).

Push ball lock pin (1) in direction of arrow and hold down until
special tool 11 8 680X is positioned in lifting eye.
Pull ball lock pin (1) outward in direction of arrow until both balls
(2) are pushed outward.
Installation note:
 4/29/2016 5/6

For checking correct mounting of special tool 11 8 680.

There must be a 6.5 mm gap between ball lock pin (1) and ball
lock pin housing.
The gap dimension can be checked using a 6.5 mm drill.

Attach special tool 11 0 000 to engine crane.

Suspend special tool 11 0 000 from the designated mounting
eyelets of special tool 11 8 680 only (see arrow).

Release nut (1) on engine mount on left and right.

Installation note:
Replace self-locking nuts.
Tightening torque 22 11 2AZ.

Screw towing eye into cylinder head.

Tightening torque 11 12 5AZ.
Suspend special tool 11 0 000 from the designated mounting
eyelets (1) only.
Lift engine out with engine crane.
 4/29/2016 6/6

Assemble engine.
Check function of DME.
 4/30/2016 1/2

41 61 000 Removing and installing engine

compartment lid

Important!
Danger of injury!
Support engine compartment lid in fully opened position
with suitable apparatus.
Removal of the engine compartment lid must be carried
out with the assistance of a second person.

Important!
These instructions only apply to vehicles without active
pedestrian protection!
Observe separate procedure for vehicles withactive
pedestrian protection!

Read contents of Body, General.

For stripping and rigging operations, refer to texts on KSD CD
(job number 41 61 000).

Release the lock (1) and detach the water hose (2).

Unfasten plug connection (3) and disconnect.
 4/30/2016 2/2

Unscrew nuts (1).

Remove engine compartment lid.
Installation note:
Install engine compartment lid at screw locations to on hinge.
Tightening torque 41 61 1AZ.
If necessary, adjust engine compartment lid.
 4/30/2016 1/2

32 33 010 Removing and installing/replacing sport

steering wheel

Note:
Chassis / wheel alignment is not necessary after the steering
wheel has been removed and installed or replaced.

Necessary preliminary work:

 Remove airbag unit

Move wheels/sports steering wheel into straight-ahead position.

Disconnect plug connection (1).
Release screw (2) and remove sport steering wheel.
Installation note:
Make sure connecting line(s) is/are correctly laid.
Tightening torque 32 3 3 1AZ.

Installation note:
Align sports steering wheel by way of marking (1) to steering
column marking (2) and attach.
 4/30/2016 2/2

Replacement:
 Reinstall both shift paddles
 Modify design cover
 Modify both switches on sport steering wheel
 If necessary, modify steering wheel module
 4/30/2016 1/1

41 63 000 Removing and installing flap for fuel filler

neck

Note:
The illustration is a schematic diagram and is to be
applied to the relevant vehicle type.

Open fuel filler flap.

Lever out lock (2) and detach fuel filler flap (1) in direction of
arrow.
 4/30/2016 1/4

52 13 002 Removing and installing front passenger

seat (normal/manual)

Necessary preliminary tasks:

 Disconnect battery earth lead
 Remove head restraint

Important!
An airbag module and a pyrotechnical seat belt tensioner
are installed in the front seat.
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.

Installation note:
 Powerlok screws must be replaced and must not be
reused
 Powerlok screws are mechanical screw locks with
trilobular threads

Move backrest to full rearward position.

Grip end fitting cover in marked area between cushion and
cover.
Unclip end fitting cover in direction of arrow (1).
 4/30/2016 2/4

Feed out end fitting cover (2) in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with front guide in cover

2. Insert cover in direction of arrow downwards in covering
3. Engage top cover in marked area in covering.

Release screw (1).
Tightening torque: 72 11 02AZ.
Remove end fitting.
Installation note:
End fitting is coded against incorrect assembly.

Move seat to upper back position.

Release and dispose of screws (1).
 4/30/2016 3/4

Adjust the seat to the front top.

Release and dispose of screws (1).

Disconnect plug connection (1).

Important!
Cover door sill with protective covers (risk of damage).

Lift out front seat.

Installation note:
 Carpet must not get between seat rails and floor panel in
area of attachment points (squeaking noises)
 Replace microencapsulated screws
 Insert all screws loose to avoid twisting
 Tighten down all screws to specified torque
 4/30/2016 4/4

Tightening torque 52 10 01AZ.

Warning!
When carrying out further work on the front seat, it is
absolutely imperative to observe the safety regulations on
handling airbag modules and pyrotechnical seat belt
tensioners
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.
 4/30/2016 1/4

52 13 001 Removing and installing front seat,

driver's side (normal / manual)

Necessary preliminary tasks:

 Disconnect battery earth lead
 Remove head restraint

Important!
An airbag module and a pyrotechnical seat belt tensioner
are installed in the front seat.
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.

Installation note:
 Powerlok screws must be replaced and must not be
reused
 Powerlok screws are mechanical screw locks with
trilobular threads

Move backrest to full rearward position.

Grip end fitting cover in marked area between cushion and
cover.
Unclip end fitting cover in direction of arrow (1).
 4/30/2016 2/4

Feed out end fitting cover (2) in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with front guide in cover

2. Insert cover in direction of arrow downwards in covering
3. Engage top cover in marked area in covering.

Release screw (1).
Tightening torque: 72 11 02AZ.
Remove end fitting.
Installation note:
End fitting is coded against incorrect assembly.

Move seat to upper back position.

Release and dispose of screws (1).
 4/30/2016 3/4

Adjust the seat to the front top.

Release and dispose of screws (1).

Disconnect plug connection (1).

Important!
Cover door sill with protective covers (risk of damage).

Lift out front seat.

Installation note:
 Carpet must not get between seat rails and floor panel in
area of attachment points (squeaking noises)
 Replace microencapsulated screws
 Insert all screws loose to avoid twisting
 Tighten down all screws to specified torque
 4/30/2016 4/4

Tightening torque 52 10 01AZ.

Warning!
When carrying out further work on the front seat, it is
absolutely imperative to observe the safety regulations on
handling airbag modules and pyrotechnical seat belt
tensioners
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.
 4/30/2016 1/3

41 35 081 Removing and installing front side wall

on left

For stripping and rigging operations, refer to texts on KSD

CD (job number 41 35 081).
Observe gap dimensions.

Important:
Do not damage adjoining body components.

Necessary preliminary tasks:

 Remove trim panel for cover on side member
 Release bumper panel at the side in the area of the wheel
arch cover

Lever out expanding rivets (1).

Release latch mechanism (2) and remove cover (3).
 4/30/2016 2/3

Loosen screws and remove side wall.

Tightening torque 41 35 1AZ.

Replacement:
 Apply additional sealant to inside of front panel in area (1)
analogous with series.
Material: Sealant D1 (sourcing reference via BMW Parts
Department).
 Modify holder (2).
 4/30/2016 3/3

For replacement, only national-market version Japan:

Replace wheel arch trim (1).
 4/30/2016 1/5

25 11 000 Removing and installing gearshift lever

Special tools required:

 25 1 120

Necessary preliminary tasks:

 Remove complete exhaust system.
 Remove heat shields.
 Remove cross member.
 Partially remove propeller shaft.

- Disconnect propeller shaft at transmission.

- Release centre mount.

- Tie up propeller shaft to underbody.

Note:
Bending the propeller shaft by an excessive
angle can cause premature damage to the
joint/propeller shaft!

Pull off button (1) with a strong jerk.

Note:
Do not twist knob during removal as this would cause the anti-
twist lock in the knob to shear off.

Installation note:
Fit knob on gearshift lever, align and press on until it snaps
noticeably into place.
 4/30/2016 2/5

Release retaining tabs and lift out gaiter.

Installation note:
Push rubber gaiter (1) down until groove (2) is fully exposed.

Unlock bearing journal (1) in direction of arrow and remove.

Installation note:
Grease bearing journal.
Grease, refer to BMW Service Operating Fluids.
 4/30/2016 3/5

Lift out gearshift arm (1).

Lever support bearing (1) with a short screwdriver out of

mounting.

Feed U-type bellows (2) with gearshift arm (1) and gearshift

lever (3) carefully out of body aperture toward the bottom.
Important!
The PVC guide inserted in the U-type bellows for the body
aperture breaks easily during removal and installation.
 4/30/2016 4/5

Release U-type bellows bead (1) from gearshift arm up.

Press retaining lugs (2) of gearshift lever mount and release
gearshift lever (3) from gearshift arm.
Installation note:
Pull U-type bellows bead from below completely over gearshift
arm cup.

Installation note:
Grease gearshift lever ball.
Grease, refer to BMW Service Operating Fluids.
Install gearshift lever in gearshift arm.
Align mount:
 Retaining of ball socket perpendicular to direction of
travel.

Installation note:
Press mount in area of retaining tabs into gearshift arm until the
retaining lugs audibly snap into place.
 4/30/2016 5/5

Installation note:
Arrow (4) on rubber boot must point in direction of travel.

Installation note:
Pull the inner rubber boot over the pot on the gearshift arm.
Button the outer rubber boot into the body aperture.
 4/30/2016 1/1

54 12 115 Removing and installing glass slide/tilt

sunroof panel

Installation note:
 Microencapsulated screws (Loctite) must be replaced and
may not be reused
 Screw connection must be completed within 20 minutes
(start of curing)
 Microencapsulated screws must not be retightened
 Clean thread of nut beforehand in event of repeated use

Necessary preliminary tasks:

 Remove both gaiters

Release left and right screws (1).

Remove glass slide/tilt sunroof panel towards top.
Installation note:
Apply Loctite to screws.
Adjust glass slide/tilt sunroof panel.
Tightening torque 54 12 01AZ.
Initialise glass slide/tilt sunroof.
 4/30/2016 1/5

51 16 ... Removing and installing grab handle

holder

Special tools required:

 2 348 128
 72 1 200

Warning!
Follow safety information for repair work on vehicles with
airbag systems.

Important!
Risk of damage! Do not use sharp tools in the area of the
head airbag.

Necessary preliminary tasks:

 Lower headlining completely

Important!
Lay out protective mats to protect the interior against swarf
from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:

- Dashboard

- Entrance area

- Passenger compartment

Drill off the rivet plate (1) down to rivet shank with a 10 mm twist
drill bit.
Unscrew holder (2).
 4/30/2016 2/5

Front holder:
Note:
Folded package of head airbag conceals bottom rivet point.
Carefully raise folded package to expose rivet point.

Drill out rivets.

Remove holder for grab handles.

Rear holder:
Note:
Folded package of head airbag conceals bottom rivet point.
Carefully raise folded package to expose rivet point.

Drill out rivets.

Remove holder for grab handles.

Deburr remaining rivets with nipper pliers.

Installation note:
Lay out possible paintwork damage on the side frame with
primer.
 4/30/2016 3/5

Removal of the top rivet heads (1):

Press off rivet heads (1) using special tool 2 348 128 and
remove.

Removal of the bottom rivet heads (1):

Use special tool 72 1 200 for collecting rivet remnants.
Shank of special tool is flexible and can be adapted to the
relevant body contours.
Note:
Insert butyl in collecting tray to secure rivet remnants against
falling out.

Insert special tool 72 1 200 through bore hole in the body

underneath the attachment point.
 4/30/2016 4/5

Position special tool from rear on rivet head in cavity.

Note:
Make sure collecting tray is correctly fitted on rivet head.
A second person will be needed to help hold the special tool on
the rivet head during the driving-out operation.
With hammer and punch drive out stem into collecting tray.
Carefully manoeuvre special tool out of body so that rivet head
does not fall out of collecting tray.

Note:
If the rivet head falls out of the collecting tray into the side frame
when the special tool is fed out, this area must be generously
filled with foam.
For details of procedure for filling cavities with foam, see further
operations.
Use cavity foam (refer to BMW Parts Department) for foam
filling.

Preparing tube for foam can:

Slide hose (1) at least 6 cm into hose (2).
Cut end of hose (1) at an angle.
Mark (3) is not required.
Fit hose to foam can.
Run hose into corresponding opening in body.
Fill cavity in an operation lasting 0,5 seconds.
 4/30/2016 5/5

Warning!
Empty foam can completely onto cardboard and after
hardening dispose of foam and can in residual waste.
Can may burst if not completely emptied.
 4/30/2016 1/2

51 45 030 Removing and installing instrument

panel trim

Important!
Risk of damage!

A hard disk is installed in the Car Information Computer (CIC).

Carry out mechanical work on the CIC and adjacent
components with care.
Avoid subjecting the CIC to vibration / shocks.

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Necessary preliminary tasks:

 Remove trim panel for roof pillar at front left and
right
 Remove side panel on dashboard, left/right
 Remove decorative strip on dashboard on left
 Remove radio and IHKA controls
 Remove steering column control panel
 Remove instrument cluster
 Remove Start/Stop switch
 Remove centre console.
 Remove right glove box with housing
Depending on version:
 Remove speaker in dashboard
 4/30/2016 2/2

 Remove control element for driver assist system

Note:
Shown removed here for purposes of clarity. Wiring harness is
therefore not included in graphic.

Detach plug connection (1) of front passenger airbag

module (2).
(Observe notes regarding Airbag plug connections).

Release and disconnect plug connection at light operating

facility.
Release screws (1) on dashboard (2).
Tightening torque 51 45 7AZ.
Remove dashboard (2) with the aid of an assistant and
unthread all electrical lines.
Installation note:
Screw dashboard (2) in place from the middle to the outside.
Make sure all electrical lines are correctly routed.

Note:
Graphic is only an example.

Installation note:
Make sure guides (1) on dashboard (2) are correctly seated in
respective mountings of the bulkhead.
Make sure gaskets are correctly seated on air ducts.
Correctly insert foam-padded part of dashboard (2) in centre
and install.
 4/29/2016 1/4

11 61 050 Removing and installing intake plenum

(N55)

Necessary preliminary work:

 Disconnect battery earth lead.
 Remove intake silencer housing.
 Remove ignition coil cover.
 Remove sound insulation from centre bulkhead upper
parts
 Release left charge air duct at throttle body.

Disconnect all plug connections (1) on engine control unit.

Open retaining clip (1).

Release wiring harness section (2) from retaining clip (1).

Release all wiring harness sections from holder (1).

Disconnect plug connection (2) at charging pressure sensor.
 4/29/2016 2/4

Release all wiring harness sections from holders (1 and 2).

Disconnect plug connection (1) on tank vent valve.

Press and hold down the unlocking device on the vacuum line
(1) on the vacuum reservoir (cylinder head cover) in the
direction of the arrow.
Detach vacuum line (1) in upward direction.
 4/29/2016 3/4

Detach vacuum line (2) in upward direction.

Disconnect plug connection (1) on throttle valve drive.

Release screw (1).
Tightening torque: 11 61 2AZ.
Unscrew nuts (2).
Tightening torque: 11 61 1AZ.
 4/29/2016 4/4

Installation note:
Replace all gaskets.

Assemble engine.
 4/30/2016 1/4

52 14 002 Removing and installing left or right front

passenger seat side (normal/electric)

Necessary preliminary tasks:

 Disconnect battery earth lead
 Remove head restraint

Important!
An airbag module and a pyrotechnical seat belt tensioner
are installed in the front seat.
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.

Installation note:
 Powerlok screws must be replaced and must not be
reused
 Powerlok screws are mechanical screw locks with
trilobular threads

For electrical front seat version:

Move backrest to full rearward position.
Grip end fitting cover centrally between seat belt strap and
cover.
 4/30/2016 2/4

Unclip end fitting cover in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with rear guide in covering.

2. Insert cover in direction of arrow downwards in covering
3. Engage top left of cover in covering.

Release screw (1).
Tightening torque 72 11 02AZ.
Remove end fitting.
Installation note:
End fitting is coded against incorrect assembly.

Move seat to upper back position.

Release and dispose of screws (1).
 4/30/2016 3/4

Adjust the seat to the front top.

Release and dispose of screws (1).

Disconnect plug connection (1).

Important!
Cover door sill with protective covers (risk of damage).

Lift out front seat.

Installation note:
 Carpet must not get between seat rails and floor panel in
area of attachment points (squeaking noises)
 Replace microencapsulated screws
 Insert all screws loose to avoid twisting
 Tighten down all screws to specified torque
 4/30/2016 4/4

Tightening torque 52 10 01AZ.

Warning!
When carrying out further work on the front seat, it is
absolutely imperative to observe the safety regulations on
handling airbag modules and pyrotechnical seat belt
tensioners
Incorrect handling may activate the pyrotechnical belt
tensioner or side airbag and thereby cause injuries.
 4/30/2016 1/4

52 14 001 Removing and installing left or right front

seat, driver's side, (normal/electric)

Necessary preliminary tasks:

 Disconnect battery earth lead
 Remove head restraint

Important!
An airbag module and a pyrotechnical seat belt tensioner
are installed in the front seat.
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.

Installation note:
 Powerlok screws must be replaced and must not be
reused
 Powerlok screws are mechanical screw locks with
trilobular threads

For electrical front seat version:

Move backrest to full rearward position.
Grip end fitting cover centrally between seat belt strap and
cover.
 4/30/2016 2/4

Unclip end fitting cover in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with rear guide in covering.

2. Insert cover in direction of arrow downwards in covering
3. Engage top left of cover in covering.

Release screw (1).
Tightening torque 72 11 02AZ.
Remove end fitting.
Installation note:
End fitting is coded against incorrect assembly.

Move seat to upper back position.

Release and dispose of screws (1).
 4/30/2016 3/4

Adjust the seat to the front top.

Release and dispose of screws (1).

Disconnect plug connection (1).

Important!
Cover door sill with protective covers (risk of damage).

Lift out front seat.

Installation note:
 Carpet must not get between seat rails and floor panel in
area of attachment points (squeaking noises)
 Replace microencapsulated screws
 Insert all screws loose to avoid twisting
 Tighten down all screws to specified torque
 4/30/2016 4/4

Tightening torque 52 10 01AZ.

Warning!
When carrying out further work on the front seat, it is
absolutely imperative to observe the safety regulations on
handling airbag modules and pyrotechnical seat belt
tensioners
Incorrect handling may activate the pyrotechnical belt
tensioner or side airbag and thereby cause injuries.
 4/30/2016 1/2

61 31 041 Removing and installing operating

element for assist system

Special tools required:

 00 9 327

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.

Carefully release cover (1) from clamps (2) with special

tool 00 9 327.
Disconnect associated plug connection and remove cover (1).
Installation note:
Make sure cover (1) is correctly seated.

Remove operating element (1) by releasing retaining clips (2)

from cover (3).
Installation note:
Make sure operating element (1) is correctly seated in cover
(2).

Installation note:
 4/30/2016 2/2

Guides (1) and clamps (2) on cover (3) must not be damaged or

missing.
 4/30/2016 1/1

35 40 001 Removing and installing or replacing

accelerator pedal module

Take off protective cap.

Release screw (1).
Pull the accelerator pedal module (2) upwards out of bracket.
Installation note:
Tightening torque 35 40 1AZ.

Pull off connector (1).

Remove accelerator pedal module.
 4/30/2016 1/1

65 20 090 Removing and installing or replacing

aerial amplifier

Necessary preliminary tasks:

 Remove cover for rear window frame at top

Disconnect plug connections (2).

Release screw (3).
Remove aerial amplifier (4) from tailgate (1).
 4/30/2016 1/1

72 12 000 Removing and installing or replacing

airbag module on passenger's side

Important!
Operations on pyrotechnical devices may only be carried
out by authorised experts.
Improper, unauthorised operations may result in serious
dangers.
Unauthorized persons are strictly prohibited from
performing any operations on this system.

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause injury.
A damaged airbag must be replaced because its
protective function is compromised or, in an extreme
situation, it can no longer execute its protective function.

Necessary preliminary tasks:

 Remove dashboard

Release all screws on airbag module.

Tightening torque 72 12 01AZ.
Remove airbag module from dashboard.
 4/29/2016 1/2

12 31 020 Removing and installing or replacing

alternator (N55)

Necessary preliminary tasks:

 Switch off ignition.
 Disconnect battery earth lead.
 Remove left charge air duct.
 Remove alternator drive belt.

Note:
In order to remove the alternator, it is necessary to remove the
air-conditioning compressor for the air conditioning system.
In so doing:

- Do not draw off A/C system refrigerant.

- Do not detach refrigerant lines from A/C compressor.

- Do not remove A/C compressor; instead, remove from

bracket only and place to one side.
Remove A/C compressor from bracket.

Note:
For purposes of improved clarity, illustrations and description
show A/C compressor removed.

Release bolts a few turns until bracket (1) is loose. Do not

remove bracket (1).
Tightening torque 64 52 5AZ.

Unlock connector (1) and remove.

Remove protective cap and release nut underneath.
 4/29/2016 2/2

Tightening torque 12 42 1AZ.

Remove positive battery cable (2).

Release screws.
Remove bracket (1) and alternator (2).
Tightening torque 12 31 1AZ.

Assemble engine.
 4/30/2016 1/2

51 41 060 Removing and installing or replacing

armrest on door trim panel, front left or
right

Necessary preliminary work:

 Remove front door handle
 Remove switch cover

 
Note:
Armrest is welded to door trim panel only on initial installation.
The armrest is screw-connected on second installation. If
applicable, release screws instead of welding spots.

Important!
Risk of damage!
To avoid damaging the contact surface, only drill down to
door trim panel area (2)

Drill out all welding spots in marked area (1) on door trim

panel (2) with 8 mm dia. welding spot drill bit.
Remove welding remains on door trim panel (2) with scalpel (for
heavy duty use).

Replacement:
Saw off all welding pins (1) on arm support (2) to dimension (A).
A = 2.0 ± 0.5 mm

Installation note:
Arm support:
 4/30/2016 2/2

- position against door trim panel (1)

- secure at front and rear with repair screw (2)

- align until bore holes (3) are centred

- tighten beginning in the middle

Tightening torque 51 41 4 AZ.
Note:
If bore holes (3) were not drilled through, increase tightening
torque accordingly to ensure that arm rest is firmly seated.
 4/30/2016 1/3

34 41 120 Removing and installing or replacing

both handbrake Bowden cables

Special tools required:

 32 1 030

Necessary preliminary tasks:

 Remove centre console.

Note:
After completing repair work:
 Adjusting parking brake

Lock adjustment unit (ASZE).

Actuate parking brake lever. Connect special tool 32 1 030.
Press limit position (1) of adjusting spring back to such an
extent that retaining hook (2) engages in limit position (1).

Press retainer (1) in balance arm (2) forward in direction of

arrow.
Detach parking brake Bowden cables (3) from balance arm (2).

Release screw (1) and remove holder (2).

 4/30/2016 2/3

Installation note:
Tightening torque 34 41 2AZ.

Release one wheel stud.

Bring wheel into position (threaded hole turned down approx.
20° from horizontal).
F = direction of travel
Installation note:
Reinstall wheel stud only after handbrake has been adjusted.
Tightening torque 36 10 1AZ.

Nipple (1) and brake shoe expander lock (2) are visible through

threaded hole.
Push in core of parking brake Bowden cable in direction of
brake shoe expander to limit position and grip firmly.
Press nipple (1) downwards through threaded hole with a
screwdriver.
Pull parking brake Bowden cables out of wheel carrier.

Installation note:
Insert parking brake Bowden cable into brake anchor
plate/brake guard plate. Sleeve must be inserted up to stop.
Nipple of parking brake Bowden cable must audibly snap into
place in brake shoe expander.
 4/30/2016 3/3

Disconnect parking brake Bowden cables from holders (1).

Pull parking brake Bowden cables rearwards out of guide tube.
 4/30/2016 1/2

34 33 505 Removing and installing or replacing

brake booster

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove brake master cylinder.
 Remove hydraulic unit.
 Remove left footwell trim

Important!
There is a risk of switching the two brake lines (1)!
After the master cylinder and hydro aggregate have been
removed, the two brake lines (1) will be exposed.
The installation position (see graphic) of the brake lines (1)
must be marked prior to removal.

Pull the retaining clip (1) off the brake pedal and pull out the
locking pin.
Unscrew nuts (2).
Installation note:
Replace self-locking nuts.
Tightening torque 35 11 1AZ.

Important!
Do not use any force when removing and installing the
brake booster; the brake booster can be damaged under
certain circumstances.
 4/30/2016 2/2

Brake lines must not be bent.

Remove non-return valve (1) from brake booster.

Carefully pull brake booster (2) out of bulkhead and tilt out.
If necessary, disengage brake line from holder on bulkhead and
press slightly to one side.

Installation note:
When the brake booster is replaced, pay attention to the
following:

 Installation sequence: Gasket (1), shim (2), gasket (1).

 Gaskets (1) must always be renewed.
 4/29/2016 1/1

16 12 010 Removing and installing or replacing

carbon canister

Necessary preliminary tasks:

 Remove the tank cover on the right.

Unlock quick-release fasteners (1) and disconnect vent lines.

Release screws (2) and remove carbon canister (3).
Installation note:
Tightening torque 16 13 1AZ.
 4/29/2016 1/8

11 41 010 Removing and installing or replacing

chain module for oil pump/vacuum pump
(N55)

Special tools required:

 00 9 140
 11 0 290
 11 0 300
 11 4 120
 11 4 280
 11 8 640
 11 8 650
 11 9 260
 2 303 793

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Remove cylinder head cover
 Remove all spark plugs.
 Remove oil sump
 Remove drive belt
 Remove drive belt tensioning device
 Remove vibration damper
 Remove sealing cap for vacuum pump
 Remove sealing cap of chain tensioner for oil pump.
 Remove chain tensioner.
 4/29/2016 2/8

Screw in special tool 11 8 650 on belt tensioner screw

connection on crankcase.
Turn camshaft sprocket with central bolt at crankshaft into
position until special tool 11 0 290 can be secured.
Simultaneously secure special tool 11 0 290 to camshaft
sprocket and special tool 11 8 650 .
Release screw (1) for camshaft sprocket.
Tightening torque 11 66 2AZ.

Important!
Before releasing the central bolt on the oil pump, the
hydraulic chain tensioner must be drained.

Carefully press tensioning rail (1) with a suitable screwdriver (2)

in direction of arrow.
As the oil pressure in the chain tensioner can only be drained
pulsating, the tensioning rail (1) must be pressed several times.

Press the tensioning rail (1) and hold down.

Fix chain tensioner piston in position with a suitable lock pin (2).
Release screws (3).
Tightening torque: 11 41 7AZ.

Note:
Sprocket must be blocked in order to release central bolt (1).

Secure special tool 2 303 793 to crankcase.

Release oil pump central bolt (1).
Tightening torque 11 41 5AZ.
 4/29/2016 3/8

Remove fastener (1) in direction of arrow.

Position flywheel (1) with special tool 11 0 300 in TDC setting.

Release aluminium screws (1).

Remove oil pump drive gear from the drive shaft.
 4/29/2016 4/8

Open screw plug (1).

Tightening torque: 11 11 9AZ.
Installation note:
Replace sealing ring.

Lock flywheel  (1) with special tool 11 9 260.

Important!
Do not remove special tools 11 0 300 and 11 4 280 to
release central bolt (1).

Release central bolt (1).

Installation note:
Release central bolt (1) with 3/4 tool (2).
 4/29/2016 5/8

Breakaway torque approx. 500 Nm.

Screw in two screws (1) and remove hub (2) in direction of

arrow.
Installation note:
Replace front crankshaft seal.

Release aluminium screw (1) with special tool 11 8 640.

Remove chain module (1) in direction of arrow.

 4/29/2016 6/8

Installation note:
Both grip discs must be attached to drive gear for oil pump with
welding spots.

Grip discs are not individually available.

If grip discs are damaged, the drive gear for oil pump with grip
discs must be replaced.

Installation note:
Grip disc (1) must be mounted.
If grip disc (1) is not mounted, central bolt can come loose
(engine damage).

Important!
Note direction of installation of camshaft sprocket (2).
Collar (see arrow) on camshaft sprocket (2) points to
engine.
Incorrect assembly will result in engine damage.
 4/29/2016 7/8

Insert chain module.

Secure aluminium screw (1) with special tool 11 8 640.
Tightening torque: 11 41 3AZ.

Insert aluminium screws (1) for chain module.

Tightening torque 11 41 6AZ.
Installation note:
Replace aluminium screws.
Pay attention to mounting flats on oil pump drive.

Position module (1) for oil pump drive.

Position module (2) for camshaft drive.
Insert hub (3) for vibration absorber with grip disc.
 4/29/2016 8/8

Insert central bolt (1).

Secure central bolt with special tool 100 9 140.
Tightening torque 11 21 1AZ.
Installation note:
Replace front crankshaft seal.

Assemble engine.
 4/30/2016 1/2

35 31 000 Removing and installing or replacing

clutch pedal

Necessary preliminary tasks:

 Remove trim panel for foot levers.
 If necessary, remove over-centre helper spring.
 If applicable, detach the air duct for footwell
ventilation and push it up.

Push the locking bolts (2) out.

Installation note:
Replace the locking bolts (2).

Detach retaining clip (1).

Unhinge the recoil spring (2).
Pull the clutch foot levers (3) off the bearing support.
Installation note:
Replace retaining clip (1).
Locking clip (1) must be seated with both legs in the pin groove.

Installation note:
Check bearing bushings (1) and replace if necessary.
Lightly grease bearing bushings (1).
4/30/2016 2/2
 4/29/2016 1/2

21 51 500 Removing and installing or replacing

clutch release bearing/lever

Note:
(gearbox removed)

Do not disassemble the release module. Otherwise there is a

risk of the release module being incorrectly reassembled.

Note:
Release bearing (1) and release lever (2) have been combined
to form a single release module.
Do not grease sliding surfaces.

image A: Cam (1) of release bearing (A=12 mm) is on sliding

surface of release lever.
Type: N43, N45, N46
image B: Cam (1) of release bearing (A=7 mm) is on sliding
surface of release lever.
Version for all other engines
 4/29/2016 2/2

Remove release module (1) from spring wire clip.

Remove release module.
Note:
Similar to graphic.

Installation note:
Check spring wire clip (5) and ball pin (6) for damage and
replace if necessary.
Apply a thin coating of grease to ball pin (6).
Grease, refer to BMW Service Operating Fluids.

Note:
Similar to graphic.

Clean guide sleeve (7).

Installation note:
Do not grease guide sleeve.

Important!
If guide sleeve is greased, the release lever can stick on
the guide sleeve.

Note:
Similar to graphic.
 4/30/2016 1/1

61 61 270 Removing and installing or replacing

console for windscreen washer system
complete with motor

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Before installing the wiper arms, allow wiper motor to run
into rest position.

Warning!
Danger of injury from emergency operation, disconnect
battery negative terminal!

Necessary preliminary tasks:

 Remove cowl panel cover

Unlock and disconnect plug connection (1).

Unfasten screws (2).
Tightening torque 61 61 1AZ.
Pull console for windscreen wiper (4) out of guide (3) and
remove.
Note:
On a right hand drive vehicle also release position at
position (3).

Installation note:
Ensure guide (3) is correctly installed.
 
 4/29/2016 1/2

16 14 500 Removing and installing or replacing

control unit for electric fuel pump

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove backrest side section, right rear seat.

Note:
Vehicles with N13 motor have a DME control unit with
integrated electric fuel pump control unit.

Disconnect plug connection (1).

Release nuts (2) and remove control unit (3).
Installation note:
Tightening torque 16 14 1AZ.

Replacement:

- Carry out programming/encoding.

4/29/2016 2/2
 4/30/2016 1/1

51 41 017 Removing and installing or replacing

cover on door handle, front left or right

Special tools required:

 00 9 321

Important!
Risk of damage!
When working on trim panel components, make sure that
the sensitive surfaces are not scratched or damaged.

Insert special tool 00 9 321 from below into recess of cover (1).

Lever out cover (1) with special tool 00 9 321 at clamps (2).
Feed out cover (1) downwards from retaining hooks (3).
Installation note:
Firstly feed in cover (1) with retaining hook (3) into door trim
panel, then clip into door trim panel.

Installation note:
Following parts of cover must not be damaged or missing.
(1) Latch mechanism
(2) Clamps
(3) Retaining hook
 4/30/2016 1/2

51 41 019 Removing and installing or replacing

door handle on door trim, front left or
right

Necessary preliminary work:

 Remove front door trim panel

Note:
Door handle is welded to door trim panel only on initial
installation. The door handle is screw-connected on second
installation. If applicable, release screws instead of welding
spots.

Important!
Risk of damage!
To avoid damaging the contact surface, only drill down to
door trim panel area (3)

Drill out welding spots (1 and 2) on door trim panel (3) with

8 mm dia. welding spot drill bit.
Remove weld residuals on door trim panel (3) and, if necessary,
on door handle with scalpel (for heavy duty use).

Replacement:
Saw off welding pins (1) on door handle (2) to dimension (A).
A = 1.0± 0.5 mm

Installation note:
Insert door handle in door trim panel (2) and attach with repair
screws (1).
 4/30/2016 2/2

Tightening torque 51 41 3AZ.

Note:
If bore holes in door handle were not drilled through, increase
tightening torque accordingly to ensure that door handle is
firmly seated.
 4/30/2016 1/2

51 42 019 Removing and installing or replacing

door handle on door trim, rear left or
right

Necessary preliminary tasks:

 Remove rear door trim panel

 
Note:
Door handle is welded to door trim panel only on initial
installation. The door handle is screw-connected on second
installation. If applicable, release screws instead of welding
spots.

Important!
Risk of damage!
To avoid damaging the contact surface, only drill down to
door trim panel area (3)

Drill out welding spots (1 and 2) on door trim panel (3) with

8 mm dia. welding spot drill bit.
Remove weld residuals on door trim panel (3) and, if necessary,
on door handle with scalpel (for heavy duty use).

Replacement:
Saw off welding pins (1) on door handle (2) to dimension (A).
A= 1.0± 0.5 mm

Installation note:
Insert door handle in door trim panel (2) and attach with repair
screws (1).
 4/30/2016 2/2

Tightening torque 51 42 3AZ.

Note:
If bore holes in door handle were not drilled through, increase
tightening torque accordingly to ensure that door handle is
firmly seated.
 4/30/2016 1/1

67 62 000 Removing and installing or replacing flat

motor for front left or right power window
regulator

Necessary preliminary tasks:

 Remove front power window regulator

Release screws and detach flat motor (1) from power window

regulator (2).

After installation:
An initialisation must be carried out in order to activate anti-trap
mechanism.
Read and comply with notes on initialisation of power window
regulator.
 4/30/2016 1/2

51 16 480 Removing and installing or replacing

front grab handle

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Fold grab handle (1) downwards.

Disengage and remove locking wedge (2) with offset
screwdriver (3), as illustrated.

Repeat procedure on rear locking wedge (1).

Note:
The version of the grab handle must be determined for the
following procedure.

Version A B

Stem length of 22 mm 15 mm

locking wedge (1)
 4/30/2016 2/2

Retaining chamber No release Welded on grab

(3) tabs, fitted handle, with release
loose tabs (2)

Only version A
Jerk back grab handle (1) until grab handle (1) detaches.

Only version B
Lightly pull grab handle (2) towards the inside by hand and hold
under tension while releasing lower and upper tab (1) with
screwdriver (3).
Remove grab handle (2) and place to side.

Installation note:
Only after grab handle (1) is snapped in correctly can locking
wedges (2) we fully locked in position in grab handle (1).
Replacement
Note:
Only version B available as from September 2010.
 4/30/2016 1/1

52 13 390 Removing and installing or replacing

front left or right head restraint

Press latch mechanism (1) and lift out head restraint (2).

 4/29/2016 1/3

16 11 060 Removing and installing or replacing fuel

filler pipe

Recycling
Fuel escapes when fuel lines are detached. Have a
suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Important!
Ensure adequate ventilation in the workbay!
Avoid skin contact (wear gloves)!
After installation of fuel tank/prior to first engine start-up:
 Fill fuel tank with at least 5 litres of fuel.
 Check earth connection at fuel filler neck to body for
continuity. If necessary, clean contact surface
between body and fuel filler pipe screw connection.

Necessary preliminary tasks:

 Extract fuel from fuel tank
 Remove rear right wheel arch trim
 Lower rear axle.

Unhook retaining strap (1) from tank flap.

Open cap and set to one side.
 4/29/2016 2/3

Important!
There may still be residual amounts of fuel in the fuel tank.
Catch and dispose of escaping fuel.

Loosen hose clamps (1).

Detach fuel filler hose from fuel filler pipe.
Installation note:
Replace hose clamps.
Tightening torque 16 12 1AZ.

Unlock quick-release fasteners (1) and disconnect vent hoses.

Slacken nut (2).
Installation note:
Tightening torque: 16 12 2AZ.

Detach the tank ventilation line from the holder.

Slacken nut (1).
Installation note:
Replace plastic nut.
Tightening torque 16 12 2AZ.
 4/29/2016 3/3

Withdraw fuel filler pipe (2) completely out of rubber cup at

wheel arch and feed out.
Installation note:
Make sure rubber cup fits correctly.

Installation note:
Clean contact surface on body and earth cable on fuel filler
pipe.
Ground connection must be guaranteed.
 4/29/2016 1/5

16 11 030 Removing and installing or replacing fuel

tank (diesel)

Recycling
Fuel escapes when fuel lines are detached. Have a
suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Important!
Ensure adequate ventilation in the workbay!
Avoid skin contact (wear gloves)!
After installation of fuel tank/prior to first engine start-up:
 Fill fuel tank with at least 5 litres of fuel.
 Check earth connection at fuel filler neck to body for
continuity. If necessary, clean contact surface
between body and fuel filler pipe screw connection.

Necessary preliminary tasks:

 Draw off fuel from fuel tank
 Remove the left tank cover.
 Remove the right tank cover.
 Remove propeller shaft.
 Detach parking brake Bowden cables from the brake
shoe expander, left and right.

Undo sheet metal nut (1).

Remove the clip (2) from the tensioning strap and remove the
heat shield (3).
 4/29/2016 2/5

Detach the guide tubes from the clip (1).

Installation note:
It is absolutely necessary to replace damaged clips (1).

Pull both guide tubes back in the direction of the arrow until the
guide tubes can be moved freely.
Important!
Parking brake bowden cables remain attached to parking
brake lever!

Installation note:
The two guide tubes must be inserted into the holder under the
centre console by touch!
Both rubber grommets (3) must be correctly pressed into the
body after securing the guide tubes in the clips (1).

Unlock the snap fastener (1) and pull off the tank ventilation
line.
Installation note:
Make sure snap fasteners engage correctly.
 4/29/2016 3/5

Important!
There may still be residual amounts of fuel in the fuel tank.
Catch and dispose of escaping fuel.

Release hose clamps (1) and loosen the fuel filling hose from
fuel filler pipe.
The fuel filling hose cannot be pulled off until the fuel tank has
been lowered.
Installation note:
Tightening torque 16 12 1AZ.

Heavily support the fuel tank.

Unfasten nut.
Installation note:
Replace self-locking nut.
Tightening torque 16 11 1AZ.

Release screws for tightening straps on left and right and

remove tightening straps.
Carefully lower the fuel tank until the plug connection and fuel
delivery line are accessible at the flange cover.
Installation note:
 4/29/2016 4/5

Tightening torque 16 11 2AZ.

Disconnect plug connection (1).

Open both locks (2) in the direction of the arrow (shown already
opened).
Press both release buttons (3) and pull off fuel delivery line. If
applicable, slightly push the connector out to make pulling the
part off easier.
Important!
Fuel delivery line must be felt and heard to snap into
place.
Damaged lock parts must be replaced without fail!

Completely lower the fuel tank.

Installation note:
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.

The following components must be remounted when the fuel

tank is replaced:

- Delivery unit
 4/29/2016 5/5

- Holder for parking brake Bowden cable guide tubes

 4/29/2016 1/5

16 11 030 Removing and installing or replacing fuel

tank (petrol/gasoline)

Recycling
Fuel escapes when fuel lines are detached. Have a
suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Important!
Ensure adequate ventilation in the workbay!
Avoid skin contact (wear gloves)!
After installation of fuel tank/prior to first engine start-up:
 Fill fuel tank with at least 5 litres of fuel.
 Check earth connection at fuel filler neck to body for
continuity. If necessary, clean contact surface
between body and fuel filler pipe screw connection.
 Check transfer function of suction jet pump.

Necessary preliminary tasks:

 Extract fuel from fuel tank
 Remove left tank cover.
 Remove the right tank cover.
 Remove propeller shaft.
 Remove  carbon canister.
 Detach the parking brake Bowden cables from the
left and right brake shoe expanders.

Undo sheet metal nut (1).

Remove the clip (2) from the tensioning strap and remove the
heat shield (3).
 4/29/2016 2/5

Detach the guide tubes from the clip (1).

Installation note:
It is absolutely necessary to replace damaged clips (1).

Pull both guide tubes back in the direction of the arrow until the
guide tubes can be moved freely.
Important!
Parking brake bowden cables remain attached to parking
brake lever!

Installation note:
The two guide tubes must be inserted into the holder under the
centre console by touch!
Both rubber grommets (3) must be correctly pressed into the
body after securing the guide tubes in the clips (1).

Unlock the snap fastener (1) and pull off the tank ventilation
line.
Installation note:
Make sure snap fasteners engage correctly.
 4/29/2016 3/5

Important!
There may still be residual amounts of fuel in the fuel tank.
Catch and dispose of escaping fuel.

Release hose clamps (1) and loosen the fuel filling hose from
fuel filler pipe.
The fuel filling hose cannot be pulled off until the fuel tank has
been lowered.
Installation note:
Tightening torque 16 12 1AZ.

Heavily support the fuel tank.

Unfasten nut.
Installation note:
Replace self-locking nut.
Tightening torque 16 11 1AZ.

Release screws for tightening straps on left and right and

remove tightening straps.
Carefully lower the fuel tank until the plug connection and fuel
delivery line are accessible at the flange cover.
Installation note:
 4/29/2016 4/5

Tightening torque 16 11 2AZ.

Disconnect plug connection (1).

Open the lock (2) in the direction of the arrow (graphic already
opened).
Press the release button (3) and pull off the fuel delivery line. If
applicable, slightly push the connector out to make pulling the
part off easier.
Important!
Fuel delivery line must be felt and heard to snap into
place.
Damaged lock parts must be replaced without fail!

Completely lower the fuel tank.

Installation note:
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.

The following components must be reinstalled when the fuel

tank is replaced:

- Delivery unit
 4/29/2016 5/5

- Holder for parking brake Bowden cable guide tubes

 4/30/2016 1/1

34 41 ... Removing and installing or replacing

gaiter for handbrake lever

Special tools required:

 00 9 317

Unclip gaiter (1), top, with special tool  00 9 317, if applicable.

Installation note:
First insert the gaiter (1) on the bottom and then clip in on the
top.

Pull gaiter (2) over parking brake lever.

Cut cable ties (1) and remove gaiter.
Installation note:
Eye of cable tie must face downward
 4/30/2016 1/2

34 41 140 Removing and installing or replacing

guide tube for handbrake cables

Special tools required:

 32 1 030

Necessary preliminary tasks:

 Remove centre console.
 Remove exhaust system.
 Remove heat shield.

Lock adjustment unit (ASZE).

Actuate parking brake lever. Connect special tool 32 1 030.
Press limit position (1) of adjusting spring back to such an
extent that retaining hook (2) engages in limit position (1).
Installation note:
Unlock adjustment unit (ASZE).
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from limit position (1) of
adjusting spring.

Press retainer (1) in balance arm (2) forward in direction of

arrow.
Detach parking brake Bowden cables (3) from balance arm (2).
 4/30/2016 2/2

Pull parking brake Bowden cables out of guide tube.

Detach the guide tubes from the clip (1).
Installation note:
It is absolutely necessary to replace damaged clips (1).

Pull both guide tubes (2) a little in direction of arrow to the back
and remove guide tubes.
Installation note:
The two guide tubes must be inserted into the holder under the
centre console by touch!
Both rubber grommets must be correctly pressed into the body
after securing the guide tubes in the clips (1).

After installation:
 Adjusting parking brake
 4/30/2016 1/1

52 13 041 Removing and installing or replacing

inner cover on left or right front seat

Necessary preliminary tasks:

 Remove front seat
Note:
Completely move the electric front seat to the top prior to
removal.

Release screw (1).
Remove cover (2) in direction of arrow.
 4/30/2016 1/2

51 21 225 Removing and installing or replacing

inside door opener in left or right front
door

Necessary preliminary work:

 Remove front door trim panel
 Remove LED for door opener if necessary

 
Note:
Door opener is welded to door trim panel only on initial
installation. The door opener is screw-connected on second
installation. If applicable, release screws instead of welding
spots.

Note:
Graphic is similar.

Lever out lock (2)

Pull off Bowden cable housing (3) towards rear/top - the
Bowden cable feeds out of its own accord in the process.
Installation note:
To install the Bowden cable, press inner door handle (1)
opposite to direction of arrow.

Drill out welding spots (1) on door opener (2) with 8 mm dia.

weld spot drill bit and remove.door opener (2).

Installation note:
 4/30/2016 2/2

Secure door opener (1) on door trim panel (2) with repair

screw (3).
Tightening torque 51 41 2AZ.
Door opener (1) must rest against door trim panel (2) at the
attachment points without gaps.
 4/29/2016 1/6

11 36 046 Removing and installing or replacing

intake and exhaust camshaft adjusters
(N55)

Special tools required:

 00 9 120
 00 9 250
 11 4 280
 11 4 290
 11 9 340

Necessary preliminary tasks:

 Remove cylinder head cover.
 Check timing.

Important!
Only use special tool 11 4 280 to loosen central bolts (1
and 2) of VANOS unit.
Modify special tool 11 4 280 for N55 engine.

Release central bolts (1 and 2).

Release chain tensioner (1).

Tightening torque 11 31 7AZ.
Important!
 4/29/2016 2/6

Have a cleaning cloth ready. A small quantity of engine oil

will emerge after the screw connection has been released.
Make sure no engine oil runs onto belt drive.

Installation note:
Replace sealing ring.

Slightly lift timing chain (1) and remove exhaust camshaft

adjuster (2) from exhaust camshaft.
Slightly tilt exhaust camshaft adjuster (2) and remove upward.

Slightly lift timing chain (1) and remove intake adjuster (2) from
intake camshaft.
Slightly tilt intake adjuster (2) and remove upward.

Important!
Risk of mixing up the intake and exhaust camshaft
adjusters.
Danger of engine damage!
 4/29/2016 3/6

Intake and exhaust camshaft adjusters are different.

The variable camshaft timing control is marked with AUS/EX for
the exhaust camshaft.
The variable camshaft timing control is marked with EIN/IN for
the intake camshaft.
The increment wheels can be fitted alternatively.

Installation note:
Replace central bolts.

Place intake adjuster onto intake camshaft.

Place exhaust camshaft adjuster onto exhaust camshaft.
Installation position of intake and exhaust camshaft adjusters
can be freely selected.
Insert central bolts (1) until stop.
Release central bolts (1) again by a 90° turn.

Important!
Incorrect assembly possible!

Press tensioning rail (1) by hand against guide rail and make

sure timing chain is guided in tensioning rail (1).
Note:
Schematic representation of removed timing chain module.
 4/29/2016 4/6

Turn increment wheel (2) in direction of arrow until retaining

pins (1) on special tool 11 4 290 match up.
11 4 290Slide on special tool in direction of arrow.

Special tool 11 4 280 must be mounted for fastening central

bolts
Use bolts to fasten special tool 11 4 290.
11 9 340Screw special tool into cylinder head.

Pretension timing chain with special tool11 9 340

00 9 2500,6 Nm
 4/29/2016 5/6

Use special tool 00 9 120 to tighten central bolts of intake

adjuster.
Tightening torque 11 36 1AZ.

Use special tool 00 9 120 to tighten central bolts of exhaust

camshaft adjuster.
Tightening torque 11 36 1AZ.

Remove all special tools.

Rev engine on the central bolt twice in the direction of engine
rotation and verify timing.
Assemble engine.
4/29/2016 6/6
 4/30/2016 1/1

51 24 300 Removing and installing or replacing left

or right gas pressure spring for tailgate

Warning!
Danger of injury!
Support tailgate in fully opened position with suitable
apparatus.

Note:
Graphic similar.

Make a written record of the installation position of the gas

pressure spring(s) before removing.
Slide retaining spring (1) to end of gas pressure spring (2) and
lever out gas pressure spring (2).
Repeat the procedure at the other end of the gas pressure
spring (2) and remove.
Installation note:
Mount gas pressure spring (2) with retaining spring (1) pushed
back.
 4/30/2016 1/4

72 12 060 Removing and installing or replacing left

or right head airbag

Special tools required:

 2 230 142

Important!
Operations on pyrotechnical devices may only be carried
out by authorised experts.
Improper, unauthorised operations may result in serious
dangers.
Unauthorized persons are strictly prohibited from
performing any operations on this system.

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause injury.
A damaged head airbag must be replaced.
A damaged head airbag exhibits an impaired protective
function and in extreme cases loses its protective function
altogether.

Necessary preliminary tasks:

 Disconnect negative battery cable
 Remove headlining
 Follow notes for unlocking and locking airbag connector
 4/30/2016 2/4

connection

Important!
Lay out protective mats to protect the interior against swarf
from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:

- Dashboard

- Entrance area

- Passenger compartment

Installation overview, retaining elements, head airbag:

 4/30/2016 3/4

1 Gas generator 3 Retaining clips for folding pack

2 Mounting bolt, gas generator 4 Folding pack, head airbag

Important!
When removing head airbag, do not damage

- Head airbag

- Retaining clips

- Trim panels
Do not damage!

To unlock the retaining clips, use special tool 2 230 142.

Unlock and remove retaining clips.
Installation note:
 4/30/2016 4/4

Retaining clips of folding pack must not be damaged.

Replace faulty retaining clips.
Replace retaining clips after airbag deployment.

Unlock plug connection(1) for gas generator and disconnect.

Drill out rivet heads in marked area (2).
Note instructions for the removal of rivets.
Remove the gas generator with the folding pack.
Installation note:
Gas generator is coded against incorrect assembly.
 4/30/2016 1/2

51 21 170 Removing and installing or replacing

outer door handle from left or right front
door

Necessary preliminary tasks:

 Remove cover on outer door handle

If necessary, lay outer door handle light (1) slightly to one side.

Pull out outer door handle (2) somewhat and feed out in
direction of arrow.
Version with Comfort Access/CA:
Carefully feed out outer door handle (2) and disconnect
associated plug connection.

Installation note:
Locator (1) must not be damaged.
 
Version with Comfort Access/CA:
Seal (2) must not be damaged.

Installation note:
Sealing (1 and 2) must not be damaged or missing.
In necessary, use string to pull lock actuation (3) outwards and
hold in position.
Install outer door handle and insert correctly into lock
actuator (3).
Remove string.
Mount cover on outer door handle and carry out function check
with open door.
 4/30/2016 2/2

After replacing version with Comfort Access/CA:

Clear fault memory and perform functional check.
 4/30/2016 1/2

51 47 440 Removing and installing or replacing

rear carpet on seat pan

Necessary preliminary work:

 Remove both front seats
 Remove rear seat
 Remove both rear door sill cover strips
 Remove both bottom B-pillar trim panels
 Remove complete centre console
 Remove central bass speaker trim on left/right

Disconnect cable (1) from handbrake check switch.

Unclip cable clip (2) from parking brake lever.
Loosen nuts (3) on cable clip only.
Installation note:
Replace self-locking nuts.
Tightening torque 34 41 1AZ.

Important!
Risk of damage!
Pay attention to cables when cutting.

Cut carpet (1) along line (2).

Feed carpet (1) out to the top from the parking brake lever (3).

Installation note:
Apertures (1) serve as alignment points when fitting carpet (2).

 
 4/30/2016 2/2

Replacement:
Lay removed carpet over new one and transfer cuts to new
carpet.
 4/30/2016 1/1

72 11 092 Removing and installing or replacing

rear left or right seat belts

Necessary preliminary tasks:

 Remove capping
 Remove rear seat

Removing left or right automatic reel:

Undo screw (1) from inertia reel unit (2).
Tightening torques 72 11 21AZ.
Remove inertia reel unit (2).
Installation note:
Inertia reel unit (2) is coded against incorrect installation.

Release screw (1).
Tightening torques 72 11 22AZ.
Remove seat belt.
Installation note:
End fitting is encoded to prevent incorrect assembly.
 4/30/2016 1/1

52 13 198 Removing and installing or replacing

rear panel on left or right front seat
backrest

Release clips (1) with diagonal cutting pliers.

Remove rear panel (2) downwards with a rotational movement.
Note:
Remove remnants of clips.

Installation note:
Retaining hooks (1) and bore holes (2) on rear panel (3) must
not be damaged.
Replace faulty clips.
 4/30/2016 1/2

51 16 045 Removing and installing or replacing

retaining ring on left or right exterior
mirror

Necessary preliminary tasks:

 Remove protective cap from exterior mirror

Release screw (1) on drive (2) for electrically adjustable exterior

mirror.

Unclip drive (1) from rear at marked points from mirror housing.

Carefully unlock and disconnect plug connection (1) at the

marked points.
Remove electric motor (2).
 4/30/2016 2/2

Fold exterior mirror forwards.

Release screws (1) from circlip (2).
Feed out retaining ring (2) in direction of arrow.

Installation note:
Make sure retaining ring (1) is correctly mounted on turn
indicator (2) and housing (3).
 4/30/2016 1/2

72 12 050 Removing and installing or replacing

side airbag, front left or right seat

Warning!
Observe safety regulations for handling airbag modules
and pyrotechnical seat belt tensioners.
Incorrect handling can cause airbags to trigger, resulting in
serious injuries.

Important!
Operations on pyrotechnical devices may only be carried
out by authorised experts.
Improper, unauthorised operations may result in serious
dangers.
Unauthorized persons are strictly prohibited from
performing any operations on this system.

Necessary preliminary tasks:

 Disconnect negative battery cable
 Remove front seat
 Partially detach backrest cover

Important!
Make sure airbag wiring harness is exactly routed when
installed.

Detach cable strap.

Release airbag wiring harness (2) from cable clips on seat
mechanism.
Raise release clip (3) and pull connector (4) out of connector
housing (1).
Note:
If necessary, release yellow connector housing (1) from holder
on seat mechanism.
 4/30/2016 2/2

Unclip Omega cable clip (1) from seat mechanism (2).

Unscrew nuts (1).

Installation note:
Replace nuts (1).
Tightening torques 72 12 03AZ.

Important!
Feed the wiring harness carefully through the seat and
backrest mechanism as the edges of the frame can be
sharp.
 4/30/2016 1/3

51 16 080 Removing and installing or replacing sun

visor and left or right counter support

Removal:

Open the cover (1) and pull out the cover (2).

Unlock the clamp (1) with suitable long-nose pliers (2) and

remove the counter support (3) by pulling it downward.

Release screws (1).
 4/30/2016 2/3

Pull out the sun visor.

Disconnect plug connection (1).

Installation:

Connect plug connection (1).

Position the sun visor.

Tighten the screws (1) and close the covers.

Engage the counter support (1) and clip the cover (2) into place.
4/30/2016 3/3
 4/30/2016 1/2

51 43 150 Removing and installing or replacing

trim for left or right door pillar (bottom)

Necessary preliminary work:

 Remove front door sill cover strip

Release trim panel (2) out of clips (1) at bottom.

Feed out trim panel (2) toward the bottom from door sill cover
strip (3).

Partially detach edge protection in area of B‐pillar trim panel.

Carefully feed out bottom trim panel (1) from trim panel (2).
Installation note:
Ensure edge protection is correctly positioned.

Installation note:
Replace faulty clamps (1).
Guides (2) on trim panel (3) must not be damaged or missing.
4/30/2016 2/2
 4/30/2016 1/1

51 49 000 Removing and installing or replacing

trim for rear lid

Necessary preliminary work:

 Remove cover for rear window frame on left/right

Release expanding rivet (1) and screws (2).

Release trim panel (3) at clips (4) and remove.

Installation note:
If necessary, replace faulty clips (1) on trim panel (2).
 4/30/2016 1/1

51 43 201 Removing and installing or replacing

trim for roof pillar at front (A-pillar), left or
right

Warning!
Follow safety instructions for working on vehicles with
airbag systems.

Important!
Do not use any sharp-edged tools to remove trim (risk of
damage to head airbag).

Detach edge protection (1) in area of trim panel (2).

Detach trim panel (2) from the first detent position of the
clamp (4) toward the inside.
Loosen the trim panel (2) toward the top and thereby detach it
from the clips (3).
Feed out trim panel (2) from dashboard and remove.
Installation note:
Make sure edge protection (1) is correctly seated.
Always replace clamps (4).

Installation note:
Always replace clamps (2).
Pry out any clips (1) remaining in the body and insert in cover
Replace faulty clips (1).
Make sure guides (3) is correctly seated in associated mounts.
 4/30/2016 1/1

51 71 447 Removing and installing or replacing

trim panel for cover on left or right side
member

Release screws (1) on bottom of trim panel (2).

Unclip the trim panel (2) along the mark (3) to the outside.
Installation note:
If applicable, replace faulty screws (1) and corresponding
mountings.

Installation note:
Latch mechanisms on holder (1) and trim panel (2) must not be
damaged.
 4/30/2016 1/1

51 43 251 Removing and installing or replacing

trim panel for left or right rear roof pillar
(C-pillar)

Pull off edge protection (1) in area of trim panel (2).

Release trim panel (2) at clip (3) and clamp (4).
Remove trim panel (2) towards inside.
Installation note:
Make sure edge protection (1) is correctly seated on trim panel
(2).

Installation note:
Guides (1) must not be missing or damaged.
If necessary, replace faulty clamps (2) and clip (3).
Check that clamp (2) is securely seated in trim panel, replace if
necessary.
 4/30/2016 1/2

51 43 148 Removing and installing or replacing

trim panel on left or right door post (top)

Necessary preliminary tasks:

 Remove trim panel for rear door post

Version with B-pillar lighting:

Unfasten plug connection (1) and disconnect.
Release cable clip (2) from B-pillar.

Detach edge protection (1) in area of trim panel (3).

Release trim panel (3) at clips (2) and feed out toward the
bottom.
Installation note:
Make sure edge protection (1) is correctly seated on trim
panel (3).
 

Complete removal only:

Release belt screw on front seat.
Feed out seat belt strap (4) from trim panel (3).

Installation note:
Feed guides (1) correctly into holder (2).
 4/30/2016 2/2

Make sure trim panel (3) is correctly fitted on roofliner.

Installation note:
Guides (1) and clips (2) on trim panel (3) must not be missing or
damaged.

 
On replacement with B-pillar lighting version:
Remount LED.
 4/30/2016 1/2

51 21 300 Removing and installing or replacing

window cavity cover strip on outside of
left or right front door

Special tools required:

 00 9 324
 00 9 325

Important!
Weather strip in plastic design cannot be removed without
damage.
 
Observe procedure for using special tool 00 9 324.
The ”Instructions on fitting window guide seals” serve as
the basis for this repair instruction and must be observed
without fail.

Important!
If reusing the existing window cavity cover strip (1), make
sure it is not bent.

Lever out weather strip (1) using special tool 00 9 324 (starting

at B-pillar).
At the same time, pry out weather strip (1) carefully using
special tool 00 9 325 in the area of the B-pillar cover.

Pull out weather strip (1) from exterior mirror (2) in direction of

arrow.
Installation note:
Moisten weather strip (1) before installation with
approved lubricant.
Weather strip (1) must lie flush with the door edge at the rear.
4/30/2016 2/2
 4/30/2016 1/7

26 11 000 Removing and installing output shaft

(inserted) completely

Special tools required:

  00 9 120
  00 9 130
 33 0 080
 33 5 070

Important!
On four-wheel drive vehicles with defective, non-engaging
drive, it is imperative that the following information is taken
account of.
 Additional work when replacing the propeller shaft.

Important!
Replacement of the sunk nut on the rear axle final drive is
absolutely required!
The sunk nut already has a screw locking.
After the propeller shaft has been screwed into the rear
axle final drive (sunk nut), a hardening time of at least 2
hours is absolutely necessary.
The hardening time may be extended at lower
temperatures!
Failure to comply with these instructions may cause
serious damage!

Necessary preliminary tasks:

 Remove complete exhaust system.
 Remove heat shields.
 Support transmission with lifter.
 Remove cross member (F22, F33).
 4/30/2016 2/7

Important!
Adhere without fail to the installation and bolt-tightening
sequence.
installation sequence:
1. Join propeller shaft to transmission
2. Join propeller shaft to rear axle final drive
3. Join centre mount
Screw-fastening sequence:
1. Insert nut
2. Flexible disc to transmission
3. Centre mount

Important!
To avoid buzzing sound after refitting the propeller shaft:
1. The flexible disc connection (1) on the front at the
propeller shaft  must be marked in one plane with
the flexible disc (2) and the three-bolt flange (3)
before removal.
2. During installation the three-bolt flange (3) must be
forced back together again with the flexible disc (2)
in the same position.
3. Replace ZNS bolts and self-locking nuts.

Release screws.
Installation note:
 4/30/2016 3/7

- Replace ZNS bolts and self-locking nuts.

- Grip mounting bolts of flexible disc at nuts and

tighten down by way of bolts.

Installation note:
Check centring mount.
If necessary, replace damaged centring.
Grease centring mount.

- Grease: BMW Service Operating Fluids.

Installation note:
Tighten down screws/bolts to specified torque.
Secure angle of rotation special tool  00 9 120 with
magnets 00 9 130 to vehicle underbody and screw down further
according to angle of rotation.
Tightening torque 26 11 1AZ.

Slacken screws (1)
Tightening torque 26 11 5AZ.
Using a suitable tool (2), secure propeller shaft at centre
universal joint against twisting.
Remove screws of centre mount fully only after opening insert
nut.
 4/30/2016 4/7

Important!
The bi-hexagonal flange nut must not be used for bracing.
Failure to comply with this instruction may result in serious
damage to the rear axle final drive.

Important!
The sunk nut must be opened against direction of travel in
clockwise direction.
If an attempt is made to open the sunk nut in direction of
travel in clockwise direction, the sunk nut is automatically
screwed in further and the insert collar of the 12-edge
flange nut is severely damaged.
If the insert collar of the flange nut was damaged, the
propeller shaft can no longer be secured using a new sunk
nut and the rear axle differential must be replaced.

Release insert nut against direction of travel in clockwise

direction with special tool 33 0 080 and 33 5 070.
Tightening torque 26 11 6AZ.

Remove retaining clip (1) and gasket (2).

Installation note:
Retaining clip and gasket must be replaced.
 4/30/2016 5/7

Remove insert nut (1).

Installation note:
Insert nut must be replaced.

Before installing propeller shaft:

Clean insert collar (1) on flange nut and gearing on bevel pinion
(2).
Fill insert collar (1) with grease.
Grease: BMW Service Operating Fluids.

Clean thread (1) of joint hub to remove adhesive residues.

Clean hub teeth (2), then coat with grease.
Grease: BMW Service Operating Fluids.
Important!
Thread of joint hub must not be fouled with grease.
 4/30/2016 6/7

Place flange nut (1) with gasket in insert collar of flange nut.

Install retaining clip (2).

Important!
Adhere without fail to the installation and bolt-tightening
sequence.
installation sequence:
1. Join propeller shaft to transmission
2. Join propeller shaft to rear axle final drive
3. Join centre mount
Screw-fastening sequence:
1. Insert nut
2. Flexible disc to transmission
3. Centre mount

Slide propeller shaft (1) to the limit position onto insert nut and
secure.
Secure output shaft at centre universal joint against turning with
 4/30/2016 7/7

a mounting lever.
Important!
The bi-hexagonal flange nut (2) must not be used for
bracing.
Failure to comply with this instruction may result in serious
damage to the rear axle final drive.

Insert nut must be screwed into place within 5 min.

Tightening torque 26 11 1AZ.
 4/29/2016 1/3

17 11 000 Removing and installing radiator (N55)

Warning!
Risk of scalding!
Only perform this repair work after engine has cooled
down.

Important!
Wear safety goggles and protective gloves.

Necessary preliminary work:

 Follow instructions for repair work on the cooling system.
 Remove fan cowl.
 Drain coolant.

Only vehicles with automatic transmissions:

Unlock and detach coolant hose (1) from transmission oil cooler
on the radiator.
 4/29/2016 2/3

Release and disconnect coolant hoses (1).

Unfasten screws (2).
Tightening torque 17 10 2AZ.

Remove cover (1) from the radiator.

Carefully feed out radiator (2) towards top and remove.

Installation note:
Make sure the installation position of the cover (1) on the left
and right module carriers (2) is correct!
 4/29/2016 3/3

Reassemble the vehicle.

Check cooling system for leaks.
 4/30/2016 1/2

61 31 321 Removing and installing radio and A/C

control panel (for vehicles equipped with
CID)

Special tools required:

 00 9 325

Note:
The following repair instructions apply in the case of vehicles
not equipped with CID:

- Removing and installing the control panel of the heating

and air conditioning system

- Removing and installing the radio receiver

Important!
Risk of damage!

A hard disk is installed in the Car Information Computer (CIC).

Carry out mechanical work on the CIC and adjacent
components with care.
Avoid subjecting the CIC to vibration/shocks.

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Carry out installation in a dust-free workshop area only.
To avoid damage, do not touch or dirty the display field.

Necessary preliminary tasks:

Remove the centre fresh air grille.
 4/30/2016 2/2

Release screws (1).
Carefully unlock the radio and air conditioning control panel (2)
at the marked points, using special tool 00 9 325.
Slightly pull out the radio and air conditioning control panel (2)
and disconnect the associated plug connection.
Remove radio and air conditioning control panel (2).
 4/30/2016 1/5

51 34 190 Removing and installing rear left or right

fixed door window in rear window frame

Special tools required:

 51 3 220

Important!
The following notes form the basis for these repair
instructions and must be adhered to at all times:
 Notes on window bonding
 General procedure to dismantle / install bonded
window glass

Note:
Removal is carried out with wire pull handles.

The following new parts / consumables are required (sourcing

reference BMW Parts Department).

Material Quantity

Spacer buffer 3x7x15 mm (from repair kit) 3

Small repair kit 1

Cutting wire 1

Necessary preliminary tasks:

 Remove cover for window guide
 Remove rubber window seal for door window in area
of fixed door window.

To avoid damage, the door must be taped off with yellow plastic
adhesive tape in area (1 and 2).
(1) Outer
(2) Inside and outside
 4/30/2016 2/5

Slide cutting wire (1) through adhesive bead above latch

mechanism (2).
Sever adhesive bead in direction of arrow up to area (A), pulling
outward.
Note:
Dashed line (1) represents the cutting wire on the inside of the
door.

Lay the cutting wire (1) at the top behind the PVC coating (2)
and feed it in behind the spacer (3) if possible.
Sever the adhesive bead up to area (A), pulling from the inside
only.
Note:
Dashed line (1) represents the cutting wire on the inside of the
door.

Lay cutting wire (1) at the bottom behind PVC coating (2) and
press underneath spacer (3).
Sever remaining adhesive bead and remove door window.
 4/30/2016 3/5

The following parts on the frame (1) will be completely or

partially damaged when separating the door window:
(2) Spacers
(3) Latch mechanism
Installation note:
Note operation for positioning the door window.

In the event of additional damage to the frame (1), the door

window must be replaced.

Replace faulty clamps (1).

Remove remnants frame in the areas (2).

Spacers on the frame will be completely or partially damaged

when separating the door window.
To achieve correct positioning of the door window, spacer
buffer* (1) must be bonded on marked areas of window
frame (2).
* Spacer buffer 3x7x15 mm from repair kit
 4/30/2016 4/5

Overview for taping of door window ()

Position (1) corresponds to bead joint.

Cut A - A

a [mm] = Position adhesive bead 1 +1 / along frame contour

b [mm] = Width adhesive bead 8 ±1

h [mm] = Height adhesive bead 15 ±2

Important!
 4/30/2016 5/5

In the marked area, the adhesive bead does not follow the contour of the frame.

F20 F30/F35/F80

a1 6 +1 mm 2 +1 mm

a2 8 +1 mm 4 +1 mm

Installation note:
Carefully insert door window (1) firstly at the bottom with special
tool 51 3 220, then press down past spacer buffer (2). Door
window (1) is not to contact spacer buffer (2) during pressing
down.
Align door window (1) and push it against spacer buffer (2).
Secure door window (1) in this position with yellow plastic
adhesive tape.
Observe minimum hardening time, remove spacer buffer (2)
and assemble door.
 4/30/2016 1/3

37 12 310 Removing and installing rear left or right

shock absorber (adaptive M chassis and
suspension))

Warning!
Vehicle may tilt off vehicle hoist if the workshop jack is
incorrectly handled.
 
When supporting components, make sure that:
 the vehicle can no longer be raised or lowered
 the vehicle does not lift off the locating plates on the
vehicle hoist.

Important!
- Read and comply with Information on replacing
shock absorbers.

Necessary preliminary tasks:

 Remove rear wheel
 Remove camber arm cover

Unlock connector (1) in direction of arrow and pull off towards

top.
Unclip wiring harness on shock absorber and place to one side.
 4/30/2016 2/3

Support wheel carrier with workshop jack.

 
Slacken nut (1).
Tightening torque 33 52 3AZ
Lift wheel carrier with workshop jack to the point where the
screw can be removed.
Slowly lower workshop jack until wheel carrier is suspended.
Remove workshop jack from under vehicle.
Installation note:
Replace screw and nut.
Note direction of insertion of screw.
Tighten down screw connection in normal position.

Release screws (1) on support bearing.

Tightening torque 33 52 1AZ.

Press shock absorber together and remove upward from wheel

arch.
 4/30/2016 3/3

Installation note:
Check protective cap (1) and sealing washer (2) for damage
and renew if necessary.
 4/30/2016 1/3

33 52 010 Removing and installing rear left or right

shock absorber

Warning!
Vehicle may tilt off vehicle hoist if the workshop jack is
incorrectly handled.
 
When supporting components, make sure that:
 the vehicle can no longer be raised or lowered
 the vehicle does not lift off the locating plates on the
vehicle hoist.

Important!
- Read and comply with Information on replacing
shock absorbers.

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Necessary preliminary tasks:

 Remove rear wheel.
 Remove camber arm cover.
 4/30/2016 2/3

Support wheel carrier with workshop jack.

 
Slacken nut (1).
Tightening torque 33 52 3AZ
Lift wheel carrier with workshop jack to the point where the
screw can be removed.
Slowly lower workshop jack until wheel carrier is suspended.
Remove workshop jack from under vehicle.
Installation note:
Replace screw and nut.
Note direction of insertion of screw.
Tighten down screw connection in normal position.

Release screws (1) on support bearing.

Tightening torque 33 52 1AZ.

Press shock absorber together and remove upward from wheel

arch.
 4/30/2016 3/3

Installation note:
Check protective cap (1) and sealing washer (2) for damage
and renew if necessary.
 4/30/2016 1/3

34 41 220 Removing and installing/renewing all

parking brake pads

Special tools required:

 32 1 030
 34 4 000
  00 9 317

Necessary preliminary tasks:

 Remove rear brake disk.

Note:
During replacement of the hand brake coverings, the following
components must also be renewed:
 Brake shoe expander
 Adjusting screw
 Spring set

If applicable unclip the gaiter (1) with special tool  00 9 317 at

top.
Installation note:
First insert the gaiter (1) on the bottom and then clip in on the
top.

Lock adjustment unit (ASZE).

Actuate parking brake lever. Connect special tool 32 1 030.
Press limit position (1) of adjusting spring back to such an
extent that retaining hook (2) engages in limit position (1).
Installation note:
Unlock adjustment unit (ASZE).
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from limit position (1) of
 4/30/2016 2/3

adjusting spring.

Disconnect return spring (1) with brake spring pliers.

Installation note:
Return spring (1) must not be overelongated.
Check and if necessary replace return spring (1).
Pay attention to installation position of adjusting screw (2).
Apply a thin coat of grease to bush and screw threads

Disconnect return spring (1) with brake spring pliers.

Installation note:
Return spring (1) must not be overelongated.
Check and if necessary replace return spring (1).

Twist roll pins (1) 90° with special tool 34 4 000 and detach.
Remove brake pads (2).
 4/30/2016 3/3

After installation:
 Adjusting parking brake
 4/29/2016 1/3

12 12 011 Removing and installing/renewing all

spark plugs (N55)

Special tools required:

 12 1 220
 12 1 230

Necessary preliminary tasks:

 Switch off ignition.
 Remove ignition coils.

Important!
Wear safety goggles.
Oil and dirt particles may get into your eyes!

Clean spark plug slot with compressed air.

1. Remove dirt contamination from the spark plug shaft.
The plug shaft must be cleaned with compressed air after
the ignition coils have been removed but before the spark
plugs have been dismounted. After removing the spark
plugs, check the sealing surface again for dirt
contamination and if necessary, clean with a damp cloth
or again with compressed air.
Note: Deposits that are not removed according to
instructions may enter the combustion chamber and lead
to uncontrolled combustion. Remaining deposits in the
area of the spark plug seal can lead to leaks and to the
 4/29/2016 2/3

spark plugs coming loose during engine operation.

2. Do not grease/oil thread or use any graphite or copper
grease. Adhere to the torque values of the packaging
information or regulation.
Note: If these instructions are not followed, especially
with regard to greasing, this may result in mechanical
damage to the spark plug housing/thread. Spark plugs
that are not tightened sufficiently lead to leaks and to the
spark plugs coming loose during engine operation.

Unscrew spark plugs with special tool 12 1 220 and an

extension with min. 8° kink.
Flexible ratchet extensions must always be used. If rigid
mounting tools are used, there is a risk of insulator breakages.
Note: Also do not use a variable plug connection with locking
capability as this also poses a risk of insulator breakages.

Installation note:
Attach new spark plug (1) 12 1 230to special tool .

Important!
Do not let spark plugs fall into the spark plug shaft. This
can lead to a reduction of the electrode gap and so impair
the smooth running of the engine, especially in idle mode.

Installation note:
Screw the spark plug hand-tight with special tool 12 1 230 into
the cylinder head plug thread to the limit position.
 4/29/2016 3/3

Installation note:
Tighten the spark plugs with a torque wrench, special tool
12 1 220 and an extension with a minimum kink of 8°.
Flexible ratchet extensions must always be used. If rigid
mounting tools are used, there is a risk of insulator breakages.
Note: Also do not use a variable plug connection with locking
capability as this also poses a risk of insulator breakages.
Observe tightening torque.
Tightening torque 12 12 2AZ.

Assemble engine.
 4/30/2016 1/2

61 71 030 Removing and installing/renewing all

washer jets of windscreen washer
system

Unlock hose coupling (1) in direction of arrow and detach

washer fluid line (2).
Unfasten plug connection (3) and disconnect.
Turn connector with holder (4) counterclockwise slightly and
remove in downward direction.

Press all washer jets (1) in direction of arrow upwards and

remove.
Open all brackets and remove washer fluid line.

Installation note:
Retaining lugs (1) must not be missing or damaged.
Check washer jet setting.
Top up window washer system.

Note:
Washer jets are preset by the manufacturer, do not change this
setting if possible.
 4/30/2016 2/2

Setting can be changed in a specific case for a customer

complaint.
Changes in the setting must take into account the possible
driving situations (high/low speed; with/without washing
additive) and must be performed with care.

If necessary, adjust left/right washer jet (1) by using screw (2).

 4/29/2016 1/2

34 21 320 Removing and installing/renewing both

brake discs

Special tools required:

 34 1 280

Necessary preliminary tasks:

 Remove and clean brake pads.

Check minimum brake disc thickness:

- Position special tool 34 1 280 at three measuring points in

area (1) and measure.

- Compare measuring result and lowest value with setpoint

value.
If the brake discs are replaced, you must also fit new brake
pads.
Always replace brake discs in pairs.

Important!
New brake pads may only be fitted if the brake disc
thickness is greater than the minimum brake disc
thickness (MIN TH).

Release bolts (1) and detach brake anchor plate.

Installation note:
Replace screws.
Tightening torque 34 21 2AZ.
 4/29/2016 2/2

Important!
To release brake disc: Do not under any circumstances
strike friction ring with a hammer or similar!
If necessary, carefully tap on base of brake disc chamber
with a rubber mallet.
Clean contact surface of brake disc at wheel hub
thoroughly and remove traces of corrosion.
Unevenness on contact surface may result in distortion of
brake disc!

Release screw (1) and remove brake disc (2).

Installation note:
Replace screw.
Tightening torque 34 21 1AZ.

After installation:
 Adjusting parking brake
 Read and comply with notes on braking in new brake
discs / brake pads.
 4/30/2016 1/1

61 31 062 Removing and installing/renewing button

for steering wheel heating

Necessary preliminary work:

 Remove lower section of steering column shroud.

Note:
Similar to graphic.

Unlock associated plug connection and disconnect.

Unlock switch (1) on both sides and press out from steering
column shroud (2).
Installation note:
Make sure switch (1) is correctly seated in steering column
shroud (2).
 4/30/2016 1/2

61 31 197 Removing and installing/renewing centre

console operating facility

Necessary preliminary tasks:

Version with manual gearbox only:
 Partially remove gearshift lever gaiter
Version with automatic transmissions only:
 Remove cover for selector lever

Important!
Risk of damage!
Centre console operating facility must not be pried out
from the outside.
 

Note:
Graphic shows example of F20 with automatic transmission.

1. Reach under front section of operating facility (1).

2. Press front latch mechanism in direction of arrow and
simultaneously raise operating facility (1) towards top.
3. Disconnect associated plug connection and remove
operating facility (1).

Installation note:
Latch mechanisms (1) must not be damaged or missing.
Make sure operating facility is correctly fitted in centre console.
 4/30/2016 2/2

In case of replacement, remount operating unit cover:

Release latch mechanism (1) and remount cover (2), depending
on equipment.

Installation note:
Latch mechanisms (1) must not be damaged or missing.
 4/30/2016 1/1

51 21 181 Removing and installing/renewing cover

on outer door handle with lock barrel

Operation is identical to:

Removing and installing/renewing complete lock barrel in left or
right front door.
 4/30/2016 1/5

64 51 591 Removing and installing/renewing

evaporator

Special tools required:

 00 9 030

Necessary preliminary tasks:

 Remove heater/air conditioner

Carefully pull rubber grommet (1) and foam seal below it over
pipes (2) and (3).
Note:
If necessary, replace damaged rubber grommet (1) and/or foam
seal.

Release screws (1).
Unlock plug connection (4) and disconnect.
Remove actuator drive (2).
Installation note:
Make sure actuator drive (2) is correctly seated in guide (3).

Release screw (1).
Open holder (2).
 4/30/2016 2/5

Loosen clasp (1).

Remove double-pipe (2).
Installation note:
Replace clasps (1) and sealing rings.
Use special tool 00 9 030 to install sealing rings without
damaging them.

Release plug connections - actuator drives at the marked points

and disconnect.
Unfasten plug connection - control unit (1) and disconnect.

Unfasten plug connection - actuator drive (1) and disconnect.

Disconnect plug connection - temperature sensor (2) and/or
remove temperature sensor from the heating and air
conditioning unit.
 4/30/2016 3/5

Release screws (1).

Release screws (1).

Release screws (1).
Unlock the distributor housing (2) at the marked points.
Remove distributor housing (2).
Installation note:
Ensure that the distributor housing (2) is correctly seated and
locked.
 4/30/2016 4/5

Release screws in marked area.

Unlock the latch mechanisms (3) in the marked areas with a

slotted screwdriver (2) (approx. 3 mm blade).
Remove upper housing section (1).

Installation note:
Retaining lugs (2) and guide pins (3) must not be damaged.
In the event of damage, replace the complete empty housing
(1).
 4/30/2016 5/5

Pull evaporator (1) in direction of arrow out of lower housing

section (2) of heater/air conditioner.
Installation note:
Make sure evaporator (1) is correctly seated in lower housing
section (2) of heater/air conditioner.

Important!
Do not bend the evaporator fins.
If necessary, clean or straighten evaporator fins with slat
comb.
 4/29/2016 1/2

17 11 035 Removing and installing/renewing fan

cowl with electric fan (N55)

Necessary preliminary work:

 Switch off ignition.
 Remove intake silencer housing.

Automatic only:
Release screw (1).
Tightening torque 17 10 4AZ.
Pull off transmission oil cooler (2) for automatic transmission in
upward direction from fan cowl.

Unlock and pull off connector (1) and unclip cable from fan
cowl.
Unlock catch (2).
Release screw (3).
Tightening torque 17 10 1AZ.
Feed out fan cowl upwards and remove.

Installation note:
Make sure fan cowl (1) and holder (2) are in correct installation
position.
 4/29/2016 2/2

Note:
Check stored fault messages.
Clear diagnostic fault entries from fault memory.
 4/30/2016 1/2

63 31 020 Removing and installing/renewing

footwell light

Important!
Follow instructions for handling light bulbs (interior
lighting).

Footwell, left/right:
Lever footwell light (1) in direction of arrow out of trim panel (2).
Disconnect plug connection behind and remove footwell
light (1).

Door, left/right:
Lever footwell light (1) in direction of arrow out of door trim
panel (2).
Disconnect plug connection behind and remove footwell
light (1).
Replacement:
 If necessary, remove bulb, note bulb type
The footwell light in LED technology must be completely
replaced!

Turn bulb holder (1) in direction of arrow and pull out of footwell

light (2).
 
 4/30/2016 2/2

Installation note:
Make sure bulb holder (1) is correctly seated and latched on
footwell light (2).

Pull bulb (1) in direction of arrow out of bulb holder (2).

 4/30/2016 1/2

61 31 342 Removing and installing/renewing gear

selector switch

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point
 Remove centre console trim

Release screws (1).
Tightening torque 61 31 1AZ.
Installation note:
Insert gear selector switch (2) correctly in front and rear fixation
of centre console support (3).

Lift gear selector switch (2) and unlock plug connection (1) at

gear selector switch (2) and disconnect.

Replacement:
Carry out vehicle programming/coding.
4/30/2016 2/2
 4/30/2016 1/2

34 52 121 Removing and installing/renewing ICM

control unit

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Warning!
The sensor system for triggering the airbag is installed in
the ICM control unit!
The battery must be disconnected before removing the
ICM control unit (ICM control unit de-energised)!
There is a risk of the airbag being triggered inadvertently if
this requirement is disregarded!

Necessary preliminary tasks:

 Disconnect negative battery cable.
 Remove centre console assy.

Warning!
Make sure that the negative battery lead is disconnected!
There is a risk of the airbag being triggered inadvertently!
 4/30/2016 2/2

Disconnect plug connection (1).

Release nuts (2) and remove ICM control unit (3).
Installation note:
Replace self-locking nuts.
Tightening torque 34 51 2AZ.
Important!
Do not trap any electrical wires when installing ICM control unit!

After removing and installing ICM control unit:

After completing repairs, use BMW Diagnosis and Information
System to
 carry out adjustment/start-up of ICM control unit
Replacement:
After completing repairs, use BMW Diagnosis and Information
System to

- carry out programming/encoding

- Carry out ride height adjustment

- Carry out adjustment/start-up of ICM control unit

 4/29/2016 1/2

12 61 285 Removing and installing/renewing oil

level sensor for engine oil (N55)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Switch off ignition.
 Remove front underbody protection.
 Drain engine oil.

Unlock connector (1) and remove.

Unscrew nuts.
Tightening torque 12 61 2AZ.
Remove oil level sensor (2).
Installation note:
Clean sealing surface on oil sump.
Replace seal on oil level sensor.
An excessively low torque value will result in oil leaks.
An excessively high torque value will result in damage to the oil
level sensor.
Top up engine oil.

Note:
 4/29/2016 2/2

Check stored fault message.

Delete fault memory.
 4/30/2016 1/1

65 20 035 Removing and installing/renewing roof

aerial

Necessary preliminary tasks:

 Detach empty housing for roof-mounted aerial

Note:
Diagram similar.

Release screw (1).

Remove roof-mounted aerial (2) by manoeuvring upwards.

Disconnect plug connection (1).

Remove aerial (2).
Installation note:
Do not mix up aerial/antenna connections (1).
 4/30/2016 1/2

32 31 070 Removing and installing/renewing

steering shaft lower section (N47/N55)

Important!
Do not turn the steering wheel once the steering shaft has
been detached from the steering box/steering column! If
the lower section of the steering shaft is separated from
the steering box/steering column, the steering column
switch cluster may be damaged when the steering wheel
is turned.

Necessary preliminary tasks:

 Remove electronics box (only N47)
 Remove trim panel for pedal mechanism
 Move steering column in "top" and "retracted"
position.

Release and detach clamping bolts (1) of steering shaft on

steering gear (in engine compartment).
Installation note:
Clean screw threads to remove all remnants of screw locking
adhesive.
Replace clamping bolts.
Tightening torque 32 31 2AZ.

Pull down steering shaft until clamping bolt (1) is accessible

with tool (2).
Release clamping bolt (1) and remove steering shaft.
 4/30/2016 2/2

Installation note:
Clean screw threads to remove all remnants of screw locking
adhesive.
Replace clamping bolts.
Counter-hold the steering shaft in the passenger compartment
on the steering column when sliding the universal joint onto the
steering column!
Connect steering spindle first to steering column and then to
steering gear.
Clamping bolt must rest in groove of steering box or steering
column.
No subsequent retorquing permitted!
Tightening torque 32 31 3AZ.

After installation:
 Turn steering wheel in both directions to the limit position.
The airbag indicator light must not light up in the process.
 4/30/2016 1/1

61 31 231 Removing and installing/renewing

steering wheel module control unit

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove airbag unit

Note:
Steering wheel cover is shown removed for purposes of clarity.

Remove control unit for steering wheel module (1) from steering

wheel (2) in direction of arrow.

Disconnect plug connection (1).

Remove steering wheel electronics control unit (2).
Installation note:
Make sure electronic steering wheel module (2) is fitted
correctly.
 4/30/2016 1/1

61 31 137 Removing and installing/renewing USB

interface connecting socket

Necessary preliminary tasks:

 Remove glove box with housing

Note:
Similar to graphic.

Release retaining clamps (1).

Push USB interface connecting socket (2) to the front from
glove box (3).
Installation note:
Retaining clips (1) must not be damaged.
Make sure USB interface connecting socket (2) is correctly
seated.
 4/30/2016 1/1

54 12 138 Removing and installing/renewing water

channel for glass slide/tilt sunroof

Necessary preliminary tasks:

 Remove glass tilt sunroof cover

Lever out linkage of left and right water channels (1) from

gate (2).
Installation note:
Linkage must audibly engage in gate.

Unclip left and right water channels (1) from carriage (2)

towards rear.
Installation note:
Water channel must audibly engage in carriage.

Important!
Perform function check only with fitted water channel.
(Risk of damage).
 4/30/2016 1/1

51 71 017 Removing and installing/replacing (left

or right) underbody panelling

Graphic is only an example. There may be differences in

specific details depending on engine version.

Release all screws along dashed line (1).

Tightening torque 51 75 1AZ
Remove underbody panelling (2).
Installation note:
Make sure underbody panelling (2) is correctly seated.
 4/30/2016 1/2

66 53 020 Removing and installing/replacing (RFK)

reversing camera

Special tools required:

 00 9 325

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Unclip reversing camera (1) from bumper trim (2) using special

tool 00 9 325.

Unlock plug connection (1) of reversing camera (2) and

disconnect.
 4/30/2016 2/2

After installation:
 Carry out reversing camera function check
 Calibrate reversing camera
 4/30/2016 1/2

61 34 ... Removing and installing/replacing 12-V

power socket

Special tools required:

 61 0 250

Depending on equipment, the following power sockets may be

fitted:
 Power socket in front centre console
 Power socket in rear centre console
 Power socket in luggage compartment

Pull out 12-V power socket from housing with special tool
61 0 250 until connector is at bottom of light ring.
For further information, see Service
Information SI 01 08 09 (531)
 

Note:
Graphic similar

Lever out power socket (1) in direction of arrow with a suitable

tool.

Release latch mechanisms (1) with a suitable tool.

Press power socket mounting (2) in direction of arrow out of
power socket frame (3).
 4/30/2016 2/2

Installation note:
Latch mechanisms (1) at socket mounting (2) must not be
damaged. Make sure socket mounting (2) is fitted correctly in
socket frame (3).
 4/30/2016 1/2

66 20 517 Removing and installing/replacing a

front centre left (inside) ultrasonic
transducer (Park Distance Control)

Necessary preliminary tasks:

 Remove ornamental grille for bumper trim (side) at front
 Only on version Sport Line and M Aerodynamic package:
Remove front bumper panel.

Disconnect plug connection.

Unlock retaining tabs (1) in direction of arrow and pull
ultrasound transducer (2) upward out of bracket (3).

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 517 Removing and installing/replacing a

front centre left ultrasonic sensor (M
Aerodynamics package ) (PDC)

Necessary preliminary work:

 Remove front bumper panel

Note:
Diagram similar.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 519 Removing and installing/replacing a

front centre right (inside) ultrasonic
transducer (Park Distance Control)

Necessary preliminary tasks:

 Remove ornamental grille for bumper trim (side) at front
 Only on version Sport Line and M Aerodynamic package:
Remove front bumper panel.

Disconnect plug connection.

Unlock retaining tabs (1) in direction of arrow and pull
ultrasound transducer (2) upward out of bracket (3).

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 519 Removing and installing/replacing a

front centre right ultrasonic sensor (M
Aerodynamics package ) (PDC)

Necessary preliminary work:

 Remove front bumper panel

Note:
Diagram similar.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 515 Removing and installing/replacing a

front left (outside) ultrasonic transducer
(Park Distance Control)

Necessary preliminary tasks:

 Remove front bumper trim.

Disconnect plug connection.

Unlock retaining tabs (1) in direction of arrow and pull
ultrasound transducer (2) upward out of bracket (3).

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 515 Removing and installing/replacing a

front left (outside) ultrasonic transducer
(Park Distance Control)

Necessary preliminary tasks:

 Remove front bumper trim.

Unfasten plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
up and out of bracket.

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 516 Removing and installing/replacing a

front right (outside) ultrasonic transducer
(Park Distance Control)

Necessary preliminary tasks:

 Remove front bumper panel

Disconnect plug connection.

Unlock retaining tabs (1) in direction of arrow and pull
ultrasound transducer (2) upward out of bracket (3).

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/29/2016 1/5

13 53 192 Removing and installing/replacing a

pressure line (N55)

Special tools required:

 32 1 270
  13 0 160

Warning!
Observe warning on cylinder head cover.
Disconnect negative battery terminal (risk of fire due to
short circuit on dismantling).
Electric fuel pump starts up automatically when door is
opened!
Carry out installation work on fuel system only with coolant
temperature below 40 °C.

Warning!
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the
high pressure line is released!

Important!
Adhere to conditions of absolute cleanliness when working
on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the
 4/29/2016 2/5

system!
 Do not allow any dirt particles or foreign bodies to
get into the system.
 Remove all traces of dirt before removing lines or
separate components.
 Use only fluff-free cloths.
 Seal all fuel system openings with protective caps or
plugs.
 High pressure lines may be rescrewed a maximum
of 10 times.

Necessary preliminary tasks:

 Remove ignition coil of corresponding cylinder.

Note:
 Ignition coils must not be fouled by fuel!
The resistance of the silicone material is reduced
significantly by contact with fuel, which may cause the
ignition coil to fail! It is therefore essential to protect the
spark plug slot against ingress of fuel with a cloth!
 Before installing ignition coils, clean spark plug slots with
compressed air.
 Make sure the spark plug slot is absolutely clean.

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel in a suitable container.
Observe country-specific waste disposal regulations.

Warning!
Wear full face guard and protective gloves.
 4/29/2016 3/5

Fuel can emerge spontaneously at high velocity from the

fuel injectors!
To reduce the fuel pressure, place rag over fuel injector
and carefully tap against the fuel injector with a spanner.
There is a risk of injury if the fuel pressure is not reduced!

Note:
The following description applies to all pressure lines.
Release the pressure line on the rail first. To reduce existing
fuel pressure if necessary. Fuel must not get into the spark plug
slot. Then disconnect the pressure line from the injector.

Unscrew nuts (2).

Disconnect pressure line (1).
Installation note:
Reinstall rubber mount (3).

Important!
If several pressure lines are removed, ensure that each
pressure line is reinstalled in its original location (cylinder).
Mark pressure lines.

Seal rail and injector with a matching plug (1) from special tool
kit 132 1 270.
 4/29/2016 4/5

Seal pressure line (1) with a matching plug from special tool

kit 232 1 270.
When reinstalling lines, lubricate the thread and bearing face of
the ball with a little transmission oil or grease! When they are
installed for the first time the nuts have a coating of lubricant
(only effective once). Penetration of lubricant into the fuel-
conducting area should be avoided.

Important!
Connect pressure line (1) without tension only.
To ensure distortion-free installation of the pressure line
and to avoid damaging the thread, it must be possible for
both nuts to be screwed on easily by hand!
If the ball bush is not in the centre of the sealing cone of
the rail and injector when the pressure line is attached, the
pressure lines must be relieved of tension.
If pressure lines are tensioned, see further procedure in
the section:
Relieving tension on pressure lines and fitting.

Adhere to tightening sequence:

Note:
Reset special tool in good time to prevent bending of pressure
lines.

Insert pressure line (1), install together with rubber mount (3)

and fit nuts (2) hand-tight only.
 First tighten down nut (1) on injector.
 Then tighten down nut (2) on rail.
Tighten down nuts with special tool 3 13 0 160.
Tightening torque 13 53 9AZ.

Relieving tension on pressure lines and fitting:

If the ball bush is not in the centre of the sealing cone of the rail
and injector when the pressure line is attached, the pressure
 4/29/2016 5/5

lines must be relieved of tension. To relieve tension on the

pressure line, the pressure line of the adjacent injector on the
same hold-down device must also be released and the hold-
down device must be released.
1. Release union nuts (2) on injectors.
2. Release union nuts (3) on rail.
3. Release screws (1) on hold-down device.
4. Fit pressure lines hand-tight.
5. Tighten screws (1) on hold-down device
Tightening torque 13 53 6AZ.
6. Tighten nuts (2) on injectors.
Tightening torque 13 53 9AZ.
7. Tighten nuts (3) on rail.
Tightening torque 13 53 9AZ.

Assemble engine.
Check fuel system for tightness.
Check function of DME.
 4/30/2016 1/2

66 20 536 Removing and installing/replacing a rear

centre left ultrasonic sensor (M
Aerodynamics package )

Necessary preliminary work:

 Remove rear bumper trim

Note:
Diagram similar.

Unlock retaining tabs (1) in direction of arrow and pull

ultrasound transducer (2) upward out of bracket (3).

Installation note:
Before installation of ultrasonic sensor (2) on wiring
harness, clean plug connection!
Retaining tabs (1) must not be damaged!
Make sure ultrasonic sensor is securely seated.

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 537 Removing and installing/replacing a rear

centre right ultrasonic sensor (M
Aerodynamics package)

Necessary preliminary work:

 Remove rear bumper trim

Note:
Diagram similar.

Unlock retaining tabs (1) in direction of arrow and pull

ultrasound transducer (2) upward out of bracket (3).

Installation note:
Before installation of ultrasonic sensor (2) on wiring
harness, clean plug connection!
Retaining tabs (1) must not be damaged!
Make sure ultrasonic sensor is securely seated.

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 536 Removing and installing/replacing a rear

middle left ultrasonic transducer

Necessary preliminary work:

 Remove rear bumper panel

Note:
Diagram similar.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.

Installation note:
Before installation of ultrasonic sensor (3) on wiring
harness, clean plug connection!
Retaining tabs (2) must not be damaged!
Make sure ultrasonic sensor is securely seated.

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/1

64 11 866 Removing and installing/replacing

actuator drive for blending flap (left)

Necessary preliminary tasks:

 Remove instrument panel trim

Note:
For purposes of clarity, illustration shows removed heating and
air conditioning unit.

Release screws (3).

Remove actuator drive (2).
Unfasten plug connection (1) and disconnect.
Installation note:
Make sure actuator drive (2) is correctly seated in guide (4).

Important!
Servomotors must be readdressed in the event of
replacement!
Addressing can only be carried out with the BMW
diagnosis system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/1

64 11 872 Removing and installing/replacing

actuator drive for blending flap (right)

Necessary preliminary tasks:

 Remove instrument panel trim

Release screws (3).
Unfasten plug connection (1) and disconnect.
Remove actuator drive (2).
Installation note:
Make sure actuator drive (2) is correctly seated in guide (4).

Servomotors must be readdressed in the event of replacement!

Addressing can only be carried out with the BMW diagnosis
system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/1

64 11 868 Removing and installing/replacing

actuator drive for defrosting flap

Necessary preliminary tasks:

 Remove actuator drive for ventilation flap, right

Note:
For purposes of clarity, illustration shows removed heating and
air-conditioning unit.

Unfasten plug connection (1) and disconnect.

Unfasten screws (2).
Remove actuator drive (3).
Installation note:
Ensure that the actuator drive (3) is correctly seated at the
marked locations in the guides.

Important!
Servomotors must be readdressed in the event of
replacement!
Addressing can only be carried out with the BMW
diagnosis system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/1

64 11 806 Removing and installing/replacing

actuator drive for fresh / recirculated air
flap

Necessary preliminary tasks:

 Remove Heating/air conditioning control unit

Note:
For purposes of clarity, illustration shows removed heating and
air-conditioning unit.

Release screws (1).

Pull off actuator drive (2).
Unlock plug connection (4) and disconnect.
Installation note:
Make sure actuator drive (2) is correctly seated in guide (3).

Important!
Servomotors must be readdressed in the event of
replacement!
Addressing can only be carried out with the BMW
diagnosis system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/1

67 11 555 Removing and installing/replacing

actuator drive for fuel filler flap

Necessary preliminary tasks:

 Remove cover housing

Unlock retaining lugs (2) with a suitable tool.

Remove actuator drive (1) from cover pot (3).

Release the actuator drive (2) by simultaneously turning and

pressing the locking pin (1).
Installation note:
Make sure the setting for the actuator drive (2) for the fuel filler
flap is correct. It must be possible to lock or unlock the fuel filler
flap completely.
 4/30/2016 1/1

61 35 980 Removing and installing/replacing aerial

for Comfort Access on left or right

Necessary preliminary tasks:

 Remove trim panel for cover on side member

Disconnect plug connection (1).

Unlock and remove aerial for Comfort Access (2) from
bracket (3).
Installation note:
Make sure aerial for Comfort Access (2) is correctly seated on
bracket (3).
 4/30/2016 1/1

65 77 016 Removing and installing/replacing airbag

control unit

Warning!
Note airbag safety regulations!
Incorrect handling can activate airbag and cause injury.

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Disconnect battery earth lead
 Remove trim panel for pedal mechanism

Release screw (1).
Unlock plug connections (2) and disconnect.
Pull airbag control unit (3) out of holder in direction of arrow.

Replacement:
Carry out vehicle programming/encoding.
 4/30/2016 1/3

32 34 030 Removing and installing/replacing airbag

unit (sport steering wheel)

Warning!
Observe the following instructions to avoid any risk of
injury by the airbag unit.

- Comply with safety regulations for handling

components with gas generators.

- Do not exert any force on the airbag unit.

- Use only specified release tool for the airbag unit.

Note: Incorrect handling may result in triggering of the
airbag unit and thereby cause serious injury.

Important!
Steering wheel must be replaced if airbag unit has been
triggered!
Follow procedure after airbag deployment.

Necessary preliminary tasks:

 Disconnect battery earth lead

Insert Torx screwdriver T20 (1) vertically into the concealed

opening until limit position (2) can be felt.
 4/30/2016 2/3

Pull Torx screwdriver (1) approx. 2-3 mm out of opening. Press

screwdriver handle towards middle of steering wheel and
simultaneously slide into opening to position Torx screwdriver
behind retaining spring bracket (refer to graphic below).

Press retaining spring bracket (1) of airbag unit inwards and

simultaneously pull airbag unit upwards until it unlocks.
Repeat procedure on other side.
Installation note:
Carefully push airbag unit in direction of steering column shaft
into steering wheel with uniform pressing force until airbag
engages noticeably and audibly.

Warning!
Danger of injury!
The airbag unit may only be set down with the airbag itself
facing up.

Tilt airbag unit forwards.

Disconnect plug connections(1) and remove airbag unit.
Installation note:
Make sure electrical leads are correctly positioned.
4/30/2016 3/3
 4/30/2016 1/3

32 34 020 Removing and installing/replacing airbag

unit

Warning!
Observe the following instructions to avoid any risk of
injury by the airbag unit.

- Comply with safety regulations for handling

components with gas generators.

- Do not exert any force on the airbag unit.

- Use only specified tools for releasing the airbag unit.

Note: Incorrect handling may result in triggering of the
airbag unit and thereby cause serious injury.

Important!
Steering wheel must be replaced if airbag unit has been
triggered!
Follow procedure after airbag deployment.

Necessary preliminary tasks:

 Disconnect battery earth lead

Insert Torx screwdriver T20 (1) vertically into the concealed

opening until limit position (2) can be felt.
 4/30/2016 2/3

Pull Torx screwdriver (1) approx. 2-3 mm out of opening. Press

screwdriver handle towards middle of steering wheel and
simultaneously slide into opening to position Torx screwdriver
behind retaining spring bracket (refer to graphic below)

Press retaining spring bracket (1) of airbag unit inwards and

simultaneously pull airbag unit upwards until it unlocks.
Repeat procedure on other side.
Installation note:
Snap airbag unit with uniform pressing force plane-parallel in
direction of steering column shaft into steering wheel.

Warning!
Danger of injury!
The airbag unit may only be set down with the airbag itself
facing up.

Tilt airbag unit forwards.

Disconnect plug connections(1) and remove airbag unit.
Installation note:
Make sure electrical leads are correctly positioned.
4/30/2016 3/3
 4/30/2016 1/1

52 26 ... Removing and installing/replacing all

guide sleeves for rear head restraints

Special tools required:

 52 0 070

Necessary preliminary tasks:

 Remove head restraint from rear seat

Insert special tool 52 0 070 into guide hole of sleeve (2) up to

upper area of retaining lug.
Feed release tongue of special tool into rear gap on retaining
lug (1).
Turn tool to release sleeve (2) and pull out by lifting upwards.
 

Installation note:
Replace guide sleeves and install as follows:

1. Short guide sleeves centre right

2. short guide sleeve with centre left lock
3. long guide sleeve, outer right
4. long guide sleeve with outer left lock
 4/29/2016 1/9

11 25 530 Removing and installing/replacing all

pistons (N55)

Special tools required:

 00 9 120
 11 4 491
 11 4 492
 11 8 141
 11 8 562
 11 8 564
 11 8 590

Warning!
Safety goggles must be worn when working on the
gudgeon pin circlip.

Important!
If pistons, connecting rods and connecting rod bearing
shells are reused, they must be reinstalled in the same
places.
Piston and gudgeon pins are paired and must not be fitted
individually.
Individual connecting rod replacement is not permitted;
they are classified by weight class.
Connecting rods and connecting rod bearing caps are
marked with the same pairing letters; mixing them up will
result in engine damage.

Necessary preliminary work:

 Remove engine.
 4/29/2016 2/9

 Mount engine on assembly stand.

 Remove intake plenum.
 Remove cylinder head.
 Remove oil sump.
 Remove oil pump.

Note:
In event of heavy oil carbon residue:

Carefully remove oil carbon residue from cylinder wall.

Note:
Graphic shows N46.

Important!
Do not release screw (1).
Oil spray nozzle (2) must not be maladjusted or bent.
If necessary, readjust (risk of damage).

Release connecting rod bolts (1).

Tightening torque 11 24 1AZ.
Remove connecting rod bearing cap (2).
Important!
Connecting rods and connecting rod bearing caps are
marked with the same pairing letters; mixing them up will
 4/29/2016 3/9

result in engine damage.

Screw special tool 11 8 590 into big end of connecting rod.

Press out connecting rod and piston to cylinder head side.
Important!
Risk of damage to oil spray nozzle.

Preliminary work:
Secure special tool 11 4 491 in vice.

Secure piston (1) with connecting rod to special tool 11 4 491 .

Note:
Graphic shows N52.

Warning!
Safety goggles must be worn for the next operation.
 4/29/2016 4/9

Warning!
Safety goggles must be worn.

To lever out piston circlip (1), support with special tool 11 4 492

on piston (2).
Lever out piston circlip (1) with special tool 11 4 492 in direction
of arrow.

Important!
Connecting rods are divided into weight classes and are
only available as a set.
Old and new connecting rods must not be installed in
mixed combinations.

Installation note:
The gudgeon pin must be able to be pressed through the bush
by hand with little force and must not display any significant
play.

Measuring piston installation clearance:

Measure piston diameter with micrometre at measuring point A
from lower edge of piston and offset at 90° to the axis of the
gudgeon pin.
Piston diameter at measuring point A.
 4/29/2016 5/9

Adjust micrometre to cylinder bore of engine block. Set internal

measuring device on micrometre to zero. Measure bottom,
centre and top of cylinder bore in direction of travel and
direction of rotation.
Diameter of cylinder bore.
Piston installation clearance.
Permissible total wear clearance.
Installation note:
If necessary, replace piston.

Warning!
Safety goggles must be worn.

Important!
The opening of the piston pin circlip must be installed on
the piston in the 6 o'clock position.
Risk of damage!

Insert piston circlip (2) into groove of special tool 11 8 562 .

Bring piston circlip (2) into working position (1).

Warning!
Safety goggles must be worn.

Slide on special tool 11 8 564 up to piston pin circlip (1)

Special tools 11 8 562 and 11 8 564 are prepared.
 4/29/2016 6/9

Warning!
Safety goggles must be worn.

The aperture on special tool 11 8 562 must point to piston

crown; only then can special tool 11 8 564 be fitted correctly.
If the special tools 11 8 562 and 11 8 564 are not positioned
correctly, the piston pin circlip must be driven in using a plastic
hammer in direction of arrow.
Note:
See graphic.

Piston pin circlip is correctly installed when opening (1) points

downwards.

Install all piston rings.

Install all bearing shells.
Coat piston and piston rings with oil.
Pre-install piston (2) in special tool 11 8 141 .
Screw on special tool 11 8 590 in connecting rod (2).
 4/29/2016 7/9

Installation note:
Make sure protective lugs (1) on special tool 11 8 590 are
positioned correctly and check for damage.

Insert piston with connecting rod in cylinder.

Important!
Risk of damage to oil spray nozzle.
Risk of breakage of piston rings.
Press in piston in direction of arrow with finger pressure
only, do not drive in.

Insert piston so that arrow on piston crown points to camshaft

drive.
Press in piston (1) with special tool 11 8 141 .

Important!
Connecting rod and connecting rod bearing cap are
marked with pairing letters (1) and must not be mixed up.
Swapping or incorrectly fitting the connecting rod bearing
cap on the big end will result in engine damage.

Apply a light coat of oil to crankshaft journal.

Assemble connecting rod and crankshaft journal.
Screw off special tool 11 8 590 in anti-clockwise direction.
Note:
Illustration shows N54.
 4/29/2016 8/9

Fit bearing caps (2) so that pairing letters match up.

Install new connecting rod bolts (1).
Join connecting rod bolts (1).
Tightening torque 11 24 1AZ.

Secure connecting rod bolts (1) with special tool 00 9 120.

Tightening torque 11 24 1AZ.

Assemble engine.
4/29/2016 9/9
 4/30/2016 1/2

72 11 098 Removing and installing/replacing all

rear lower straps

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.

Necessary preliminary tasks:

 Remove rear seat

Removal of left lower strap:

Release screw (1).
Tightening torque 72 11 23AZ.
Unfasten plug connection (2) and disconnect.
Remove lower strap (3).
Installation note:
Lower strap is coded against incorrect assembly.

Removal of right and middle lower strap:

Note:
Remove the middle lower strap only in combination with the
right lower strap.

Release screw (1).

Tightening torque 72 11 23AZ.
Unlock plug connections (2) and disconnect.
Remove lower strap (3).
Installation note:
Lower strap is encoded against incorrect assembly (3).

Lower strap with belt tensioner:

Removal is depicted for the left lower strap; the right strap is
 4/30/2016 2/2

removed in the same manner.

Unfasten plug connection (2) and disconnect.
Release screw (1).
Tightening torque 72 11 23AZ.
Remove lower strap (3).
Installation note:
Coding (4) determines the installation position and prevents the
lower strap (3) from turning.

Note:
Middle lower strap (5) can only be removed in conjunction with
right lower strap.
 4/29/2016 1/3

11 33 050 Removing and installing/replacing all

rocker arms (N55)

Special tools required:

 11 4 481
 11 4 482

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove intermediate lever.
 Remove exhaust camshaft.

Important!
Roller cam followers (1) on intake side are divided into
bearing classes.
The tolerance classes are marked according to the
graphic in numbers from 1 to 5.
Already used roller cam followers (1) may only be reused
in the same position.

Loosen and remove roller cam followers (1) from hydraulic

valve clearance compensating element.
Place all roller cam followers (1) in neat order on special tool
11 4 481 .
Installation note:
Prior to installation of intermediate levers, ensure proper
installation position of roller cam followers (1).
 4/29/2016 2/3

Classification of roller cam follower intake.

Standard: Number 3. standard.
Number 2. slow idle.
Number 4. fast idle.
In case of repair: rough idling speed.
Repair: 1
Number 1. slow speed in idle.
Number 5. high speed in idle.

Loosen and remove roller cam followers (1) on exhaust side

from hydraulic valve clearance compensating element.
Place all roller cam followers (1) in neat order on special tool
11 4 482 .
Installation note:
Prior to installation of exhaust camshaft, ensure proper
installation position of roller cam followers (1).

Remove hydraulic valve clearance compensating element (1)

on intake side in direction of arrow.
Installation note:
If hydraulic valve clearance compensating elements (1) are
reused, they must be placed together with rocker arms in neat
order in special tool 11 4 481.

Remove hydraulic valve clearance compensating element (1)

on exhaust side in direction of arrow.
Installation note:
If hydraulic valve clearance compensating elements (1) are
 4/29/2016 3/3

reused, they must be placed together with rocker arms in neat

order in special tool 11 4 482.

Assemble engine.
Check function of DME; if necessary, readjust uniform mixture
distribution.
 4/29/2016 1/2

11 34 552 Removing and installing/replacing all

valves (N55)

Special tools required:

 11 4 481
 11 4 482

Necessary preliminary tasks:

 Remove cylinder head.
 Remove intermediate lever.
 Remove eccentric shaft.
 Remove intake camshaft.
 Remove exhaust camshaft.
 Remove rocker arm.
 Remove valve springs.
 Remove valve stem seals.

Arrangement:
1) Intake valve 5 mm dia.
2) Valve stem seal with lower spring cup
3) Valve spring
4) Upper spring cup
5) Valve keys
If the valves are to be reused, they must be placed in neat order
in special tool 11 4 481.

Arrangement:
1) Discharge valve 6 mm dia.
 4/29/2016 2/2

2) Valve stem seal with lower spring cup

3) Valve spring
4) Upper spring cup
5) Valve keys
If the valves are to be reused, they must be placed in neat order
in special tool 11 4 482.

Assemble engine.
Check function of Digital Engine Electronics; if necessary,
readjust uniform mixture distribution.
 4/30/2016 1/3

65 12 070 Removing and installing/replacing

amplifier (hi-fi system/Harman Kardon)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Note:
Comply with notes and notes on handling optical fibres.

Necessary preliminary tasks:

 Disconnect negative battery cable

Open flap (1) of luggage compartment wheel arch panel (2).

 4/30/2016 2/3

Release nut (2) and screw (3).

Pull out holder (1) including amplifier in direction of arrow.

Release screw (1).
Unfasten plug connection (2) and disconnect.
Pull amplifier (3) out of holder (4) in direction of arrow.

Replacement:
Lugs (1) must be correctly slid into guide (2).
Check that amplifier (3) is securely seated.
 4/30/2016 3/3

Replacement:
In Harman Kardon version, perform vehicle programming and
encoding.
 4/30/2016 1/3

65 12 075 Removing and installing/replacing

amplifier (with DVD changer/hifi
system/Harman Kardon)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Note:
Comply with notes and notes on handling optical fibres.

Necessary preliminary tasks:

 Disconnect negative battery cable
 Remove luggage compartment wheel arch panel on left.

Release screws (1) and nuts (2).

Remove and set aside DVD changer (3) with holder.
 4/30/2016 2/3

Pull out holder (1) including amplifier in direction of arrow.

Release screw (1).
Unfasten plug connection (2) and disconnect.
Pull amplifier (3) out of holder (4) in direction of arrow.

Installation note:
Lugs (1) must be correctly slid into guide (2).
Check that amplifier (3) is securely seated.
 4/30/2016 3/3

Replacement:
In Harman Kardon version, perform vehicle programming and
encoding.
 4/29/2016 1/10

13 53 310 Removing and installing/replacing an

injector (N55)

Special tools required:

 13 0 320
 00 9 170
 13 0 190
 13 0 280

It is of vital importance to adhere to the warnings on removing

the injectors!

Necessary preliminary tasks:

 Disconnect negative battery terminal (risk of fire due to
short-circuiting on dismantling).
 Remove ignition coil of corresponding cylinder.
 Disconnect pressure lines of corresponding cylinder.

Note:
The following description applies to all injectors in cylinders 1-6.

Unlock connector (1) from injectors and detach.

Slacken nut (2).
Tightening torque 12 90 5AZ.
Remove ground cable (3).
 4/29/2016 2/10

Important!
First, release screw (2). The, release screw (1).
Otherwise, the hold-down device may tilt.

Remove holding-down element (3).

Pull injectors upward out of cylinder head and remove.
Note:
If several injectors are removed, ensure that each injector is
reinstalled in its original location (cylinder).
Mark injectors.

Procedure in event of stuck injector:

Use special tool 13 0 320 to remove injectors that are stuck.
Lightly oil pull-out thread (1) and unscrew completely (see
graphic) before using the special tool.
Important!
Pull-out thread (1) is a left-hand thread!

Fit special tool (1) 13 0 320 on injector slot. Join screws (2) to

injector slot by a few threads. Screw in pull-out thread (4) until it
is possible to screw the threaded sleeves (3) onto the injectors.
Screw threaded sleeves (3) onto injectors and tighten down.
Tighten down screws (2).
 4/29/2016 3/10

Tightening torque 13 53 13AZ.

Important!
Set torque wrench (1) to 5 Nm clockwise rotation.
Together with special tool 13 0 320 this corresponds to a
tensile force of max. 2000 N. The injector must be
replaced if the torque wrench is activated when the
injector is pulled out!

Fit torque wrench (1) and special tool (2) 00 9 170 on hexagon

head (3) of special tool 13 0 320.
Turn torque wrench (1) in clockwise direction until the injector is
pulled out.

After removing, fit protective caps (1 and 2) to injector tip and

fuel line connection.
Installation note:
When installing a new injector:
 Replace decoupling element (3).

Installation note:
When reusing fuel injector:
 Replace decoupling element (1).
 Replace Teflon ring (2).
A Teflon ring that has already been installed once in the
cylinder head must be replaced before the injector is
 4/29/2016 4/10

reinstalled.

Replace Teflon ring:

Before replacing the Teflon ring (1), make sure your hands and
the work surface are clean and free of oil.
Avoid mechanical contact with injector tip (2).

Remove Teflon ring (2) using special tool (3) 13 0 191 from the

set of special tools 13 0 190 from the injector (1).
Use a fluff-free cloth only to remove combustion residues from
cylindrical part of injector tip (do not use ultrasound or other
tools/agents).
Do not clean injector tip.

Push new Teflon ring (1) onto installation cone (2) 13 0 283

from the set of special tools 13 0 280.
 4/29/2016 5/10

Mount Teflon ring (1) with installation cone (2) 13 0 283 onto

injector tip (3).
Note:
 Do not use fingernails to slide Teflon ring on.
 Do not use any lubricating agents.
 The sealing ring is expanded when slid on.

Using special tool (1) 13 0 281 from the set of special

tools 13 0 280 push Teflon ring into injector groove (3).

To bring the widened Teflon ring to installation size, push

special tool (1) 13 0 282 from the set of special tools 13 0 280
as far as it will go onto injector (2).
Do not use any lubricating agents.
 4/29/2016 6/10

Note:
Pull mounting tip (1) of special tool 13 0 282 towards rear to
release installation cone (2) 13 0 281.

Installing injector:

Before installing injector in engines that have been run:

Important!
Injectors must not be twisted to 6 Nm!
The injector must be replaced if this value is exceeded!

 Check injector bore for dirt.

 4/29/2016 7/10

Clean only dirty injector bores.

Important - do not damage injector!
 Clean injector bore: To do so, preferably slide injector
without decoupling element (1) but with new Teflon ring
(2) in and out of injector bores several times.
The Teflon ring must subsequently be replaced.
 Clean contact surfaces of decoupling elements (1) in
cylinder head.
 Replace decoupling element (1).

Important!
Injection quantity compensation!

An injector quantity compensation must be carried out if an

injector is replaced or changed on the cylinder side.
Injector quantity compensation is carried out with the aid of a
so-called adjustment value.
The adjustment value is printed in three digits on the injector
body.
The adjustment value must be read off before installation!

Enter the adjustment value according to the installation location

(cylinder) of the injector.
If injector quantity compensation is not carried out, the engine
may run roughly or fail to start.
Injection quantity compensation is described at the end of these
instructions.

Insert injectors in injector bores.

Fit special tool (1) 13 0 320 on injector slot. Join screws (2) to
injector slot by a few threads. Screw in the pull-out thread (4)
until the threaded sleeves (3) can be screwed onto the
injectors. Screw threaded sleeves (3) onto injectors and tighten
down.
 4/29/2016 8/10

Tighten down screws (2).

Tightening torque 13 53 13AZ.

Important!
Set torque wrench (1) to 2 Nm counterclockwise rotation.

Fit torque wrench (1) and special tool (2) 00 9 170 on hexagon

head (3) of special tool 13 0 320.
Turn torque wrench (1) in counterclockwise direction until 2 Nm
are reached.

Installation note:
Install hold-down device (1) with curvatures (black arrows)
downward.

Fit hold-down device (3) on injectors.

Fit screws (1) hand-tight.
Only fit the screw (2) loosely to prevent the hold-down device
from tilting.
 4/29/2016 9/10

Fit pressure lines with rubber mount (3) on injectors and rail.

Tighten nuts (1) and (2) manually only.

Firstly tighten screw (1).

Tightening torque 13 53 6AZ.
Then tighten down screw (2).
Tightening torque 13 53 6AZ.

Tighten down pressure lines on injectors (1).

Tightening torque 13 53 9AZ.
Then tighten down pressure lines (2) on the rail.
Tightening torque 13 53 9AZ.
Installation note:
Reinstall line damper (3).
 4/29/2016 10/10

Perform an injection quantity compensation:

The adjustment value is printed with three digits - depending on
the version - on the injector body.

- Connect BMW diagnosis system.

- Identify vehicle.

- Select ”Function selection.”

- Select ”Service functions.”

- Select ”Engine electronics.”

- Select ”Adjustment functions.”

- Select ”Adjust injectors.”

- Select ”Test plan”

- For each replaced injector, the adjustment value must be

entered according to the installation location (cylinder).

Clean spark plug slot.

Assemble engine.
Check fuel system for tightness.
Check function of DME.
 4/30/2016 1/2

66 20 515 Removing and installing/replacing an

ultrasonic converter at the front left (M
Aerodynamics package, PDC)

Necessary preliminary tasks:

 Remove front bumper panel

Note:
Diagram similar.

Unfasten plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.

Installation note:
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/2

66 20 516 Removing and installing/replacing an

ultrasonic converter at the front right (M
Aerodynamics package, PDC)

Necessary preliminary work:

 Remove front bumper panel

Note:
Diagram similar.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.

Installation note:
Before installation of ultrasonic sensor (2) on wiring harness,
clean plug connection!
Retaining hooks (1) of ultrasonic transducer (2) must engage
exactly in mountings (3).

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/1

52 26 030 Removing and installing/replacing

armrest for rear seat backrest (through-
loading facility)

Unlock right backrest and tilt forwards.

Release screw (1).
Tightening torque 52 26 02AZ.
Feed out centre armrest from left and right guides (2).
 4/30/2016 1/2

51 42 060 Removing and installing/replacing

armrest in rear door, left or right

Necessary preliminary tasks:

 Remove rear door handle
 Remove rocker switch for side window operation

 
Note:
Armrest is welded to door trim panel only on initial installation.
The armrest is screw-connected on second installation. If
applicable, release screws instead of welding spots.

Important!
Risk of damage!
To avoid damaging the contact surface, only drill down to
door trim panel area (2)

Drill out all welding spots in marked area (1) on door trim

panel (2) with 8 mm dia. welding spot drill bit.
Remove welding remains on door trim panel (2) with scalpel (for
heavy duty use).

Replacement:
Remove welding pins (1) on armrest (2) to dimension (A).
A= 2.0 ± 0.5 mm

Installation note:
Arm support:
 4/30/2016 2/2

- position against door trim panel (1)

- secure at front and rear with repair screw (2)

- align until bore holes (3) are centred

- tighten beginning in the middle

Tightening torque 51 42 4AZ.

Note:
If bore holes (3) were not drilled through, increase tightening
torque accordingly to ensure that arm rest is firmly seated.
 4/29/2016 1/2

17 11 150 Removing and installing/replacing

auxiliary radiator (N55)

Necessary preliminary work:

 Remove front section of wheel arch cover on left.

Warning!
Risk of scalding!
Only perform this repair work after engine has cooled
down.

Important!
Wear safety goggles and protective gloves.

Recycling:
Coolant emerges when coolant lines are detached. Catch
and dispose of escaping coolant in a suitable container.
Observe country-specific waste disposal regulations.
 4/29/2016 2/2

Detach coolant lines (1).

Catch and dispose of escaping coolant.
Release clip (2).
Removing auxiliary coolant cooler (3).

Installation note:
Check coolant hoses for damage.

Note:
After completion of repair work, check coolant level.
If necessary, add coolant.
Reassemble the vehicle.
 4/30/2016 1/1

67 31 530 Removing and installing/replacing

backrest adjustment motor

Necessary preliminary tasks:

 Remove covers on front seat

Unfasten plug connection (1) and disconnect.

Unfasten screws (2).
Remove electric motor (3).

Note:
Perform function check.

Replacement:
Initialise backrest adjustment motor.
 4/30/2016 1/1

52 26 011 Removing and installing/replacing

backrest for left rear seat

Necessary preliminary tasks:

 Remove armrest side section
 Unclip rear seat and lay down towards front

Release screw (1).
Installation note:
Replace screw (1).
Tightening torque 52 26 01AZ.

 Tilt backrest slightly forwards.

 Pull backrest forwards and outwards out of centre mount

Installation note:
The plastic bush (1) in the right backrest frame may slide during
removal of the left backrest.
Make sure plastic bush (1) is fitted correctly in the right backrest
frame.
The plastic bush (1) must be retained in the backrest frame.
If applicable, clip the plastic bush (1) in from the outside in.
 4/30/2016 1/1

52 26 012 Removing and installing/replacing

backrest for right rear seat

Necessary preliminary tasks:

 Remove armrest side section
 Unclip rear seat and lay down towards front

Release screw (1).
Installation note:
Replace screw (1).
Tightening torque 52 26 01AZ.

 Tilt backrest slightly forwards. 

 Pull backrest forwards and outwards out of centre mount

Installation note:
The plastic bush (1) may slide during removal of the right
backrest.
Make sure plastic bush (1) is fitted correctly in the right backrest
frame.
The plastic bush (1) must be retained in the backrest frame.
If applicable, clip the plastic bush (1) in from the outside in.
 4/30/2016 1/1

52 26 081 Removing and installing/replacing

backrest frame for centre rear seat

Necessary preliminary tasks: 

 Remove the centre backrest cover
 Remove middle rear seat backrest seat belt buckle

Release screws (1).
Remove the actuating unit (2).

Installation note:
Make sure unlocking rod (1) is correctly seated in the operating
unit.
 4/30/2016 1/3

52 13 030 Removing and installing/replacing

backrest frame on left or right front seat
(normal/manual)

Important!
When working on the front seat it is absolutely essential to
observe the safety regulations on handling airbag
modules.
Improper handling may trigger the side airbag and as a
result cause injuries.

Necessary preliminary work:

 Remove front seat
 Remove rear panel on front seat backrest

Cut open cable strap (1).

Press locks (2) outwards and at the same time remove
connector (3) in direction of arrow from connector housing (4).

Unclip airbag wiring harness (1) in marked area.

Release airbag wiring harness (1) from cable clips on seat
mechanism.
 4/30/2016 2/3

Version with seat heating only:

Unlock plug connection (1) and disconnect.
Unclip wiring harness (2) in marked area.
Release wiring harness (2) from cable clips on seat
mechanism.
Important!
Feed all the wiring harnesses carefully through the seat
and backrest mechanism as the edges of the frame can
be sharp.

Unhook backrest cover (1) on left and right.

Release screws (2) on left and right.
Tightening torque 52 10 02AZ.
Remove backrest frame (3) completely towards top.

Replacement:

- Remove backrest cover with upholstery

4/30/2016 3/3
 4/30/2016 1/2

52 26 008 Removing and installing/replacing

backrest side section on left or right rear
seat backrest

Pull seat belt to middle and place over head restraint.

Pull top backrest side section (1) forwards and pull out upwards
(2).

Press latch mechanism (2) to unlock the clip (1).

Pull clip (1) towards front out of the body.
If necessary, replace faulty clip (1).

Insert the clip (1) in the backrest side section (2).

Installation note:
Insert guides (1) from backrest side section into mountings.
4/30/2016 2/2
 4/30/2016 1/1

65 20 150 Removing and installing/replacing back-

up aerial

Necessary preliminary tasks:

 Remove backrest side section on left of rear seat backrest

Unfasten plug connection (1) and disconnect.

Slacken nut (2).
Remove backup aerial (3).
 4/30/2016 1/2

84 10 702 Removing and installing/replacing base

plate (with rear passenger compartment
fresh air grille)

Special tools required:

 00 9 327

Necessary preliminary tasks:

 Remove rear centre console cover
 Remove insert in centre armrest storage
compartment
 Remove decorative trim on centre console

Release centre console (1) at nuts (2).

Tightening torque 51 16 3AZ.
Release air duct (3) from bracket (4).
Lift centre console (1) slightly and pull air duct (3) out of centre
console (1) toward the rear.
Installation note:
Feed air duct (3) into centre console (1) and slide in about half
way (see next operation for further procedure).
After complete installation of air duct (3), check that it is
correctly seated in bracket (4).

Installation note:
Reach through openings in centre console (1) and feed air
duct (2) in toward the front.
Make sure air duct (2) is correctly seated in centre console (1).

Unlock and disconnect associated plug connections in area (A).

 4/30/2016 2/2

Unclip line (1) at centre console (2).

Reach under the base plate and unclip associated line (1) on
centre console.
Installation note:
Make sure plug connections are correctly seated.
Ensure correct cable routing.

Mount special tool 00 9 327 as illustrated.

Reach under base plate (1) from behind.
Carefully leverage out base plate (1) along marked line (A) and
simultaneously press lightly from below to disengage latch
mechanisms.
Remove base plate (1) and feed out line.

Note:
Centre console is shown removed for purposes of clarity.

Installation note:
Make sure line (1) is properly routed.
Catches (2) must not be damaged or missing.
Make sure base plate is correctly engaged on centre console.
 4/30/2016 1/2

84 10 700 Removing and installing/replacing base

plate

Special tools required:

 00 9 327

Necessary preliminary tasks:

 Remove rear centre console cover

Unlock and disconnect associated plug connections in area (A).

Unclip line (1) at centre console (2).
Reach under the base plate and unclip associated line (1) on
centre console.
Installation note:
Make sure plug connections are correctly seated.
Ensure correct cable routing.

Mount special tool 00 9 327 as illustrated.

Reach from rear under base plate (1).
Carefully leverage out base plate (1) along marked line (A) and
simultaneously press lightly from below to disengage latch
mechanisms.
Remove base plate (1) and feed out line.

Note:
Centre console is shown removed for purposes of clarity.

Installation note:
Make sure line (1) is properly routed.
Catches (2) must not be damaged or missing.
 4/30/2016 2/2

Make sure base plate is correctly engaged on centre console.

 4/29/2016 1/2

34 11 220 Removing and installing/replacing both

front brake discs (Brembo)

Special tools required:

 34 1 280

Necessary preliminary tasks:

 Remove wheels.
 Remove and clean brake pads.

Check minimum brake disc thickness:

- Position special tool 34 1 280 at three measuring points in

area (1) and measure.

- Compare measuring result and lowest value with setpoint

value.
If the brake discs are replaced, you must also fit new brake
pads.
Brake discs may only be replaced in pairs (on each axle).

Important!
New brake pads may only be fitted if the brake disc
thickness is greater than the minimum brake disc
thickness (MIN TH).

Release screws (1), remove brake caliper (2) towards rear and

tie up.
Installation note:
Tightening torque 34 11 2AZ.
 4/29/2016 2/2

Important!
To release brake disc: Do not under any circumstances
strike friction ring with a hammer or similar!
If necessary, carefully tap on base of brake disc chamber
with a rubber mallet.
Clean contact surface of brake disc at wheel hub
thoroughly and remove traces of corrosion.
Unevenness on contact surface may result in distortion of
brake disc!

Release screw (1) and remove brake disc (2).

Installation note:
Replace screw.
Tightening torque 34 11 1AZ.

After installation:
 Read and comply with notes on braking in new brake
discs / brake pads.
 4/29/2016 1/2

34 11 220 Removing and installing/replacing both

front brake discs

Special tools required:

 34 1 280

Necessary preliminary tasks:

 Remove wheels.
 Remove and clean brake pads.

Check minimum brake disc thickness:

- Position special tool 34 1 280 at three measuring points in

area (1) and measure.

- Compare measuring result and lowest value with setpoint

value.
If the brake discs are replaced, you must also fit new brake
pads.
Brake discs may only be replaced in pairs (on each axle).

Important!
New brake pads may only be fitted if the brake disc
thickness is greater than the minimum brake disc
thickness (MIN TH).

Release screws (1) and remove brake anchor plate (2) to the
rear.
Installation note:
Tightening torque 34 11 2AZ.
 4/29/2016 2/2

Important!
To release brake disc: Do not under any circumstances
strike friction ring with a hammer or similar!
If necessary, carefully tap on base of brake disc chamber
with a rubber mallet.
Clean contact surface of brake disc at wheel hub
thoroughly and remove traces of corrosion.
Unevenness on contact surface may result in distortion of
brake disc!

Release screw (1) and remove brake disc (2).

Installation note:
Replace screw.
Tightening torque 34 11 1AZ.

After installation:
 Read and comply with notes on braking in new brake
discs / brake pads.
 4/30/2016 1/2

61 31 221 Removing and installing/replacing both

multifunction steering wheel switches (M
sports steering wheel)

Necessary preliminary tasks:

 Remove airbag unit

Release screws (1) on steering wheel.

Release screw (2) on rear side of steering wheel.
Remove design cover.
Installation note:
Make sure design cover is correctly seated.

Note:
Steering wheel is shown removed for purposes of clarity.
Both multifunction steering wheel switches are connected to
each other by wiring harness (2).

Release screws (1) for shift paddles.

Feed out wiring harness (2) and disconnect plug connection (3).
Installation note:
Make sure electrical wiring is correctly routed.

Note:
Steering wheel is shown removed for purposes of clarity.
 4/30/2016 2/2

Lift off shift paddles and release screws (1) on rear side of

steering wheel.
Remove both multifunction steering wheel switches with wiring
harness on front side of steering wheel.
Installation note:
Make sure electrical wiring is correctly routed.
Make sure shift paddles are correctly seated.
Make sure multifunction steering wheel switches are correctly
seated.
 4/30/2016 1/1

61 31 221 Removing and installing/replacing both

multifunction steering wheel switches

Necessary preliminary tasks:

 Remove airbag unit

Release screws (1) on left/right on back of steering wheel (2).

Disconnect plug connection (1).

Remove both multifunction steering wheel switches (2) together
with cover from steering wheel in direction of arrow.
Installation note:
Make sure multifunction steering wheel switch (2) is fitted
correctly.
Make sure electrical wiring (3) is correctly routed.

Remove switch of multifunction steering wheel (1) from

cover (2).
Installation note:
Make sure electrical wiring is correctly routed.
 4/29/2016 1/6

34 21 200 Removing and installing/replacing both

rear brake pads of disc brake

Special tools required:

 34 1 050
 34 1 280

Important!
 Brake pad wear sensor: after removal it must be
replaced (brake pad wear sensor loses its retention
capability in the break pad).
 Retaining pins and expanding spring: for vehicles
older than 48 months it is recommended to replace
the retaining spring!
So as not to damage the surface coating, if possible do
not mechanically clean the guide surfaces for the brake
pads on the brake caliper mounting bracket. Instead, clean
with brake cleaner BMW part no. 83 19 2 154 780 and
apply a thin coating of brake pad paste BMW part no. 83
19 2 158 851 (3 g) or 83 19 2 158 852 (100 g).
Spread brake pad paste onto the marked surfaces using a
brush!
Observe guideline for applying brake pad paste on brake
pads and brake anchor plate!

Necessary preliminary tasks:

 Remove wheels.
 Remove brake pad wear sensor.

Lift out retaining spring (1).

 4/29/2016 2/6

Remove cover plug (1).

Important!
Tie brake caliper back and do not allow to hang from
brake hose.

Unscrew guide bolts (1).

Remove brake caliper (2) by pulling forward.
Installation note:
Tightening torque 34 21 4AZ.
Clean guide screws only; do not grease.
Check thread.
Replace all guide screws which are not in perfect condition.

Installation note:
During the placement of the brake caliper, it is absolutely
necessary to ensure that the brake pad T-heads (1) of the outer
brake pad is placed correctly onto the contact surface (2).
 4/29/2016 3/6

Important!
The position of the outer brake pad in relation to the
contact surface (2) must especially be ensured with brake
pads that are already partially worn!

Remove outer brake pad.

Inner brake pad is located with its spring in the piston.
Important!
Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change
brake pads round.

Clean brake pads.

Do not grease backs of brake pads sleeve.

Important!
When pressing down piston, note brake fluid level in
expansion tank.
Overflowing brake fluid will damage the paintwork.

Turn piston back fully with special tool 34 1 050.

Check minimum brake disc thickness:

- Position special tool 34 1 280 at three measuring points in

area (1) and measure.

- Compare measuring result and lowest value with setpoint

value.
 4/29/2016 4/6

Important!
New brake pads may only be fitted if the brake disc
thickness is greater than the minimum brake disc
thickness (MIN TH).

Check dust boot for damage and renew if necessary.

Clean contact surface (1) of brake piston with brake cleaner
and apply a thin coating of brake pad paste.
Important!
Dust boot must not come into contact with brake pad
paste as this may cause the dust boot to swell.

Clean contact surfaces (1) of brake pad T-heads/brake caliper

housing with brake cleaner and apply a thin coating of brake
pad paste.
 4/29/2016 5/6

Clean contact surface (1) of brake caliper with brake cleaner

and apply a thin coating of brake pad paste.

So as not to damage the surface coating, if possible do not

mechanically clean the guide surfaces (1) for the brake pads on
the brake caliper mounting bracket. Clean guide surfaces (1
and 2) with brake cleaner and apply a thin coating of brake pad
paste.

So as not to damage the surface coating, if possible do not

mechanically clean the guide surfaces (1 and 2) for the brake
pads on the brake caliper mounting bracket. Clean guide
surfaces (1 and 2) with brake cleaner and apply a thin coating
of brake pad paste.

Apply a thin coating of brake pad paste to T-head of inner brake

pad in area (1) and (2).
 4/29/2016 6/6

Apply a thin coating of brake pad paste to T-head of outer brake

pad in area (1) and (2).

Note:
After completing repair work:

- Fully depress brake pedal several times so that

brake pads contact brake discs.

- When installing new brake pads at front and rear

axles, brake fluid level must be brought up to ”MAX”
marking.

- Read and comply with notes on braking in new

brake discs / brake pads.

- When replacing pads, reset CBS display in

accordance with factory specification.
 4/29/2016 1/3

11 36 655 Removing and installing/replacing both

solenoid valves (N55)

Important!
On removing and installing the VANOS solenoid valve
(intake) and VANOS solenoid valve (exhaust), adhere to
conditions of absolute cleanliness.
Possible malfunction if there is dirt contamination in the
valves:
 Irregular operation
 OBD fault entry
 Exhaust gas emission characteristics.
 Low engine performance

Necessary preliminary tasks:

 Remove ignition coil cover.

Disconnect plug connection (1) on VANOS intake solenoid

valve.
Disconnect plug connection (2) on VANOS exhaust solenoid
valve.

Release screw (2).
Remove VANOS intake solenoid valve (1) with holder towards
 4/29/2016 2/3

the front.
Release screw (3).
Move VANOS exhaust solenoid valve (4) with holder approx.
10 millimetres towards the front
Tightening torque 11 36 3AZ.

Turn the VANOS exhaust solenoid valve (1) approx. 90° in

direction of arrow until it can be removed from the front on
engine wiring harness.

Remove O-ring (2).
Remove support ring (1).
Installation note:
Replace support and O-rings.

Assemble engine.
Check function of Digital Engine Electronics.
4/29/2016 3/3
 4/30/2016 1/1

61 61 100 Removing and installing/replacing both

windscreen wiper arms

Special tools required:

 61 6 060

Important!
After installation check setting dimension and contact
angle of the wiper arm.

Remove protective cap (1).

Release nut underneath.
Tightening torque 61 61 2AZ.

Important!
Risk of breakage!
Do not bend wiper arm when removing.

 
Detach windscreen wiper arm with special tool 61 6 060.
 4/30/2016 1/1

51 21 235 Removing and installing/replacing

Bowden cable for inside door opener on
left or right front door

Necessary preliminary tasks:

 Remove front door trim panel

Note:
Graphic is similar.

Lever out lock (1)

Pull off Bowden cable housing (2) towards rear/top - the
Bowden cable feeds out of its own accord in the process.

Installation note:
To install the Bowden cable, press inner door handle (1) in
direction of arrow.
 4/30/2016 1/1

51 22 235 Removing and installing/replacing

Bowden cable for inside door opener on
left or right rear door

Necessary preliminary tasks:

 Remove rear door trim panel

Note:
Graphic is similar.

Lever out lock (1)

Pull off Bowden cable housing (2) towards rear/top - the
Bowden cable feeds out of its own accord in the process.

Installation note:
To install the Bowden cable, press inner door handle (1) in
direction of arrow.
 4/29/2016 1/4

34 11 000 Removing and installing/replacing brake

pads on both front disc brakes (Brembo)

Special tools required:

 34 1 050
 34 1 280

Important!
 Brake pad wear sensor: after removal it must be
replaced (brake pad wear sensor loses its retention
capability in the break pad).
 Retaining pins and expanding spring: for vehicles
older than 48 months it is recommended to replace
the retaining spring!
So as not to damage the surface coating, if possible do
not mechanically clean the guide surfaces for the brake
pads on the brake caliper mounting bracket. Instead, clean
with brake cleaner BMW part no. 83 19 2 154 780 and
apply a thin coating of brake pad paste BMW part no. 83
19 2 158 851 (3 g) or 83 19 2 158 852 (100 g).
Spread brake pad paste onto the marked surfaces using a
brush!
Observe guideline for applying brake pad paste on brake
pads and brake anchor plate!

Necessary preliminary tasks:

 Remove front wheels.
 Remove brake pad wear sensor.

Pull brake pad wear sensor (1) forward out of the brake pad
(left side only when replacing brake pads).
Drive out retaining pins (2).
Remove expanding spring (3).
Remove brake pads (4).
Installation note:
The following installation sequence must be followed.
 4/29/2016 2/4

- Install new brake pads.

- Align brake pads with the retaining pins in the brake

caliper.

- Fully depress brake pedal several times so that brake

pads contact brake discs.

- Fit retaining pins and expanding spring.

Important!
Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change
brake pads round.
Do not grease backs of brake pads sleeve.

Clean brake pads.

Check minimum brake disc thickness:

- Position special tool 34 1 280 at three measuring points in

area (1) and measure.

- Compare measuring result and lowest value with setpoint

value.

Important!
New brake pads may only be fitted if the brake disc
thickness is greater than the minimum brake disc
thickness (MIN TH).

Press brake piston fully back with special tool 34 1 050.

Important!
When pressing piston back, note brake fluid level in
expansion tank.
Overflowing brake fluid will damage the paintwork.
 4/29/2016 3/4

Check dust boot for damage and renew if necessary.

Clean contact surface (1) of brake piston with brake cleaner
and apply a thin coating of brake pad paste.
So as not to damage the surface coating, if possible do not
mechanically clean the guide surfaces (2) for the brake pads on
the brake caliper mounting bracket. Clean guide surface (2)
with brake cleaner and apply a thin coating of brake pad paste.
Clean both inner and outer guide surfaces (2) and apply a thin
coating of brake pad paste.

Lightly coat both sides of the contact surface in area (1 and 2)

with brake pad paste.

Lightly coat the brake pad contact surface on both sides in area
(1) with brake pad paste.
 4/29/2016 4/4

Note:
After completing repair work:

- Fully depress brake pedal several times so that

brake pads contact brake discs.

- When installing new brake pads at front and rear

axles, brake fluid level must be brought up to ”MAX”
marking.

- Read and comply with notes on braking in new

brake discs / brake pads.

- If necessary, when replacing pads, reset CBS

display in accordance with factory specification.
 4/29/2016 1/6

34 11 000 Removing and installing/replacing brake

pads on both front disc brakes

Special tools required:

 34 1 050
 34 1 280

Important!
 Brake pad wear sensor: after removal it must be
replaced (brake pad wear sensor loses its retention
capability in the break pad).
 Retaining pins and expanding spring: for vehicles
older than 48 months it is recommended to replace
the retaining spring!
So as not to damage the surface coating, if possible do
not mechanically clean the guide surfaces for the brake
pads on the brake caliper mounting bracket. Instead, clean
with brake cleaner BMW part no. 83 19 2 154 780 and
apply a thin coating of brake pad paste BMW part no. 83
19 2 158 851 (3 g) or 83 19 2 158 852 (100 g).
Spread brake pad paste onto the marked surfaces using a
brush!
Observe regulation on applying brake pad paste to brake
pads and brake anchor plates!

Necessary preliminary tasks:

 Remove wheels.
 Remove brake pad wear sensor.

Lift out retaining spring (1).

 4/29/2016 2/6

Remove plastic plugs (1).

Unfasten guide bolts (1) and lift out brake caliper towards rear
of vehicle.
Installation note:
Tightening torque 34 11 4AZ.
Clean guide screws only; do not grease.
Check threads.
Replace all guide screws which are not in perfect condition.

Important!
Tie brake caliper back and do not allow to hang from
brake hose.

Installation note:
When placing the brake caliper, it is absolutely necessary to
make sure that the brake pad T-head (1) of the outer brake pad
is correctly placed onto the contact surface (2).
 4/29/2016 3/6

Important!
The position of the outer brake pad in relation to the
contact surface (2) must especially be ensured with brake
pads that are already partially worn!

Remove outer brake pad.

Inner brake pad is located with its spring in the piston.
Important!
Mark any worn brake pads.
In the event of one-sided brake pad wear, do not change
brake pads round.

Observe minimum thickness of brake pads.

Clean brake pads.
Do not grease backs of brake pads sleeve.

Check minimum brake disc thickness:

- Position special tool 34 1 280 at three measuring points in

area (1) and measure.

- Compare measuring result and lowest value with setpoint

value.

Important!
New brake pads may only be fitted if the brake disc
thickness is greater than the minimum brake disc
thickness (MIN TH).
 4/29/2016 4/6

Important!
When pressing down piston, note brake fluid level in
expansion tank.
Overflowing brake fluid will damage the paintwork.

Turn piston back fully with special tool 34 1 050.

Check dust boot for damage and renew if necessary.

Clean contact surface (1) of brake piston with brake cleaner
and apply a thin coating of brake pad paste.
Important!
Dust boot must not come into contact with brake pad
paste as this may cause the dust boot to swell.

Clean contact surface (1) of brake pad T-heads/brake caliper

housing with brake cleaner and apply a thin coating of brake
pad paste.

Clean contact surface (1) of brake pads with brake cleaner and

apply a thin coating of brake pad paste.
 4/29/2016 5/6

So as not to damage the surface coating, if possible do not

mechanically clean the guide surfaces (1) for the brake pads on
the brake caliper mounting bracket. Clean guide surfaces (1
and 2) with brake cleaner and apply a thin coating of brake pad
paste.

So as not to damage the surface coating, if possible do not

mechanically clean the guide surfaces (1 and 2) for the brake
pads on the brake caliper mounting bracket. Clean guide
surfaces (1 and 2) with brake cleaner and apply a thin coating
of brake pad paste.

Apply a thin coating of brake pad paste to T-head of inner brake

pad in area (1) and (2).
 4/29/2016 6/6

Apply a thin coating of brake pad paste to T-head of outer brake

pad in area (1) and (2).

Note:
After completing work:

- When installing new brake pads at front and rear axles,

brake fluid level must be brought up to ”MAX” mark.

- Fully depress brake pedal several times so that brake

pads contact brake discs.

- Read and comply with notes on braking in new brake

discs / brake pads.

- When replacing pads, reset CBS display in accordance

with factory specification.
 4/30/2016 1/1

61 35 975 Removing and installing/replacing

bumper aerial for Comfort Access

Necessary preliminary tasks:

 Remove rear bumper panel

Disconnect plug connection (1).

Unlock bumper aerial for Comfort Access (2) from bracket (3)
and remove.
 
Installation note:
Ensure that the bumper aerial for Comfort Access (2) is
correctly seated in the designated holder (3).
 4/30/2016 1/1

51 24 146 Removing and installing/replacing button

for rear lid actuation

Necessary preliminary work:

 Remove trim for rear lid

Release and disconnect plug connection (1) at microswitch.

Slacken screws (2) until circlip (3) can be twisted.
Tightening torque 51 24 3AZ.
Turn circlip (3) in the direction of arrow and remove.

Remove button (1) from tailgate (2) in direction of arrow.

Installation note:
Make sure button (1) is correctly aligned.
Perform function check with tailgate open.
 

Replacement:
Install  BMW badge.
 4/30/2016 1/2

66 51 030 Removing and installing/replacing

camera for Lane Departure Warning

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Expand two-part mirror base cover (1) by pressing from below

and detach.
Feed out two-part mirror base cover (1) and remove.
Note:
Latch mechanisms of two-part mirror base cover (1) must not
be damaged.

Disconnect plug connection (1).

Unclip cable in marked area.
Unlock retaining claps (2) and remove camera (3) in direction of
arrow.

Installation note:
Guides (2) on camera (1) must be correctly inserted in counter
supports on windscreen!
Make sure camera (1) is securely seated.

Replacement:
Carry out calibration via BMW diagnosis system:
Service functions:
 Body
 4/30/2016 2/2

 Lane departure warning

 Calibrate camera

Note:
Heating of camera for lane departure warning is integrated in
windscreen.
If heating is defective, the windscreen must be replaced!
 4/30/2016 1/2

64 53 551 Removing and installing/replacing

capacitor (with desiccant insert) for
heating and air conditioning system

Special tools required:

 00 9 030

Warning!
Danger of injury!
Refrigerant circuit is under high pressure!
Avoid contact with refrigerant and refrigerant fluid.
Read and comply with safety information:
 Handling R 134a tetrafluorethane refrigerant
 Handling refrigerant fluid

Important!
Risk of damage!
Restart engine only when air conditioning system has
been correctly filled.
Follow instructions for opening and replacing parts in
refrigerant circuit!

Note:
Desiccant insert cannot be replaced separately.

Necessary preliminary tasks:

 Drain off air conditioning system
 Remove radiator
 4/30/2016 2/2

Release screws (1).
Pull out refrigerant lines (2) from condenser (3) and set aside.
Tightening torque 64 53 3AZ.
Release screw (4).
Remove condenser (3) in direction of arrow.
Installation note:
The fins on the radiator and condenser should not be damaged.
Replace sealing rings.
Use special tool 00 9 030 to install sealing rings without
damaging them.

After installation:
 Evacuate and fill heating and air conditioning system
 4/30/2016 1/3

51 45 075 Removing and installing/replacing

carrier for instrument panel

Necessary preliminary tasks:

 Remove instrument panel trim
 Detach steering column from dashboard carrier
 Detach plug connections on airbag control unit
 Unclip power distribution box at front
US version:
 Disconnect plug connection from driver's knee
protection airbag module

Unfasten plug connection (1) and disconnect.

Feed out wiring harness (2) towards passenger compartment.

Undo bolts (1) on bulkhead.

Tightening torque 51 45 4AZ.

Unlock and detach plug connections (1 and 2).

Feed out cable (3).
 4/30/2016 2/3

Release nuts (1) and remove holder (2).

Tightening torque 51 45 3AZ.
Unscrew nut (3).
Tightening torque 51 45 5AZ.
Installation note:
Instead of nuts (3) threaded bolts can come loose from heating and air-conditioning unit. Before installing the
carrier, screw threaded bolts into the heating and air-conditioning unit.
Release nuts (4) on A-pillar.
Tightening torque 51 45 2AZ
Release screw (5) by approx. 2 turns.
 4/30/2016 3/3

Tightening torque 51 45 1AZ.

Carefully pull carrier (6) forwards, paying attention to further cable clips.
Remove carrier (6).

Installation note:
Replace compensating element (1) every time after dismantling
the support.
Fully screw in installation plate (2). When applying tightening
force to the screw, installation plate (2) is automatically
adjusted.
Make sure foam ring (3) is fitted correctly.

Replacement:
Remount airbag control unit (1).
Remount wiring harness (2).
Remount non-existing retaining brackets on the new part if
necessary.
US version:
Remove airbag module for driver's knee protection
 4/29/2016 1/3

REP-REP-RAF3018N55-1832050   Removing and installing/replacing catalytic converter (N55)

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

18 32 050 Removing and installing/replacing

catalytic converter (N55)

Warning!
Risk of burning!
Only perform this repair work after the exhaust system has
cooled down.

Necessary preliminary work:

 Remove front underbody protection.
 Remove rear underbody protection.
 Remove exhaust system.
 Expose monitoring sensor cable.
 Four-wheel drive vehicles only:
Remove reinforcement plate.

Note:
The oxygen sensor is in danger of being damaged when the
catalytic converter is removed and installed.
Remove the control sensor.
 4/29/2016 2/3

Release nuts (1).

Tightening torque 18 20 1AZ.

Release clamp (1). The clamp must be renewed every time it is

removed.
Tightening torque 18 31 2AZ.
In so doing, secure catalytic converter against falling out.
Feed out catalytic converter and remove.
Installation note:
Clean sealing surface. Renew clamp and seal.

Modify monitoring sensor when replacing the catalytic

converter.
Reassemble the vehicle.
Check exhaust system for leaks.
4/29/2016 3/3
 4/30/2016 1/2

65 11 070 Removing and installing/replacing CD

changer

Necessary preliminary tasks:

 Disconnect battery earth lead

Note:
Follow instructions for handling optical fibres.

Open flap (1) of luggage compartment wheel arch panel (2).

Release screws (1) at marked points.

Pull the CD changer (2) out toward the front.

Unlock and disconnect plug connection (1) of the CD

changer (2).
 4/30/2016 2/2

Replacement:
Release screws (1) at left and right and remove retaining
bracket (2) of CD changer.
 4/30/2016 1/2

65 50 057 Removing and installing/replacing

Central Information Display (CID)

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove centre fresh air grille

Release screws (1).
Tightening torque 65 50 1AZ.
Remove CID (2) towards top.

Unlock plug connection and disconnect.

Remove CID (1).

Replacement:
Carry out vehicle programming/coding.

Note:
 4/30/2016 2/2

In the case of replacement of 6.5" central information

display in vehicles with production date up to
07/2013Entry Head Unit must be updated.
 4/30/2016 1/1

51 16 206 Removing and installing/replacing centre

armrest

Necessary preliminary work:

 Move both front seats forwards
 Remove rear centre console trim

Note:
Open the centre armrest, because the spring (1) will otherwise
be under too much tension.

Detach the spring (1) with the screwdriver (2).

Installation note:
Make sure the spring (1) is correctly seated.

Drive the hinge axes (1) out.

Note:
The hinge axes (1) are secured with gearing (3) on the outside.

Remove the spring (2), open the centre armrest and feed out of
storage compartment.
 4/30/2016 1/2

51 16 160 Removing and installing/replacing centre

console cover

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Necessary preliminary tasks:

 Remove decorative trim on centre console
Manual gearbox only:
 Remove gaiter
With automatic transmission only:
 Remove cover for preselector lever

Release cover (1) at latch mechanisms (2) and clamps (3).

Slightly raise the cover (1) and disconnect associated plug
connection.
Feed out cover (1) toward the top / rear.

Installation note:
The following parts must not be damaged or missing:

- Guides (1)
 4/30/2016 2/2

- Latch mechanisms (2)

- Clamps (3)
 
Replacement:
Convert the operating unit (4).
 4/30/2016 1/2

63 31 165 Removing and installing/replacing centre

console LED

Special tools required:

 00 9 325

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Necessary preliminary tasks:

 Partially remove radio and IHKA controls

Note:
For clarification, the radio and A/C operating units are shown
removed.
 4/30/2016 2/2

Loosen cover (1) at marked points with special tool 00 9 325

from clamps.
Disconnect plug connection to LED and remove cover (1).

Installation note:
Clamps (1) and retaining lugs (2) must not be damaged or
missing.

Lever out latch (1) and pull out LED (2) in direction of arrow.

Installation note:
Latch mechanism (1) must not be damaged or missing.
Make sure LED (2) is correctly seated.
 4/30/2016 1/1

64 22 165 Removing and installing/replacing centre

fresh air grille

Special tools required:

 00 9 327

First unclip the fresh air grille (1) at the top using special
tool 00 9 327 and then remove to the front.
Unlock and disconnect plug connections behind.

Important!
Risk of damage!

Installation note:
The fresh air grille (1) must first be correctly
engaged at the top on the dashboard!
Only afterwards, lock the bottom clamps.
After installation, ensure that the fresh air
grille (1) is properly seated.

Clamps at marked points of fresh air grille (1) must be neither

damaged nor bent.
Replace clamps if necessary.

Replacement:
Modify switch for hazard warning flashers/central locking
system
 4/29/2016 1/2

17 51 000 Removing and installing/replacing

charge air cooler (N20, N26, N55)

Necessary preliminary tasks:

 Remove fan cowl.
 Remove underbody protection

Important!
Coat sealing rings of snap fasteners with lubricant.
Pressure pipes cannot be fitted without lubricant.

Unlock the left and right pressure pipes on the charge air
cooler, pull them off and then set them aside.
Release screws (1).
Tightening torque 17 10 3AZ.
Detach the charge air cooler from the left and right of the
module carrier (2).
Remove charge air cooler (3) towards bottom.

Check the gaskets (1) and (2) on the charge air cooler and

replace damaged gaskets.
 4/29/2016 2/2

Installation note:
When installing the charge air cooler, make sure that the
sealing lip (1) of the charge air cooler is installed above the
sealing lip (2) of the bumper panel.
If applicable, mount the sealing lips with a screwdriver (3).

Reassemble the vehicle.

 4/30/2016 1/4

21 52 500 Removing and installing/replacing clutch

master cylinder

Note:
After completing repair work, bleed clutch hydraulic
system.

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism.

Turn locks (1) 90° counterclockwise.

Unlock latch mechanism (2).
Remove cover (3).

Draw off brake fluid up to supply hose of clutch hydraulic

system (1).

- For this purpose, use only a vacuum pipe that is

 4/30/2016 2/4

exclusively used for removing brake fluid.

Detach supply hose (1) from expansion tank.
Note:
Graphic similar.

Remove retainer (1).

Installation note:
Check retainer (1), replace if necessary.
Both shanks of retainer (1) must rest in groove of bolts (2) and
engage audibly.

Slide out bolt (2).

Installation note:
Lightly grease bolt (2).

Remove over-centre helper spring.

Release screws (1) on clutch master cylinder (2).

Tightening torque 21 52 2AZ.

Disconnect return spring (1).

Detach retaining clip (3) and pull clutch pedal with clutch master
cylinder off bearing support.
Press bolt ends (2) together and remove pin.
Installation note:
 4/30/2016 3/4

Replace retaining clip and bolt.

The retaining clip must be seated with both shanks in the pin
groove.

Detach clamp (1) with a screwdriver (2).

Important!
Protect the carpet with suitable agents from contamination
with brake fluid.

Detach hydraulic line from clutch master cylinder (3).

Detach supply hose (1) from clutch master cylinder.

Important!
Do not pull supply hose completely into interior.

Lever clutch switch (1) out of clutch master cylinder  (2) with a

screwdriver.
Release plug connection (3) and disconnect connector (4) from
clutch switch (1).
 4/30/2016 4/4

Installation note:
The clutch switch is protected from incorrect installation.
The clutch switch must snap audibly into place.
 4/30/2016 1/3

21 52 510 Removing and installing/replacing clutch

slave cylinder (plastic)

Special tools required:

 13 3 010

Note:
After completing work bleed clutch hydraulic system.

Seal hydraulic line to clutch slave cylinder with special tool

 13 3 010.

Release nuts or screws and remove clutch slave cylinder (1)

with holder (2).
Installation note:
Replace self-locking nuts.
Tightening torque 21 52 1AZ.
 4/30/2016 2/3

Unlock spring clamp (1).

Disconnect hydraulic line (2).

Press cylinder together by hand.

Connect hydraulic line with cylinder pressed.

Remove special tool  13 3 010.

Hold cylinder piston vertically downwards.
Press piston 5 times into cylinder.

Press in piston until it engages.

Install clutch slave cylinder.
Bleed clutch hydraulic system.
Installation note:
Clean thrust member (1) and contact surface on release
lever.
 4/30/2016 3/3

Lightly grease thrust member (1) on contact surface (2).

Grease, refer to BMW Service Operating Fluids.
 4/30/2016 1/1

61 31 299 Removing and installing/replacing clutch

switch module

Necessary preliminary work:

 Remove trim panel for pedal mechanism.

Note:
For purposes of clarity, clutch master cylinder (2) is shown
removed.

Lever out clutch switch module (1) from clutch master

cylinder (2) with screwdriver.
Unlock plug (4) and disconnect from housing (3).

Installation note:
Clutch switch module is secured against incorrect installation.
Clutch switch module must snap audibly into place.
 4/30/2016 1/2

84 10 800 Removing and installing/replacing

Combobox

Important!
Read and comply with notes on protection against
electrical damage (ESD protection).

Comply with notes and instructions on handling optical fibre.

Necessary preliminary tasks:

 Disconnect battery earth lead

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.
 
Remove luggage compartment floor trim panel (1) in direction of
arrow.

Unlock plug connections (1) and disconnect.

Unscrew nuts (2).
Tightening torque 84 10 1AZ.
Remove Combox (3).
Installation note:
Note colour coding of plug connection.
 4/30/2016 2/2

Replacement:
 Carry out vehicle programming/encoding
 4/30/2016 1/3

51 16 165 Removing and installing/replacing

complete centre console

Special tools required:

 2 298 504

Necessary preliminary tasks:

 Remove front storage compartment
 Remove rear centre console cover
 Remove trim panel for pedal assembly
 Remove trim for instrument panel at bottom right
 Loosen the gaiter for the parking brake lever from
the centre console
With automatic transmission only:
 Remove gear selector switch

Important!
Read and comply with notes on handling wiring harnesses
and cables.

Unscrew nuts (1).

Tightening torque 51 16 3AZ.
 4/30/2016 2/3

Disconnect plug connections (2), depending on version.

Release screws (1).
Tightening torque 51 16 4AZ.
Unfasten screws (2).
Tightening torque 51 16 3AZ.
Detach wiring harness (3) from central console mount using
special tool 2 298 504.

Raise the centre console (1) rear and feed out gaiter (2).

Remove centre console (1) to the rear/top.
If applicable, note other plug connections and cable clips.
Installation note:
Feed centre console (1) correctly into dashboard including
guides (4).
Make sure wiring harness (3) is in correct position.

Replacement (depending on version):

- Modify air ducts (1)

- Modify retaining bracket (2)

- Change over centre armrest.

 4/30/2016 3/3

- Modify knee pad

- Modify insert in storage compartment

- Modify base plate for telephone

 4/30/2016 1/2

63 31 000 Removing and installing/replacing

complete interior roof light (front)

Special tools required:

 00 9 325

Important!
Follow instructions for handling light bulbs (interior
lighting).

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

Only version with roof switch cluster:
 Remove roof switch cluster

For interior roof light equipment:

Carefully lever out interior roof light (1) with special
tool 00 9 325 in direction of arrow.
Unlock and disconnect associated plug connection, remove
interior roof light (1).
Installation note:
Make sure interior roof light (1) is correctly seated.

For roof switch cluster equipment:

Release interior roof light (1) at clamps (2) and feed out of roof
switch cluster (3).
 
Installation note:
Clips (2) must not be missing or damaged.
 4/30/2016 2/2

Make sure interior roof light (1) is correctly seated in roof switch

cluster (3).

Replacement:
 If necessary, convert bulb.
 Note bulb type
 4/30/2016 1/1

63 31 003 Removing and installing/replacing

complete interior roof light (rear)

Special tools required:

 00 9 325

Important!
Follow instructions for handling light bulbs (interior
lighting).

Carefully lever out interior roof light (1) with special

tool 00 9 325 in direction of arrow.
Unlock and disconnect associated plug connection, remove
interior roof light (1).

Replacement:
 If necessary, convert bulb.
 Note bulb type
 4/30/2016 1/2

51 21 140 Removing and installing/replacing

complete lock barrel in left or right front
door

Lever out cap (1) and release screw underneath.

Installation note:
If necessary, replace faulty trim (1).

Insert ignition key into lock barrel.

Turn ignition key slightly and pull off cover (1) in direction of
arrow with outside door handle (2) opened slightly.
 
Installation note:
Lock barrel must be correctly seated in support for outer door
handle.
Check function of lock barrel.

Version with light package:

Installation note:
Make sure outside door handle light (1) is correctly positioned in
area (2).
Guides (3) of outside door handle light (1) must be correctly
seated in support for outer door handle (4).

Replacement:
Remove latch mechanisms (1) and detach cover (2) from lock
 4/30/2016 2/2

barrel (3).
 
Installation note:
Latch mechanisms (1) of cover (2) must not be damaged or
missing.
Gear (4) of lock barrel (3) must not be damaged.
 4/30/2016 1/1

51 37 000 Removing and installing/replacing

complete rear left or right power window
regulator

Necessary preliminary work:

 Release door window at rear

Note:
Disengage, but do not remove, the door window and secure in
the door window frame.

Unlock plug connection (1) and disconnect.

Release nuts (2) and feed out power window regulator (3).
Tightening torque 51 35 2AZ.
 
Replacement
Swap over flat motor for power window regulator.
 4/30/2016 1/1

64 11 380 Removing and installing / replacing

control unit for air conditioning

Necessary preliminary tasks:

 Remove glove box

Unlock plug connections (1) and disconnect.

Unlock latch mechanism (3) downward.
Pull out control unit (2).

Replacement:
Carry out vehicle programming/encoding.
 4/30/2016 1/1

61 35 360 Removing and installing/replacing

control unit for camera-based driver
support systems (KAFAS)

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point
 Remove trim panel for pedal mechanism

Note:
For purposes of clarity, schematic diagram shows footwell side
trim panel removed.

Release latch mechanisms on equipment holder (1) in direction

of arrow.
Feed out control unit (2) from equipment holder towards top.
Disconnect plug connections (3) and remove control unit (2).
 
Installation note:
Make sure control unit (2) is correctly installed in equipment
holder.

Replacement:
Carry out programming/coding.
Carry out calibration:
 Service function
 Body
 Display and information functions
 Camera-based driver support systems
 Calibration of lane departure warning
 4/30/2016 1/2

37 14 566 Removing and installing/replacing

control unit for Vertical Dynamic Control

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove luggage compartment trim panel at rear
right

Unlock connector (1) and remove.

Pull out control unit (2) towards top.

After installation:
Replacement only:
 Carry out programming/encoding
 4/30/2016 2/2

 Start up the VDM with the aid of the diagnosis system

 4/30/2016 1/1

61 35 080 Removing and installing/replacing

control unit/module for left or right seat
adjustment

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Note:
To facilitate installation/removal of control unit, move seat
upwards and to the rear fully.

Unlock metal tab (1) towards front and remove control unit for
seat adjustment (2) towards bottom.
Unlock and disconnect all associated plug connections.

Installation note:
Make sure control unit for seat adjustment (1) is correctly
seated in bracket (2).
Guides (3) and metal tab (4) must not be damaged.

Replacement:
Carry out programming/encoding.
 4/30/2016 1/1

61 35 095 Removing and installing/replacing

control unit/module for seat heating

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Note:
To facilitate installation/removal of control unit, move seat
upwards and to the rear fully.

Disconnect plug connection (1).

Open lock (2) in direction of arrow and remove control
unit/module for seat heating (3) towards bottom.
Installation note:
Make sure control unit/module for seat heating (3) is correctly
engaged.
 4/30/2016 1/1

61 31 195 Removing and installing/replacing

controller

Important!
Risk of damage!
The button for the controller must not be removed!

Necessary preliminary tasks:

 Remove decorative trim on centre console

Release screws (1).
Tightening torque 61 31 2AZ.
Remove controller (2).
 4/29/2016 1/2

17 11 100 Removing and installing/replacing

coolant expansion tank (N47 D16/20
K/U/O/T 1, N57 D30 O/T 1, N55)

Necessary preliminary tasks:

 Pinch off coolant hoses on coolant expansion tank with
pinch-off tools.
 F33 only:
Remove right front end strut.

Unlock and detach coolant hose (1) from top of expansion tank.

Release screw (2).
Tightening torque 17 10 5AZ.
Unlock locks (3) in direction of arrow. Pull off expansion tank
upwards from carrier support until coolant hose below
expansion tank is accessible.

Unlock and disconnect plug on coolant level switch (1).

Unlock and detach coolant hose (2).
Lift out expansion tank.

Check coolant level, top up coolant if necessary.

4/29/2016 2/2
 4/29/2016 1/4

11 51 000 Removing and installing/replacing

coolant pump (N55)

Warning!
Risk of scalding!
Only perform this work after engine has cooled down.

Important!
If a coolant pump that has already been operated is
reused, it must be filled with coolant after removal.
Mixture ratio, water: coolant = 1 : 1
Protect plug connections against coolant and
contamination.

Recycling:
Catch and dispose of drained coolant in a suitable
container.
Observe country-specific waste disposal regulations.

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
 4/29/2016 2/4

steering parts must be replaced.

Necessary preliminary work:

 Follow diagnosis instructions.
 Remove underbody protection
 Remove fan cowl.
 Drain coolant.

Release screws (1).
Remove cover (2).

Disconnect plug connection (1) from coolant pump.

 4/29/2016 3/4

Release hose clamp (1 and 2).

Installation note:
Note installation hose clamps.

Tightening torque 11 53 5AZ.

Follow assembly instructions:

Installation note:
Hose clamps (1) must be installed in the centre of the marked
area (see graphic).

Release screws (1).
Tightening torque 11 51 2AZ.
Installation note:
Replace aluminium screws.
 4/29/2016 4/4

Installation note:
If the electric coolant pump is reused, it must be rotated one
turn due to the breakaway torque at the impellers.

Assemble engine.
Bleeding instructions must be observed without fail.
 4/29/2016 1/3

11 53 000 Removing and installing/replacing

coolant thermostat (N55)

Special tools required:

 17 2 050

Warning!
Risk of scalding!
Only perform this work after engine has cooled down.
Danger of injury!
Use only special tool 17 2 050 to lock and release spring
strap.

Recycling
Observe country-specific waste disposal regulations.
Catch and dispose of drained coolant in a suitable
container.

Important!
Read and comply with General Notes.
Protect plug connections against coolant and
contamination.
Cover plug connections with suitable materials.

Necessary preliminary tasks:

 4/29/2016 2/3

 Drain coolant.
 Remove fan cowl.
 Remove front underbody protection.
 Place collecting vessel for coolant under engine
compartment.

Unscrew bolt (1) and set expansion tank aside.

Unfasten plug connection (1).

Loosen hose clamps (2), detach coolant hoses from thermostat.
Unlock quick-action lock (3) and detach coolant hose from
thermostat.
Unlock quick-action lock (4) and detach thermostat from
radiator.
Remove thermostat (5) toward the top.

Assemble engine.
Fill the cooling system.
Observe capacities.
 
Installation note:
Check coolant hoses for cracks and damage.
 4/29/2016 3/3

Renew coolant hoses as required.

Recommendation:
On vehicles older than five years, renew coolant hoses.
 

Check function of cooling system.

 4/30/2016 1/1

51 21 370 Removing and installing/replacing cover

(seal) on front door at bottom left or right

Unclip cover (1) in direction of arrow from front door (2).

Installation note:
Pry out any clips remaining in the bore holes (3) and insert in
cover
Clip clips of cover (1) correctly into bores (3).

Installation note:
Clips (1) of cover (2) must not be damaged or missing.
When installing, only press on clips (1) as cover (2) will
otherwise become uneven.
 4/30/2016 1/1

51 16 041 Removing and installing/replacing cover

cap on left or right exterior mirror

Necessary preliminary tasks:

 Remove mirror glass

Press together latch mechanisms (1) and remove protective

cap from the outside.

Installation note:
Latch mechanisms (1) and guides (2) on protective cap (3)
must not be damaged or missing.
 4/30/2016 1/1

51 12 ... Removing and installing/replacing cover

for rear bottom bumper panel (M
Aerodynamics package)

Necessary preliminary work:

 Remove rear bumper trim

Release expanding rivets (1).

Release latch mechanisms along line (2) and remove cover (3).
Installation note:
Latch mechanisms must not be damaged or missing.
 4/30/2016 1/1

51 49 003 Removing and installing/replacing cover

for rear window frame on left or right

Special tools required:

 00 9 325

Necessary preliminary work:

 Release holding straps of storage shelf
 Remove cover for rear window frame at top

Release screw (1) and remove retaining knob.

Detach cover (2) with special tool 00 9 325 from clip (3).
Release the cover (2) at latch mechanisms (4) and remove.

Installation note:
Following parts of cover (1) must not be missing or damaged:
(2) Latch mechanism
(3) Clip
(4) Guide
 4/30/2016 1/1

51 13 ... Removing and installing/replacing cover

in engine compartment on left or right

Left side:
Turn locks (1) 90° counterclockwise.
Unlock catch (2).
Remove cover (3).

Right side:
Turn locks (1) 90° counterclockwise.
Unlock catch (3).
Remove cover (2).
 4/30/2016 1/2

51 22 180 Removing and installing/replacing cover

on outer door handle, left or right

Lever out cap (1) and release screw underneath.

Pull out cover (1) in direction of arrow with outer door handle (2)

opened slightly.

Version with light package:

Installation note:
Make sure outer door handle light (1) is exactly positioned in
area (2).
Guides (3) of outer door handle light (1) must be correctly
seated in support for outer door handle (4).

Installation note:
Guides (1) must not be damaged.
 4/30/2016 2/2

Replacement
Note:
Similar to graphic.

Detach cover (2) from filler piece (3).

Installation note:
Latch mechanisms (1) of cover (2) must not be damaged.
 4/30/2016 1/2

51 21 180 Removing and installing/replacing cover

on outside door handle

Lever out cap (1) and release screw underneath.

Installation note:
If necessary, replace faulty trim (1).

Pull off cover (1) in direction of arrow with outer door handle (2)

opened slightly.

Version with light package:

Installation note:
Make sure outer door handle light (1) is correctly positioned in
area (2).
Guides (3) of outer door handle light (1) must be correctly
seated in support for outer door handle (4).

Installation note:
Guides (1) must not be damaged.
 4/30/2016 2/2

Replacement
Note:
Similar to graphic.

Detach cover (2) from filler piece (3).

Installation note:
Latch mechanisms (1) of cover (2) must not be damaged.
 4/30/2016 1/2

51 34 420 Removing and installing/replacing cover

on window frame of rear door (front), left
or right

Necessary preliminary tasks:

 Open rear side window
 Remove cover on door window frame
 Remove rear weather strip

Important!
The ”Instructions on fitting window guide seals” serve as
the basis for this repair instruction and must be observed
without fail.

Pull rubber seal (1) off of cover (4).

Pull rubber window seal (2) out of window guide.
Release screws (3).
Feed out cover (4) forwards/upwards.
Installation note:
Coat rubber seal (1) and rubber window seal (2) with
approved lubricant before mounting.
Fitted foam parts must not be damaged when cover (4) is
pushed in.

Installation note:
If necessary, replace faulty plastic nuts (1).

Installation note:
Make sure rubber seal (1) is correctly mounted on cover (2) and
 4/30/2016 2/2

rear door (3).
 4/30/2016 1/2

51 34 425 Removing and installing/replacing cover

on window frame of rear door, rear left
or right

Necessary preliminary tasks:

 Remove outer window cavity cover strip
 Remove cover on door window frame

Pull out rubber window seal (1) from cover (2).

Installation note:
Moisten rubber guide (1) prior to fitting with approved lubricant.

Important!
Follow the instructions for bonding sound insulation.

Open sound insulation (1) in area (A).

Release screw (2) behind the sound insulation (1).
Hold cover and undo screws (3).

Guide cover (1) downward and manoeuvre it out of rubber

window seal (2) in area (A).
 4/30/2016 2/2

Remove trim (1) upwards.

Installation note:
Make sure cover (1) is correctly seated on rubber window
seal (2) in area (A).

Installation note:
Threads (1) of cover (2) must not be damaged.
 4/30/2016 1/1

51 13 116 Removing and installing/replacing cowl

panel cover

Necessary preliminary tasks:

 Remove both windscreen wiper arms.
 Remove cover in engine compartment on the left
and right

Release expanding rivets/clips (1) on left/right.

Turn snap fastener (2) approx. 90° counterclockwise.
Lift out cover (3).
Installation note:
Replace damaged expanding rivets/clips (1).
Check cover (3) for correct fit.
Close snap fasteners (2) from the middle.
The fastener is closed if the arrow tips point to each other.
 4/30/2016 1/2

51 16 383 Removing and installing/replacing

damper for glove box

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Necessary preliminary work:

 Remove right glove box

Note:
For better illustration, the damper has already been
disconnected from the retaining bracket.

Unclip damper (1) from retaining bracket (2) and slide back in

direction of arrow.

Turn damper (1) approx. 90° in direction of arrow and

disconnect.
4/30/2016 2/2
 4/29/2016 1/5

16 14 090 Removing and installing/replacing

delivery unit (petrol)

Special tools required:

 16 1 190
 33 5 070

Recycling
Fuel escapes when fuel lines are detached. Have a
suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Important!
Ensure adequate ventilation in the workbay!
Avoid skin contact (wear gloves)!
Ensure absolute cleanliness when performing repair work
on the open fuel system. Dirt contamination in the fuel
tank may impair driving or may even result in vehicle
breakdown.

Necessary preliminary tasks:

 Draw off fuel
 4/29/2016 2/5

Only unclip seat bench (1) as shown on the left and right and
fold up in direction of arrow.
Secure seat bench on front seat (2).

Fold both floor trim panels (1) to the side.

Unscrew nuts (2).
Remove cover for service opening (3).

Disconnect plug connection (1).

Open the lock (2) in the direction of the arrow (graphic already
opened).
Press the release button (3) and pull off the fuel delivery line. If
applicable, slightly push the connector out to make pulling the
part off easier.
 4/29/2016 3/5

Important!
Fuel delivery line must be felt and heard to snap into
place.
Damaged lock parts must be replaced without fail!

Fit special tool 16 1 190 with wide crank web (1) towards rear
onto locking ring (2).
Connect special tool 33 5 070 with reversible ratchet head
1/2 " (3) and position on special tool 16 1 190.
Release locking ring (2) in counterclockwise direction.
Installation note:
Replace the sealing ring between the flange head and fuel tank.

First, unscrew the flange cover with container (1) from the fuel
tank.
Note:
Graphic shows fuel tank removed.

Feed both hoses (1) out of the fuel tank.

Raise the fuel pump by continuing to turn the delivery unit.
Note:
Graphic shows fuel tank removed.
 4/29/2016 4/5

Carefully remove the delivery unit (1) from the fuel tank.

Make sure that the fuel level sensor is not damaged or bent
during the removal.
Note:
Graphic shows fuel tank removed.

Disconnect the plug connection (1) from the left fuel level

sensor.
The plug connections (2 and 3) will remain connected.
Important!
Connector housings (1 and 2) are not encoded and
accidental switching is possible!
Plug assignment:
 (1) Fuel level sensor, left (cannot be mistakenly
switched).
 (2) Fuel level sensor, right
 (3) Fuel pump

Disconnect the hose connection to the left tank half.

Turn the fuel hose (1) by 90° in direction of arrow.
 4/29/2016 5/5

Press the unlocking tab (1) and pull the connector out of the
delivery unit in the direction of the arrow.
Installation note:
Replace sealing ring on the connector (2).
Make sure the connector latches correctly.
 4/30/2016 1/2

61 14 005 Removing and installing/replacing

distribution box (front)

Special tools required:

 00 9 325

Warning!
Observe safety information for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.

Turn locks (1) 90° counterclockwise.

Unlock catch (3).
Remove cover (2).

Release latch mechanisms (1) and remove lid (2).

Installation note:
Make sure cover (2) is correctly locked.
 4/30/2016 2/2

Installation note:
Latch mechanisms (1) and gasket (2) on lid (3) must not be
damaged or missing.
Make sure gasket (2) is correctly seated in lid (3).

Release power distribution box (1) with special tool 00 9 325

from lower section (2) and pull power distribution box (1)
upward.

Release and disconnect all plug connections in area (1).

Remove power distribution box (2).
Installation note:
Make sure all plug connections are correctly locked.
 4/30/2016 1/2

61 14 010 Removing and installing/replacing

distribution box (rear)

Warning!
Observe safety information for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.
 
Remove luggage compartment floor trim panel (1) in direction of
arrow.

Slacken nut (1).

Tightening torque 61 35 8AZ.
Remove power distribution box (2) from guide (3) in direction of
arrow.

Release and disconnect all plug connections in area (1).

Remove power distribution box (2)
Installation note:
Make sure all plug connections are correctly locked.
4/30/2016 2/2
 4/30/2016 1/1

63 31 170 Removing and installing/replacing door

handle light on left or right front door

Necessary preliminary tasks:

 Remove front support for outer door handle

Note:
Graphic shown on the F30 by way of example

Feed out outside door handle light (1) with cable from support
for outer door handle (2).

Installation note:
Make sure door handle light (1) is correctly positioned in
area (2).
Guides (3) of door handle light (1) must be seated in support for
outer door handle (4).
 4/30/2016 1/1

63 31 175 Removing and installing/replacing door

handle light on left or right rear door

Necessary preliminary work:

 Remove rear support for outer door handle

Note:
Graphic shown on the F30 by way of example

Feed out outside door handle light (1) with cable from support
for outer door handle (2).

Installation note:
Make sure door handle light (1) is correctly positioned in
area (2).
Guides (3) of door handle light (1) must be seated in support for
outer door handle (4).
 4/30/2016 1/3

51 21 090 Removing and installing/replacing door

lock in left or right front door

Special tools required:

 51 2 190

Necessary preliminary tasks:

 Remove sound insulation in front door

Disengage Bowden cable (2) from outer door handle at marked

position.
Installation note:
Driver's side only:
Make sure locking pin (1) is correctly seated in mounting of
door lock (3).

Lever out locking rod (1).

Unfasten plug connection (2) and disconnect.
Release screws (3).

Only with driver's door:

Disengage door lock (1) at locking pin (2).
Installation note:
Make sure locking pin (2) is correctly seated in mount (3).
 4/30/2016 2/3

Turn door lock (1) as shown and manoeuvre out below door

reinforcement (2).
Important!
Do not damage door lock seal (3) when removing (water
ingress)!

Installation note:
Schematic diagram of removed support for outer door handle.
For it to be possible to install the door lock, locking pin (1) must
be in the installation position on the support (2).

Installation note:
Install door lock (1) and screw in screws (2) but to not tighten.
Slide special tool 51 2 190 into opened rotary striker until striker
engages in first stage
 4/30/2016 3/3

Installation note:
Pre-tension door lock (1) with knurled screw (2) until special
tool 51 2 190 just contacts corner points (3)

Important!
To tension door lock (1), it is only permitted to tighten
knurled screw (2) by a further 1 to 1.5 turns (max.) (risk of
damage).
Door lock seal must rest uniformly on inner door panel
(water ingress).

Tighten screws of door lock (1).

Observe tightening sequence: bottom - top - inner.
Tightening torque 51 21 1AZ.
 4/30/2016 1/2

51 22 090 Removing and installing/replacing door

lock in left or right rear door

Special tools required:

 51 2 190

Necessary preliminary tasks:

 If necessary, close side window
 Remove sound insulation in rear door

Disconnect Bowden cable at bottom (1) and top (3) from door

lock (2).
Installation note:
Bowden cable must be correctly engaged in locators in door
lock (2).
Bowden cable must be laid without kinks in bend to door
lock (2).
Seal (4) must be correctly fitted on Bowden cable.

Important!
Door cannot be opened if Bowden cable (1) is incorrectly
laid.

Lever out locking rod (1).

Unfasten plug connection (2) and disconnect.
Release screws (3) and manoeuvre out door lock above door
aperture.
Important!
Do not damage gasket at door lock during removal (water
ingress).

Installation note:
Install door lock (1) and screw in screws (2) but to not tighten.
Slide special tool 51 2 190 into opened rotary striker until striker
 4/30/2016 2/2

engages in first stage

Installation note:
Pre-tension door lock (1) with knurled screw (2) until special
tool 51 2 190 just contacts corner points (3)

Important!
To tension door lock (1), it is only permitted to tighten
knurled screw (2) by a further 1 to 1.5 turns (max.) (risk of
damage).
Door lock seal must rest uniformly on inner door panel
(water ingress).

Tighten screws of door lock

Observe tightening sequence: bottom - top - inner.
Tightening torque 51 22 1AZ.

Installation note:
Check function of child safety catch, as problems may arise:

- Lock does not centre in body aperture

- Lock scrapes on inner door panel

- Lock snags on inner door panel

 4/30/2016 1/2

51 21 280 Removing and installing/replacing door

stop on left or right front door

Necessary preliminary tasks:

 Close door windows
 Remove sound insulation in front area only

Note:
Operations are shown for F10 as an example.
After disengaging door stop, use suitable means of preventing
door from opening past its maximum permissible opening angle
(risk of damaging paintwork or bodywork).

Note:
Secure front door against falling closed.

Lever out seal (1).

Release screw (2).
Tightening torque 51 21 3AZ.
Release screws (3).
Tightening torque 51 21 5AZ.
Installation note:
Seal (1) must not be damaged.

Remove door stop (1) via aperture (2).

 4/30/2016 2/2

Installation note:
Following parts of door retainer (3) must not be damaged:
(1) Hinge
(2) Thread
 4/30/2016 1/2

51 22 280 Removing and installing/replacing door

stop on left or right rear door

Necessary preliminary tasks:

 Close door windows
 Remove sound insulation in front section

Note:
Secure rear door against falling closed.
After disengaging door stop, use suitable means of preventing
door from opening past its maximum permissible opening angle
(risk of damaging paintwork or bodywork).

Pull out rubber cover (1).

Release screw (3).
Tightening torque 51 22 5AZ.
Release screw (2).
Tightening torque 51 22 3AZ.
Slide out door stop.
Installation note:
Seal (1) must not be damaged.

Remove door stop (1) via aperture (2).

 4/30/2016 2/2

Installation note:
Following parts of door retainer (3) must not be damaged:
(1) Hinge
(2) Thread
 4/30/2016 1/1

51 32 170 Removing and installing/replacing door

window glass, front left or right

Necessary preliminary tasks:

 Remove sound insulation in front door
 Remove weather strip on inside of front door

Move door window (1) until the mount stop (2) can be operated

via the recess (3) on the guide rails (4).
Using a screw driver, press stop of mount (2) on the left and
right toward the rear and disengage door window (1) toward the
top.
Installation note:
Make sure door window (1) is correctly seated on rubber
window seal at front and rear.
Door window (1) must be correctly clipped into stop of
mount (2).

Turn door window glass and lift out rearwards/top.

Installation note:
The door window does not require adjustment.
 4/30/2016 1/2

67 31 510 Removing and installing/replacing drive

unit for seat cushion tilt adjustment

Necessary preliminary tasks:

 Remove driver's or front passenger seat
 Remove front seat cover

Release screws (1).
Remove cushion shell (2).

Detach spring (1) at seat frame (2).

Remove fuse (1) from shaft (2).

 4/30/2016 2/2

Unscrew nuts (1).

Pull drive with transmission (3) out of seat frame (2) and
remove.

Unfasten plug connection (2) and disconnect.

Release screws (3).
Tightening torque 67 31 1AZ.
Remove drive unit for seat cushion tilt adjustment (1).

Note:
Carry out a function check.

Replacement:
Initialise seat height adjustment drive unit.
 4/30/2016 1/2

51 16 355 Removing and installing/replacing

driver's side fold-down compartment

Special tools required:

 00 9 325

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Open fold-down compartment (1).

Detach fold-down compartment (1) from clips (2) with special
tool 00 9 325 and remove in direction of arrow.
Installation note:
Clamps (2) on fold-down compartment (1) must not be
damaged or missing.

Installation note:
Clamps (1) on fold-down compartment (2) must not be
damaged or missing.
4/30/2016 2/2
 4/30/2016 1/2

34 52 516 Removing and installing/replacing DSC

control unit

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove hydraulic unit.

Important!
Risk of damage to the contacts when removing and
installing the hydraulic unit.

Release screws (1) and carefully detach control unit (2) towards

front.

Installation note:
Keep sealing surfaces clean.
Replace screws.
Observe tightening sequence (1-4).
 4/30/2016 2/2

Tightening torque 34 51 1AZ.

Replacement:

- Carry out programming/encoding

- Steering angle sensor adjustment

or
adjustment for active steering

- Brake line mix-up test:

- Function check, hydraulic unit

 4/30/2016 1/3

34 51 527 Removing and installing/replacing DSC

hydraulic unit

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove sound insulation bulkhead upper part,
centre.
  Draw off brake fluid.

Note:
Extract brake fluid out of expansion tank. Use a suction bottle
used exclusively for drawing off brake fluid.
Do not reuse drawn out brake fluid.

 
After completing repair work:
  Bleed braking system
  Brake line mix-up test:

Important!
Do not mix up brake lines.
If necessary, mark before removal.
Close off connecting bores with seal plugs.

Important!
Remove and/or loosen the following holders for better
movement of brake lines!

Remove holder for brake lines (1).

Detach the brake lines (2) from the rubber grommet.
 4/30/2016 2/3

Detach brake line (1) from holder.

Disconnect plug connection (2).
Unfasten brake lines (3).
Installation note:
Tightening torque 34 32 1AZ.

Release screw (4) and feed out hydro aggregate in upward

direction.
Important!
Brake lines must not be bent!

Installation note:
Tightening torque 34 51 5AZ.

When replacing hydraulic unit:

Release screws (1) and convert holder (2).
Installation note:
Tightening torque 34 51 4AZ.

Modify DSC control unit.

When replacing control unit:

 4/30/2016 3/3

- Carry out programming/encoding

- Adjustment of steering angle sensor

 4/29/2016 1/3

11 37 005 Removing and installing/replacing

eccentric shaft (N55)

Special tools required:

 11 4 481

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove servomotor for eccentric shaft drive.
 Remove intermediate lever.

Note:
All bearing caps (1) of eccentric shaft are marked with numbers
from 1 to 6 (1 for 1st cylinder to 6 for 6th cylinder).

Release screws on bearing caps 1 to 6 (1).

Set all bearing caps down in special tool  11 4 481 in a neat and
orderly fashion.
Remove eccentric shaft with gentle tilting and swivel motion.
Place eccentric shaft on special tool 11 4 481.

Important!
Needle bearings (1) can break very easily.

Installation note:
 4/29/2016 2/3

Replace eccentric shaft.

Carefully pull needle bearing (2) apart at point of separation.
Slide on all needle bearings (1) of eccentric shaft.

Install bearing shells (1) as pictured.

Note:
If bearing shells need to be replaced due to a defect, always
replace bearing shells (1) and needle bearings together.

Installation note:
Any installation position may be selected for bearing shells (1
and 2).

If bearing shells (1) in cylinder head are inserted with tips

pointing downward, the bearing shells (2) must be inserted in
the opposite direction in the bearing cap (see example in
picture).

Installation note:
All bearing caps (1) of eccentric shaft are marked with numbers
from 1 to 6 (1 for 1st cylinder to 6 for 6th cylinder).

Insert eccentric shaft.

Coat all bearing positions with engine oil.
 4/29/2016 3/3

Put on all bearing caps (1) according to cylinder assignment.

Insert all screws.
Tightening torque 11 31 2AZ.
Installation note:
Gearing of eccentric shaft must be greased with
Longtime PD 1 (2.4).

Check intermediate shaft for ease of movement.

Assemble engine.
 4/30/2016 1/1

65 75 055 Removing and installing/replacing

emergency power siren with tilt sensor

Necessary preliminary tasks:

 Remove rear left wheel arch panel

Release screws (1) and lower complete mounting plate (2).

Unlock and disconnect associated plug connection, remove
complete mounting plate (2).

Release nut (1) and remove emergency power siren with tilt

sensor (2) from mounting plate (3).

Replacement:
Carry out vehicle programming/encoding.
 4/30/2016 1/1

61 31 021 Removing and installing/replacing

emergency starting coil

Necessary preliminary tasks:

 Remove steering column shroud lower section

Release emergency starting coil (1) and pull in direction of

arrow out of steering column shroud (2).
Installation note:
Make sure emergency starting coil (1) is correctly seated.
 4/30/2016 1/3

65 20 030 Removing and installing/replacing empty

housing for roof-mounted aerial

Special tools required:

 65 2 010

Warning!
Danger of injury!
Special tool has sharp edges!
Adapt working height to vehicle height with non-tilting and
non-slip platform.
Handle special tool correctly and make sure it is
positioned without tilting or slipping on the vehicle.
Risk of damage!
In order to prevent dents in the roof, do not exert any
pressure on the roof.

Important!
Note to customer:
In order to guarantee a permanent connection and
adhesive hardening:
After bonding the empty housing for the roof-mounted
aerial, wait 24 hours before driving the vehicle through a
car wash.

Note:
Clean roof.

Mask roof (2) around empty housing for roof-mounted aerial (3)

 4/30/2016 2/3

with yellow plastic adhesive tape (1). To do so, slide plastic

adhesive tape under empty housing (3) slightly.

Important!
Risk of damage!
Make sure your arms do not cross over (1) when holding
special tool  65 2 010.
Pull handle must always be ahead of the guiding hand (2).

Important!
Risk of damage!
To avoid paintwork damage on the roof and empty
housing (3), do not fit special tool  65 2 010  askew.

Cut through adhesive bead all round with special tool  65 2 010.

Pull on handle (1) and align blade on handle (2).
Note:
Use sharp blades only. Replace blade if necessary.
 Refer to Service Information 01 15 08 475

Remove empty housing (3).

Installation
Empty housing for roof-mounted aerial is secured with window
glass adhesive. All preparatory operations correspond to the
Window bonding notes.
 4/30/2016 3/3

Note:
Replace empty housing for roof-mounted aerial if centering
pins (1) on empty housing are damaged.
Bonding surface (2) must be clean and free from grease.

Apply trace of adhesive bead all round outer contour as follows.

Distance between adhesive bead and edge of aerial cover:
A. 6.5 mm ±1 mm
 
Start and end of bead trace must have an overlap length of
max. 10 mm.
Important!
To prevent the adhesive from escaping, the adhesive
bead diameter must not exceed max. 2.5 mm to 3.5 mm.

Note:
Attach the empty housing coated with adhesive by hand. To
spread the adhesive better, move the housing back and forth
horizontally slightly when pressing down.
 
Secure empty housing if necessary with adhesive tape and
press down uniformly.
After bonding, leave vehicle to stand for at least 3 hours at
room temperature.
 4/30/2016 1/3

61 31 233 Removing and installing/replacing

engine electrical system for lane
departure warning (M sports steering
wheel)

Necessary preliminary tasks:

 Remove airbag unit

Release screws (1) on steering wheel.

Release screw (2) on rear side of steering wheel.
Remove design cover.

Disconnect plug connection (1).

Carefully unlock retaining clip (2) on latch mechanisms (3) with
suitable tool (e. g. screwdriver with 3-mm blade).
Note:
The unlocking procedure is simplified by pressing down the
retaining clip (2).

Remove engine electrical system of Lane Departure

Warning (1) from steering wheel (2) in direction of arrow.
 4/30/2016 2/3

Installation note:
Retaining clip (2) and guides (1) on engine electrical system of
Lane Departure Warning (3) must not be damaged or missing.

Installation note:
First press down retaining clip (1) in area (A) until it engages.
Then press down in area (B) until it engages.
Make sure engine electrical system of Lane Departure Warning
is correctly seated.
Make sure plug connection (2) is correctly locked.

Replacement from build date 03/2009:

Engine electrical system must be readjusted.
The service module ”Adjustment actuator Lane Departure
Warning” can be found at:
- Body
- Camera-based driver support systems
 4/30/2016 3/3

- Adjustment actuator Lane Departure Warning

 4/29/2016 1/7

11 65 020 Removing and installing / replacing

exhaust turbocharger (N55)

Warning!
The module consists of exhaust turbocharger and exhaust
manifold.
The weight of the turbocharger is approx. 15 kg.

Necessary preliminary tasks:

 Remove the catalytic converter.
 Remove charge air duct.
 Drain coolant.
 Remove expansion tank.
 Remove air duct
 Remove right engine mount.

Release screws (1).
Tightening torque 11 53 4AZ.

Release screw (1).
Tightening torque 11 53 10AZ.
If necessary, use appropriate tool to loosen coolant return line
(3) and coolant flow line (2) at connection point.
 4/29/2016 2/7

Installation note:
Replace sealing rings.

Release screw (1).
Loosen screws (3) but do not remove.

Release screw (1).
Tightening torque 11 42 6AZ.
If necessary, use appropriate tool to loosen oil return lines  (2).
Installation note:
Replace sealing ring.

Release screw (1).
Tightening torque 11 42 7AZ.
If necessary, use appropriate tool to loosen oil return lines  (2).
Oil may escape when the oil return line is disconnected.
Installation note:
Replace sealing ring.
 4/29/2016 3/7

Release screw (1).
Tightening torque: 11 42 4AZ.
If necessary, use appropriate tool to loosen coolant return lines
(2) at connection point.
Installation note:
Replace sealing ring.

Loosen plug connection (1) at blow-off valve.

Release screw (2).
Tightening torque 11 65 4AZ.
If necessary, use appropriate tool to loosen oil feeder lines at
point of connection (3).
Oil may escape when the oil return line is disconnected.
Installation note:
Replace sealing ring.

Disconnect vacuum hose (1) from vacuum line.

 4/29/2016 4/7

Disconnect vacuum hose (1) from cylinder head cover.

Remove heat shield (1).

Tightening torque: 11 65 2AZ
Loosen all flange nuts (2) along the line.
Remove module by manoeuvring downwards on gearbox side.
Note:
Overall weight of module is approximately 15 kg.

Note:
Oil supply line (2) can only be replaced after removal of the
exhaust turbocharger.

Release screw (1).

If necessary, use appropriate tool to loosen oil feeder lines at
point of connection (2).
 4/29/2016 5/7

Installation note:
Replace all sealing rings (1).

Installation note:
Replace all graphite seals (1).
Position exhaust turbocharger on cylinder head and hold in
place with two bolts.

Insert bolt (1) but do not tighten at this point.

 4/29/2016 6/7

Important!
The module consists of exhaust turbocharger and exhaust manifold and must be installed stress-free.
Torque and tightening sequence must be observed without fail.
Tightening torque: 11 65 1AZ.
1. Join all flange nuts in sequence 1 to 15 to 8 Nm.
2. Tighten all flange nuts to a torque of 13 Nm in sequence (1 to 15).
Installation note:
Flange nuts 1 to 5 are accessible from above.
Flange nuts 6 to 15 are accessible from below.
 4/29/2016 7/7

Secure screws (3).
Tightening torque: 11 65 9AZ.
Tighten bolt (1).
Tightening torque 11 65 8AZ.

Top up with coolant.

Assemble engine.
Observe BMW Diagnosis System instruction.
Carry out BMW leakage test for intake system.
 4/30/2016 1/2

34 41 250 Removing and installing/replacing

expander for parking brake shoes

Special tools required:

 32 1 030

Necessary preliminary tasks:

 Remove parking brake shoes.

Lock adjustment unit (ASZE).

Actuate parking brake lever. Connect special tool 32 1 030.
Press limit position (1) of adjusting spring back to such an
extent that retaining hook (2) engages in limit position (1).
Installation note:
Unlock adjustment unit (ASZE).
Lever out restraining hook (2) with a suitable screwdriver.
Restraining hook (2) must detach from limit position (1) of
adjusting spring.

Pull brake shoe expander (1) forward, disconnect parking brake

Bowden cable (2) and remove brake shoe expander.
 4/30/2016 2/2

After installation:
 Adjust parking brake.
 4/30/2016 1/2

64 51 520 Removing and installing/replacing

expansion valve (N20, N26, N55)

Special tools required:

 00 9 030

Warning!
Danger of injury!
Refrigerant circuit is under high pressure!
Avoid contact with refrigerant and refrigerant fluid.
Read and comply with safety information:
 Handling R 134a tetrafluorethane refrigerant
 Handling refrigerant fluid

Important!
Risk of damage!
Restart engine only when air conditioning system has
been correctly filled.
Follow notes for opening and replacing parts in refrigerant
circuit.

Note:
If air conditioning system is opened for more than 24 hours:
 Renew condenser assy.

Necessary preliminary tasks:

 Drain off air conditioning system
 4/30/2016 2/2

Release screws (1).
Tightening torque 64 53 1AZ.
Remove refrigerant lines and place to side.
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to install sealing rings without
damaging them.

Release screws (1).
Tightening torque 64 53 2AZ.
Remove expansion valve (2).

Installation note:
Place expansion valve (1) exactly on refrigerant lines (2) and
(3).
Fit screws of expansion valve (1) and make sure retaining clip
(4) is correctly positioned.

After installation:
 Evacuate and fill air conditioning system
 4/29/2016 1/5

13 53 332 Removing and installing/replacing feed

line (N55)

Special tools required:

 13 5 020
 32 1 270
 13 5 160

Warning!
Disconnect negative battery terminal (risk of fire due to
short circuit on removal).
Electric fuel pump starts up automatically when door is
opened!
Carry out installation work on fuel system only with coolant
temperature below 40 °C.

Wear safety goggles.

Important!
Adhere to conditions of absolute cleanliness when working
on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the
 4/29/2016 2/5

system!
 Do not allow any dirt particles or foreign bodies to
get into the system.
 Remove all traces of dirt before removing lines or
separate components.
 Use only fluff-free cloths.
 Seal all fuel system openings with protective caps or
plugs.

Important!
Ignition coils must not be contaminated by fuel.
The resistance of the silicone material is reduced
significantly by contact with fuel, which may cause the
ignition coil to fail!
Cover ignition coil with suitable means.

Necessary preliminary tasks:

 Remove intake plenum.

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel in a suitable container.
Observe country-specific waste disposal regulations.
 4/29/2016 3/5

Unlock and detach vacuum line (1) from the vacuum pump.
Unlock and pull off connector (2) from the high pressure pump
and connector  (3) from the oil temperature sensor.

Release screws (1) below cable channel (2).

Replace aluminium screws.
Installation note:
Adhere to tightening/torque sequence.

Release fuel hose (3) and seal with special tool (1) 13 5 160.

Release nut (1) on high pressure pump.
Remove feed line (2).
Close off feed line and high pressure pump with a matching
plug from set of special tools  32 1 270.
 4/29/2016 4/5

Installation note:
Adhere to tightening/torque sequence.

First, fit feed line on high pressure pump and engine block only
hand-tight. Do not connect fuel hose to the feed line yet.

Tighten screws (1) below the cable channel.

Tightening torque 13 53 10AZ.
Replace aluminium screws.

Tighten union nut (1) with special tool  13 5 020.

Tightening torque 13 53 7AZ.
Re-connect fuel hose (3) to feed line.
 4/29/2016 5/5

Assemble engine.
Check fuel system for tightness.
Check function of DME.
 4/30/2016 1/1

51 11 181 Removing and installing/replacing

finisher rod on ornamental grille for
bumper panel 

Remove cover (1) with latch mechanisms from bumper panel

(2) in direction of arrow.

Installation note:
No catches (1) are permitted to be damaged or missing.
 4/30/2016 1/1

51 47 072 Removing and installing/replacing

finishing strip on rear left or right
entrance (outer)

Special tools required:

 00 9 317

Lift cover panel (2) up and out at clips (1) using special
tool 00 9 317.
Remove cover (2).
Note:
Depending on the model, cover panel (2) is secured with a
different number of clips (1).

Installation note:
If necessary, remove clips (1) from entrance with a suitable tool.
Replace faulty clamps (1).
 4/30/2016 1/2

67 62 020 Removing and installing/replacing flat

motor for rear left or right power window
regulator

Necessary preliminary tasks:

 Remove rear power window regulator

Release screw connections (1).

Remove flat motor (2) from power window regulator.
Cable must not come loose from power window.
Installation note:
Simultaneously tighten both screw connections (1).
The shaft of the flat motor (2) must be pulled into the holder of
the power window regulator under slight tension.
Tightening torque 51 35 1AZ.

Flat motor (2) must engage exactly at the marked points of the

power window regulator (1).
Important!
Ensure that the flat motor (2) is assembled without
tension.

After installation:
An initialisation must be carried out in order to activate anti-trap
mechanism.
Read and comply with notes on initialisation of power window
regulator.
4/30/2016 2/2
 4/29/2016 1/3

11 22 500 Removing and installing/replacing

flywheel (N55)

Special tools required:

 11 4 180
 11 9 260
 11 9 265

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Remove transmission.
 Remove clutch.

Automatic transmission:
Secure flywheel (1) with special tool 11 9 260.
Unfasten flywheel bolts.
 4/29/2016 2/3

Tightening torque 11 22 1AZ.

Installation note:
Flywheel (1) is secured with an dowel pin.

Manual gearbox:
Fasten dual-mass flywheel with special tool 11 9 260 and
11 9 265.
Release flywheel bolts with special tool 11 4 180/
Tightening torque 11 22 2AZ.
Installation note:
Fit new flywheel bolts.
Clean all threads for flywheel bolts in crankshaft.

Installation note:
Pay attention to dowel pin.

Installation note:
Ensure installed position of magnet wheel is correct.
 4/29/2016 3/3

Assemble engine.
 4/30/2016 1/1

64 11 908 Removing and installing/replacing

footwell temperature sensor (left)

Necessary preliminary tasks:

 Remove lower section of steering column shroud

Feed out foam material (3) downwards as pictured.

Pull temperature sensor (2) out of the air duct (1) and
disconnect the corresponding plug connection.
 4/30/2016 1/1

64 11 908 Removing and installing/replacing

footwell temperature sensor (right)

Necessary preliminary tasks:

 Remove glove box

Unfasten plug connection (1) and disconnect.

Remove temperature sensor (2) from air duct (3).
 4/30/2016 1/4

67 31 500 Removing and installing/replacing

forward/back seat adjustment drive unit

Necessary preliminary tasks:

 Raise front seat as far up as possible
 Procedure in event of faulty drive for forward/back
seat adjustment:
Additional work in event of faulty drive for
forward/back seat adjustment

Removal of electric motor for forward/back seat adjustment:

Unfasten plug connection (1) and disconnect.

Lift long flex shaft (3) out of guide in direction of arrow.

Pull out flex shaft (3) from electric motor for forward/back seat
adjustment (1).
Remove electric motor for forward/back seat adjustment (1) in
direction of arrow from holder (2).

Installation of electric motor for forward/back seat adjustment:

Slide seat rail with opening forwards or back until bushing for
flex shaft mounting of worm gear is flush.
Insert short flex shaft.
 4/30/2016 2/4

Connect electric motor for forward/back seat adjustment (2) to

short flex shaft (1).
Installation note:
Make sure flex shaft (1) is correctly seated in electric motor (2)
and seat rail mounting.

Clip in electric motor for forward/back seat adjustment (2) into

holder (3).
Installation note:
Electric motor for forward/back seat adjustment (2) must audibly
engage in holder (3).
 4/30/2016 3/4

Insert long flex shaft (2) in worm gear on seat rail.

Bend long flex shaft (2) upwards and slide into electric motor for forward/back seat adjustment (1).
Clip in flex shaft into carrier plate.
Installation note:
Make sure flex shaft (2) is correctly seated in electric motor (1) and seat rail mounting.

Installation note:
PTFE hoses are shrink-fitted onto end pieces.
Check that hoses are free from damage.

Note:
Carry out a function check.
 4/30/2016 4/4

Replacement:
Initialize drive unit for forward/back seat adjustment.
 4/30/2016 1/1

51 47 000 Removing and installing/replacing front

(inside) left or right door sill cover strip

Special tools required:

 00 9 317

Important!
Do not raise door sill cover strip (1) over entire length
simultaneously.

Unclip rear door sill cover strip (1) from clips (2) starting from
the rear with special tool 00 9 317.

If necessary lift clip (1) from floor panel (2) and clip on door sill
cover strip.

Installation note:
Replace defective clips (1) on door sill cover strip (2).
 4/30/2016 1/1

31 35 000 Removing and installing/replacing front

anti-roll bar

Necessary preliminary tasks:

 Remove anti-roll bar links from anti-roll bar.
 Lower front axle support.

Unscrew nuts (1).

Tightening torque 31 35 1AZ.
Remove retaining brackets.
Remove anti-roll bar (2) forward.
Installation note:
Replace nuts (1).
Check both rubber mounts for damage.
 In the event of rubber mount damage, the anti-roll bar
must be renewed.
 4/30/2016 1/1

51 47 315 Removing and installing / replacing front

carpet for passenger compartment

Necessary preliminary work:

 Clamp off battery lead from negative connection
point
 Remove both front seats
 Remove complete accelerator pedal module
 Remove centre console.
 Remove front left/right footwell side trim panel
 Remove cover for central bass speaker left/right

Important!
Risk of damage!
Pay attention to cables when cutting.
Start cuts towards centre of vehicle as far as is possible.
This guarantees that cutting edges are covered by storage
compartment and/or dashboard.

Cut out the carpet along the lines (1), including on the right
side.
Remove carpet towards rear/top and if necessary feed out
cable.

Installation note:
Apertures (1) serve as fixing points for fitting carpet.
Replacement:
Lay removed carpet over new one and transfer cuts to new
carpet.
 4/30/2016 1/2

26 11 090 Removing and installing/replacing front

centring mount for propeller shaft

Special tools required:

 00 5 500
 11 1 310
 11 2 030

Necessary preliminary tasks:

 Remove propeller shaft.

Completely fill centring bore hole (1) with viscous grease.

Drive special tool 11 1 310 with a plastic hammer into centring
bore hole.
The centring bearing (1) is forced out of the propeller shaft by
the pressure on the grease filling.
If necessary, top up grease repeatedly.
Note:
To drive out the bearing, you can also fill the centring bore
hole with water instead of grease.

Installation note:
Remove grease or water from mount bore.
Drive in centring mount (1) with special tools 11 2 030 and
00 5 500 into propeller shaft (observe protrusion).
 4/30/2016 2/2

Grease centring mount.

- Grease: BMW Service Operating Fluids.

Installation note:
+2
Observe protrusion A = 4 mm of centring (1).
 4/30/2016 1/3

72 11 033 Removing and installing/replacing front

left or right seat belt

Necessary preliminary tasks:

 Remove panel for door post

For electrical front seat version:

Move backrest to full rearward position.
Grip end fitting cover centrally between seat belt strap and
cover.
Unclip end fitting cover in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with rear guide in covering.

2. Insert cover in direction of arrow downwards in covering
3. Engage top left of cover in covering.

For manual front seat version:

Move backrest to full rearward position.
Grip end fitting cover in marked area between cushion and
cover.
Unclip end fitting cover in direction of arrow (1).
Feed out end fitting cover (2) in direction of arrow.
 4/30/2016 2/3

Installation note:
Install end fitting cover as follows:

1. Insert cover with front guide in cover

2. Insert cover in direction of arrow downwards in covering
3. Engage top cover in marked area in covering.

Release screw (1).
Tightening torque: 72 11 2AZ.
Remove end fitting.
Installation note:
End fitting is coded against incorrect assembly.

Release screws (1).
Tightening torque: 72 11 4AZ.
Remove deflector bar (2).
Release screw (3).
Tightening torque: 72 11 3AZ.
Set down belt deflector with belt (4).

Release screw (1).
Tightening torque: 72 11 1AZ.
Remove inertia reel mechanism (3).
Installation note:
Encoding (2) of automatic reel must be seated in body recess.
 4/30/2016 3/3

Only for US models:

Unlock plug connection (4) and disconnect.
Release screw (1).
Tightening torque: 72 11 1AZ.
Remove inertia reel mechanism (3).
Installation note:
Encoding (2) of automatic reel must be seated in body recess.
 4/30/2016 1/1

51 71 038 Removing and installing/replacing front

left or right wheel arch cover (front
section)

Necessary preliminary work:

 Remove front wheel

Note:
For a better view surrounding components have been omitted.

Release screws (1).
Feed out wheel arch  cover (2).
Installation note:
Ensure wheel arch cover (2) and cooling air routing are
correctly fitted.

Replacement:
Modify lid (1) on wheel arch cover (2).
 4/30/2016 1/1

51 71 039 Removing and installing/replacing front

left or right wheel arch cover (rear
section)

Necessary preliminary work:

 Remove front wheel

Note:
For a better view surrounding components have been omitted.

Release all screws (3).

Release expanding rivets (2) and (4).
Installation note:
Replaced expanding rivets (2).

Remove front wheel arch cover (1).

Installation note:
Make sure front wheel arch cover (1) is correctly seated.
 4/30/2016 1/3

72 11 070 Removing and installing/replacing front

lower strap fitting (belt tensioner),
driver's seat

Note:
Only F30 and F35 from Chinese production:
On these vehicles, the following part numbers must be installed
when replacing the lower strap:

Production Optional Faulty part Required new

date equipment part
S5ALA
(Active Part Parts Part Parts
Protection) number number

until not fitted 7 292 029 Lower 7 388 505 New

09/2013 strap, part
left kit
with
lower
strap
and
seat
belt*

until not fitted 7 292 030 Lower 7 388 506 New

09/2013 strap, part
right kit
with
lower
strap
and
seat
belt*

until Installed 7 292 029 Lower 7 259 387 Lower

09/2013 as strap, strap,
optional left left
equipment

until Installed 7 292 030 Lower 7 259 388 Lower

09/2013 as strap, strap,
optional right right
equipment
 4/30/2016 2/3

from Installed 7 292 029 Lower 7 259 387 Lower

09/2013 after strap, strap,
series left left
production

from Installed 7 292 030 Lower 7 259 388 Lower

09/2013 after strap, strap,
series right right
production

*When a new part is installed, the seat belt must also be replaced
on vehicles with production date before 09/2013 without optional
equipment S5ALA (Active Protection)!
(Seat belt is included in the new part kit.)

Necessary preliminary tasks:

 Remove driver's seat.

Warning!
Read and comply with safety regulations for handling
airbag modules and pyrotechnical belt tensioners.
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.

Switch off the ignition!

Installation note:
 Microencapsulated screws must be replaced and may not
be reused
 The screw connection must be closed within 20 minutes
(start of hardening)
 Microencapsulated screws must not be retightened
 If the nut is used on more than one occasion, first clean
the thread

Unfasten plug connection (1) and disconnect.

 4/30/2016 3/3

Unlock plug connection (3) and pull all connectors out of

connector housing (2).
Disconnect all cable straps.
Removing wiring harness.
Installation note:
 Replace cable strap.
 Cables must not be under tension
 Plugs are coded and must be reinstalled in the correct
sequence in the connector housing

Release screw (1).
Tightening torque 72 11 05AZ.
Remove belt pretensioner (3).
Installation note:
Replace screw (1).
Belt tensioner (3) is secured through recess (2) on retaining
bracket.
 4/30/2016 1/3

72 11 071 Removing and installing/replacing front

lower strap fitting (belt tensioner), front
passenger seat

Note:
Only F30 and F35 from Chinese production:
On these vehicles, the following part numbers must be installed
when replacing the lower strap:

Production Optional Faulty part Required new

date equipment part
S5ALA
(Active Part Parts Part Parts
Protection) number number

until not fitted 7 292 029 Lower 7 388 505 New

09/2013 strap, part
left kit
with
lower
strap
and
seat
belt*

until not fitted 7 292 030 Lower 7 388 506 New

09/2013 strap, part
right kit
with
lower
strap
and
seat
belt*

until Installed 7 292 029 Lower 7 259 387 Lower

09/2013 as strap, strap,
optional left left
equipment

until Installed 7 292 030 Lower 7 259 388 Lower

09/2013 as strap, strap,
optional right right
equipment
 4/30/2016 2/3

from Installed 7 292 029 Lower 7 259 387 Lower

09/2013 after strap, strap,
series left left
production

from Installed 7 292 030 Lower 7 259 388 Lower

09/2013 after strap, strap,
series right right
production

*When a new part is installed, the seat belt must also be replaced
on vehicles with production date before 09/2013 without optional
equipment S5ALA (Active Protection)!
(Seat belt is included in the new part kit.)

Necessary preliminary tasks:

 Remove front passenger seat

Warning!
Read and comply with safety regulations for handling
airbag modules and pyrotechnical belt tensioners.
Improper handling can lead to triggering of the
pyrotechnical seat belt tensioner or side airbag, resulting
in injuries.

Switch off the ignition!

Installation note:
 Microencapsulated screws must be replaced and may not
be reused
 The screw connection must be closed within 20 minutes
(start of hardening)
 Microencapsulated screws must not be retightened
 If the nut is used on more than one occasion, first clean
the thread

Unfasten plug connection (1) and disconnect.

 4/30/2016 3/3

Unlock plug connection (3) and pull all connectors out of

connector housing (2).
Disconnect all cable straps.
Removing wiring harness.
Installation note:
 Replace cable strap.
 Cables must not be under tension
 Plugs are coded and must be reinstalled in the correct
sequence in the connector housing

Release screw (1).
Tightening torque 72 11 05AZ.
Remove belt pretensioner (3).
Installation note:
Replace screw (1).
Belt tensioner (3) is secured through recess (2) on retaining
bracket.
 4/30/2016 1/2

61 14 035 Removing and installing/replacing front

positive battery cable distributor

Warning!
Observe safety information for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.

Turn locks (1) 90° counterclockwise.

Unlock catch (3).
Remove cover (2).

Release and disconnect all plug connections in area (1).

Disengage cover (2) in direction of arrow and take off.
Release nut from positive wire (3) and remove retaining
bracket (3).
Tightening torque 61 21 4AZ.
 
Installation note:
Make sure all plug connections are correctly latched.
Make sure cover (2) is correctly locked.
Risk of short circuits!
Ensure positive wire (3) is correctly seated.

Release latch mechanism (arrow) and pull relay carrier (1) up

 4/30/2016 2/2

and out of power distribution box.

Release nut from flat positive terminal wire (2) and remove flat
positive terminal wire (2).
Tightening torque 61 21 4AZ.
Installation note:
Risk of short circuits!
Make sure flat positive terminal wire (2) is correctly seated.

Release nuts (1) and remove power distribution box.

Tightening torque 61 21 2AZ.
 4/30/2016 1/1

51 13 001 Removing and installing/replacing front

radiator grille, middle left or right

Necessary preliminary tasks:

 Remove front bumper panel

Release all retainers (1).

Remove front radiator grille (2) towards front.

Installation note:
All catch mechanisms and guides on the front radiator grille (2)
may be neither damaged or missing.
Press on chrome ring to push front radiator grille (1) into
bumper trim.
Fixtures must be correctly locked.
 4/30/2016 1/1

51 47 490 Removing and installing / replacing front

underbody protection

Note:
Illustration only an example. Detail deviations (depending on
engine version) are possible.

Release screws (1).
Tightening torque 51 75 1AZ.
Release all screws along line (2).
Tightening torque 51 75 1AZ.
Remove underbody protection (3).
 4/29/2016 1/3

11 42 020 Removing and installing/replacing full-

flow oil filter (N55)

Warning!
Risk of scalding!
Only perform this repair work on an engine that has cooled
down.

Recycling:
Catch and dispose of drained coolant.
Observe country-specific waste disposal regulations.

Necessary preliminary work:

 Drain coolant.
 Remove intake plenum.
 Unfasten oil filter cover.
 Protect drive belt against dirt contamination.

Release hose clamp (1).

Tightening torque 11 53 6AZ.
Release screws (4) from coolant hose on cylinder head.
 4/29/2016 2/3

Tightening torque: 11 53 7AZ.

Release screw (3).
Tightening torque: 11 42 2AZ.

Unfasten screws (2).

Tightening torque: 11 42 2AZ.
Detach connector from oil pressure switch (3).
Note:
Have cleaning cloth ready to catch residual oil.

Installation note:
Replace all gaskets.
If necessary, replace filter element.
When replacing, modify oil-to-water heat exchanger and oil
pressure switch (3).

Note:
Hot-climate version

Release screw (1).
Tightening torque 17 22 4AZ.
Remove engine oil pipes (2).
Unlock coolant hose (3) and pull off.
Release screws (4) from coolant hose on cylinder head.
Tightening torque: 11 53 7AZ.
Release screw (5) from oil filter.
Tightening torque 11 42 2AZ.

Pull off connector (1) from oil pressure switch.

Release screw (2) from oil filter.
 4/29/2016 3/3

Tightening torque: 11 42 2AZ.

Note:
Have cleaning cloth ready to catch residual oil.

Installation note:
Replace all gaskets.
If necessary, replace filter element.
If replacing, modify thermostat housing and oil pressure switch

Assemble engine.
Note:
Protect drive belt against dirt contamination.

Installation note:
Bleeding instruction must be observed without fail.
 4/30/2016 1/2

51 16 365 Removing and installing/replacing glove

box cover

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Necessary preliminary tasks:

 Remove right glove box

Note:
For better illustration, the damper has already been
disconnected from the retaining bracket.

Unclip damper (1) from retaining bracket (2) and slide back in

direction of arrow.

Loosen latch mechanisms (1) and feed glove box cover (2) out

of housing (3) in direction of arrow.

Note:
It is not possible to remove the lock barrel (1) and opener (2)
without causing damage.

In the case of replacement (version with lock barrel):

 4/30/2016 2/2

Assemble new lock barrel (1).

Click lock barrel (1) into new opener (2) (ensure that it is in the
correct installation position).
Click opener (2) into the glove box cover (3).
In the case of replacement (version without lock barrel):
Click opener (2) into the glove box cover (3).
 
 4/30/2016 1/1

63 31 150 Removing and installing/replacing

glovebox light

Important!
Follow notes for handling light bulbs (interior lights).

Note:
Similar to graphic.

Lever out glove box light (1) in direction of arrow.

Unfasten plug connection and disconnect.
Remove glove box light (1).
Replacement:
 If necessary, remount bulb, check bulb type
 4/30/2016 1/2

61 31 334 Removing and installing/replacing grip

trim for gear selector switch

Special tools required:

 00 9 327

Note:
Symbol plate (1) is glued on.

Mount special tool 00 9 327 as illustrated.

Detach symbol plate (1) from upper shell (2) in direction of
arrow.
Important!
Risk of damage!
Do not leverage side panel (3) out of upper shell (2).

Installation note:
Remove any adhesive residue.
Remove the protective film from the back of the symbol plate
before installing.
Make sure symbol plate (1) is correctly seated on upper shell
(2).

Release screw (1) and remove upper shell (2) with side panel
(3) in direction of arrow.

Installation note:
Fixtures (1) and guide pins (2) on gear selector switch (3) must
not be damaged or missing.
 4/30/2016 2/2

Installation note:
Guides (1) and P-button (2) must not be damaged or missing.
Make sure P-button (2) is correctly seated in upper shell (3).
Make sure side panel (4) is correctly seated in upper shell (3)!
For better installation, secure UNLOCK button outside on the
side panel (4) using adhesive tape.
Feed in upper shell with side panel into fixtures and guide pins
on gear selector switch.
 4/30/2016 1/2

61 31 334 Removing and installing/replacing grip

trim for gear selector switch

Special tools required:

 00 9 327

Note:
Symbol plate (1) is glued on.

Mount special tool 00 9 327 as illustrated.

Detach symbol plate (1) from upper shell (2) in direction of
arrow.
Important!
Risk of damage!
Do not leverage side panel (3) out of upper shell (2).

Installation note:
Remove any adhesive residue.
Remove the protective film from the back of the symbol plate
before installing.
Make sure symbol plate (1) is correctly seated on upper shell
(2).

Release screw (1) and remove upper shell (2) with side panel
(3) in direction of arrow.

Installation note:
Fixtures (1) and guide pins (2) on gear selector switch (3) must
not be damaged or missing.
 4/30/2016 2/2

Installation note:
Guides (1) and P-button (2) must not be damaged or missing.
Make sure P-button (2) is correctly seated in upper shell (3).
Make sure side panel (4) is correctly seated in upper shell (3)!
For better installation, secure UNLOCK button outside on the
side panel (4) using adhesive tape.
Feed in upper shell with side panel into fixtures and guide pins
on gear selector switch.
 4/30/2016 1/1

51 12 825 Removing and installing/replacing guide

for rear centre bumper panel

Necessary preliminary tasks:

 Remove rear bumper trim

Feed out cable (1).

Unscrew nuts (2).
Tightening torque 51 12 2AZ.
Remove guide (3).

Installation note:
Latch mechanisms (1) of guide (2) must not be damaged or
missing.
 4/30/2016 1/1

51 12 828 Removing and installing/replacing guide

for the bumper panel, rear left or right

Necessary preliminary tasks:

 Remove rear bumper trim

Release screws (1).
Tightening torque 51 12 3AZ.
Unscrew nuts (2).
Tightening torque 51 12 3AZ.
Remove guide (3).

Installation note:
Latch mechanisms (2) and gasket (3) of the guide (1) must not
be damaged or missing.
 4/30/2016 1/1

54 12 155 Removing and installing/replacing

handle strip for sliding roof

Partially open sliding head liner.

Reach between glass slide/tilt sunroof panel and sliding head liner with one hand and unlock retaining lugs (2)
one after the other.
At the same time remove handle strip (1) downwards.
Installation note:
Retaining lugs must not be damaged.
 4/30/2016 1/1

84 31 550 Removing and installing/replacing

hands-free microphone, driver's side

Lever out microphone (1) in direction of arrow.

Disconnect plug connection (1) and remove microphone (2).

Replacement:
Release catch (1) and remove microphone (2) from trim (3).
 4/30/2016 1/1

84 31 020 Removing and installing/replacing

hands-free system speaker

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism

Disconnect plug connection (1).

If necessary, release cable straps from latch mechanisms (2).
Unlock latch mechanisms (2) and remove speaker (3) from
bracket.
 
Installation note:
Latch mechanisms (2) must not be damaged.
Guide lugs of bracket must be seated in grooves of speaker (3).
Speaker (3) must snap audibly into place in bracket.
 4/30/2016 1/2

51 44 011 Removing and installing/replacing

headlining (version with slide/tilt sunroof)

Necessary preliminary work:

 Remove both trim panels for roof pillar at front (A-
pillar)
 Remove both trim panels for door post at top (B-
pillar)
 Remove both trim panels for rear roof pillar (C-pillar)
 Remove rear interior roof light
 Remove both sun visors and counter supports
 Remove all grab handles
 Remove trim panel for storage shelf
 Detach edge protection from all doors and tailgate in
headlining area.
Depending on version:
 Remove mirror lights
 Remove roof switch cluster
 Remove front ceiling light
 Remove microphones

Version with load area net mounts:

Remove all load area net mounts (1):

- Open protective cap (2)

- Release screw (3).

- Remove load area net mounts (1)

Installation note:
Observe location data on rear side of load area net mount (1).

Fold down rear seat backrest.

Adjust backrest of driver's and front passenger seat all the way
back.
Detach edge protection (1) toward the inside.
 4/30/2016 2/2

Important!
The following tasks must be carried out with a second
person assisting:

Release headliner at clips (2) and expanding rivet (3).

Remove the headlining through the rear lid opening.

Installation note:
If necessary, replace faulty clips (1).
 

Replacement (depending on version):

Cut out pre-stamped aperture (2) with scalpel.
Important!
Ensure a clean cut so that the headliner material is not
damaged on the inside.
 4/30/2016 1/1

52 26 210 Removing and installing/replacing

headrest for left or right rear seat

Fold the rear seat backrest forward and adjust the headrest (1)
to the maximum top position.
Press lock (2) and pull upwards and out head restraint (1).
 4/30/2016 1/1

64 11 213 Removing and installing/replacing

heating and air conditioning blower

Necessary preliminary tasks:

 Remove trim for instrument panel at bottom right

Unlock plug connections (2) and disconnect.

Release screws at marked points.
Remove blower (1).
 
Installation note:
Hold blower (1) in installation position and tighten all screws
evenly.
 4/30/2016 1/4

64 11 206 Removing and installing/replacing

heating and air-conditioning unit
(N13,N20,N26,N55)

Special tools required:

 00 9 030
 17 2 050
 32 1 270

Warning!
Danger of injury!
Refrigerant circuit is under high pressure!
Avoid contact with refrigerant and refrigerant fluid.
Read and comply with safety information:
 Handling R 134a (tetrafluorethane) refrigerant
 Handling refrigerant oil

Important!
Risk of damage!
Restart engine only when air conditioning system has
been correctly filled.
Follow notes for opening and replacing parts in refrigerant
circuit.
If air conditioning system is opened for more than 24
hours: Replace condenser for air conditioning.

Necessary preliminary tasks:

 Drain off air conditioning system
 Remove support for dashboard
 4/30/2016 2/4

Recycling
Coolant emerges when coolant lines are detached. Have a
suitable collecting vessel ready.
Catch and dispose of escaping coolant.
Observe country-specific waste disposal regulations.

Note:
Only applicable to: F20,21 / N13

Unlock plastic clamp (1) on intake pipe (2) and open.

Note:
Example illustration F20 / N13

Release screws (1).

Tightening torque 64 53 1AZ.
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to mount sealing rings without
damaging them.

Important!
Connections must not be mixed up!
Mark connection sequence of water hoses prior to
removal.

Release hose clamps (1) with special tool 17 2 050 and detach

coolant hoses (2).
 4/30/2016 3/4

Important!
Carefully blow out coolant ports on the heat exchanger to
remove the remaining coolant.
Close openings or line to heat exchanger with special
tool 32 1 270, to avoid media leak and dirt contamination.

Warning!
Protect passenger compartment against
emerging coolant.
Unfasten plug connection (3) and disconnect.
Unclip the air duct (1) to the right of the
heating and air-conditioning unit (2).
Unclip the wiring harness at the marked
points.
Feed out heating and air-conditioning unit (2)
in direction of arrow.
Attention!
In the event of incorrect installation, there is a
risk of water damage in the passenger
 4/30/2016 4/4

compartment!
Installation note:
Spray condensate drain (4) with lubricant G13
(sourcing reference BMW Parts Department)
before installation of heating and air-
conditioning unit (2).
Heating and air-conditioning unit (2) must fit
exactly on condensate drain (4).
Perform a visual inspection after installing the
heater (2).

Replacement:
 Modify evaporator
 Modify heat exchanger
 Modify expansion valve
 Modify all actuator drives

After installation:
 Evacuate and fill air conditioning
 Bleed and fill cooling system
IMPORTANT!
Filling and bleeding must not be performed in ECO-PRO
MODE!
 4/29/2016 1/4

13 51 017 Removing and installing/replacing high

pressure pump (Bosch) (N55)

Warning!
Observe warning on cylinder head cover.
Disconnect negative battery terminal (risk of fire due to
short-circuiting on dismantling).
Electric fuel pump starts up automatically when door is
opened!
Carry out installation work on fuel system only with coolant
temperature below 40 °C.

Important!
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the
high pressure line is released!

Important!
Adhere to conditions of absolute cleanliness when working
on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the
system!
 Do not allow any dirt particles or foreign bodies to
get into the system.
 Remove all traces of dirt before removing lines or
separate components.
 Use only fluff-free cloths.
 Seal all fuel system openings with protective caps or
plugs.

Important!
 4/29/2016 2/4

Ignition coils must not be contaminated by fuel.

The resistance of the silicone material is reduced
significantly by contact with fuel, which may cause the
ignition coil to fail!
Cover ignition coil with suitable means.

Necessary preliminary tasks:

 Remove feed line.
 Remove pressure line.

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Release screws (1).
Remove high pressure pump (2).
When removing the high pressure pump, ensure that the pump
tappet does not fall out.
Installation note:
Before installing the high pressure pump, the cam of the high
pressure pump drive must be turned to BDC. To do this, twist
 4/29/2016 3/4

the engine if necessary in the direction of engine rotation to the

central bolt of the crankshaft.
Adhere to tightening/torque sequence.

Lay depth gauge (1) flat on high pressure pump flange.

Turn engine at central bolt in direction of engine rotation until
the depth gauge shows that the camshaft has reached the BDC
position.

Installation note:
Replace O-ring (1) and coat with engine oil.
Clean contact surfaces.

Install high pressure pump (2).

Installation note:
Provisionally fasten screws (1) on high pressure pump (2) and
tighten alternately in 90° increments until final tightening,
otherwise the piston may break as a result of tilting!
 4/29/2016 4/4

Tightening torque 13 53 1AZ.

Attach connector.

Assemble engine.
Check fuel system for tightness.
Check function of DME.
 4/29/2016 1/7

11 65 040 Removing and installing/replacing high-

pressure exhaust turbocharger (small
turbocharger) (N47S)

Special tools required:

 11 8 600

Warning!
Risk of burning!
Only perform this repair work on an engine that has cooled
down.

Recycling:
Catch escaping engine oil with suitable auxiliary materials.
Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

 Remove acoustic cover
 Remove air filter housing.
 4/29/2016 2/7

 Remove fan cowl

 Remove right charge-air duct
 Remove cover for windscreen cowl panel.

Important!
In event of exhaust turbocharger damage:
 Pressure pipes
 Charge air cooler
 Intake plenum
- must be checked for foreign bodies, damage and correct
function.

Release screws (1).

Release screws (1) and mounting screws at top.

 4/29/2016 3/7

Remove retaining plate (1) and set down in upward direction of

valve hood.

Release screws on heat shield (1). Heat shield (2) remains on

exhaust manifold.

Release screw (1) on intake hose (2).

 4/29/2016 4/7

Unlock clip (1) in direction of arrow.

Detach intake hose (2) in direction of arrow.
Remove intake hose (3).

Release screws (1) and (2) on connecting pipe (3).

Twist out connecting pipe (1) in direction of arrow.

Installation note:
Check sealing rings for damage and replace if necessary.
Coat sealing rings when installing with lubricant.
 4/29/2016 5/7

Release screws (1) on connecting pipe (2).

Installation note:
Check sealing rings for damage and replace if necessary.
Coat sealing rings when installing with lubricant.

Release screws (1).
Screw (2) can be released only vacuum unit screws (3) have
been slackened slightly.
Tightening torque 11 65 2AZ.

Release banjo bolt (1).

Tightening torque 11 42 2AZ.
Note:
Catch escaping engine oil in a suitable collecting vessel.

Installation note:
 4/29/2016 6/7

Align oil line (2) centrally.

Clean sealing surfaces and replace seal.
Check oil level and top up if necessary.

Release screw (1) and hose clamp (2) from oil return line (3).

Important!
The turbine wheel blades must not be damaged when the
turbocharger is removed!

Release screws (2) on exhaust turbocharger with special

tool 11 8 600 in conjunction with a torque wrench (1).
Installation note:
 When special tool 11 8 600 is used, 7 Nm on the torque
wrench (1) scale correspond to an actual tightening
torque of 8 Nm
Tightening torque 11 65 4AZ.
 Convert oil lines where necessary to new turbocharger.
 Replace all seals
 Clean sealing surfaces on exhaust manifold
 Replace gasket for turbocharger
 4/29/2016 7/7

Assemble engine.
 4/30/2016 1/2

61 67 100 Removing and installing/replacing high-

pressure nozzle of headlight cleaning
system on left (or right)

Special tools required:

 00 9 340

Necessary preliminary tasks:

 Remove front bumper panel

Note:
Work shown on the F30 by way of example, deviations in detail
are possible in other models.

Use special tool 00 9 340 to lift the cover (1).

Slowly pull out high-pressure nozzle of headlight washer

system (1) at cover (2).
Unclamp cover (2) in direction of arrow and remove.
Allow high-pressure nozzle of headlight washer system (1) to
slide back slowly.

Unlock safety coupling (1) of high-pressure line (2) and detach

high-pressure line (2) in direction of arrow.
Lift retaining lugs (3) in direction of arrow and feed high-
pressure nozzle (4) towards rear out of bumper panel.
 
 4/30/2016 2/2

Installation note:
Keep hose connection for high-pressure nozzle (4) and high-
pressure line (2) clean and free from grease.
Make sure high-pressure line (2) is correctly engaged on high-
pressure nozzle (4).
Make sure high-pressure nozzle (4) is correctly engaged on
front bumper panel.
Carry out a function check before fitting bumper panel.
If necessary, top up washer fluid.
 4/30/2016 1/3

41 61 060 Removing and installing/replacing hinge

for engine compartment lid

Warning!
Support engine compartment lid in fully opened position
with suitable apparatus. Risk of injury.

Important!
These instructions only apply to vehicles without active
pedestrian protection!
Observe separate procedure for vehicles withactive
pedestrian protection!

For stripping and rigging operations, refer to texts on KSD

CD (job number 41 61 060).

Necessary preliminary tasks:

Remove gas prop for engine compartment lid
 4/30/2016 2/3

Position suitable cloth under engine compartment lid without

gaps.

Important!
After nuts have been slackened no lateral forces must be
exerted on the engine compartment lid!
Secure engine compartment lid with a second person.

Unscrew nuts (1).

Tightening torque 41 61 1AZ.

Release screws (1) and remove hinge.

Tightening torque 41 61 2AZ.
Installation note:
Adjust hinge together with engine compartment lid.
4/30/2016 3/3
 4/29/2016 1/1

13 62 560 Removing and installing/replacing hot

film air mass meter (N55)

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.

Release screws (1).
Tightening torque 13 71 4AZ.
Pull hot film air mass meter (2) out of upper section of intake
silencer housing.

Note:
Check stored fault message.
Delete fault memory.
 4/30/2016 1/1

61 31 066 Removing and installing/replacing hotel

position switch

Special tools required:

 00 9 327

Necessary preliminary tasks:

 Open glove box.

Lift out hotel position switch (1) with special tool 00 9 327

toward the front.
Disconnect associated plug connection and remove hotel
position switch (1).
 4/30/2016 1/3

51 34 160 Removing and installing/replacing

housing cover on inner left or right door
window frame

Necessary preliminary tasks:

 Open side window
 Remove rear door trim panel
Version with roller sunblind:
 Remove roller sunblind from fixed side window

Version with roller sunblind:

Press hook (1) down toward the inside using your thumb until
the locking tab (2) becomes visible through the distortion.
In this position pull off hook (1) towards the outside.
Installation note:
Locking tab (2) and mounting T-piece on hook (1) must not be
damaged or missing.

Version with roller sunblind:

Installation note:
Retaining clip (1) must not be bent or damaged.

Pry off weather strip (1) towards the top.

4/30/2016 3/3
 4/30/2016 1/2

51 16 040 Removing and installing/replacing

housing on left or right exterior mirror

Necessary preliminary tasks:

 Remove protective cap on exterior mirror

Release screws (1).

Release screw (1).
Remove housing (2) carefully and disconnect plug connection
at side repeater (3).

Installation note:
Make sure retaining ring (1) is correctly mounted on side
repeater (2) and housing (3).
 4/30/2016 2/2

Installation note:
Screw holes (1) must not be damaged.
 

Replacement:
Feed side repeater (2) out of housing (3) in direction of arrow.
 4/29/2016 1/2

11 41 115 Removing and installing/replacing

hydraulic valve (N55)

Necessary preliminary tasks:

 Remove fan cowl with electric fan.
 Have a cleaning cloth ready to catch escaping oil

Detach connector (1) from hydraulic valve (2).

Release screw (1) and remove hydraulic valve.

Tightening torque: 11 41 4AZ.

Replace O-ring (1).
 4/29/2016 2/2

Assemble engine.
Check function of Digital Engine Electronics.
Check oil pressure.
Diagnosis path:

- Digital Motor Electronics

- Complete vehicle

- Power train

- Engine electronics

- Engine oil

- Oil-pressure control
 4/29/2016 1/1

12 .. ... Removing and installing/replacing

ignition coil cover (N55)

Pull ignition coil cover (1) upward off of rubber mount.

 4/30/2016 1/2

51 22 225 Removing and installing/replacing inside

door opener of rear left or right door

Necessary preliminary tasks:

 Remove rear door trim panel
 Remove LED for door opener if necessary

 
Note:
Door opener is welded to door trim panel only on initial
installation. The door opener is screw-connected on second
installation. If applicable, release screws instead of welding
spots.

Note:
Graphic is similar.

Lever out lock (2)

Pull off Bowden cable housing (3) towards rear/top - the
Bowden cable feeds out of its own accord in the process.
Installation note:
To install the Bowden cable, press inner door handle (1)
opposite to direction of arrow.

Drill out welding spots (1) on door opener (2) with 8 mm dia.

weld spot drill bit and remove.door opener (2).

Installation note:
Secure door opener (1) on door trim panel (2) with repair
 4/30/2016 2/2

screw (3).
Tightening torque 51 42 2AZ.
Door opener (1) must rest against door trim panel (2) at the
attachment points without gaps.
 4/30/2016 1/3

51 16 063 Removing and installing/replacing inside

mirror (overview)

Important!
Rear-view mirrors with modified mirror base are installed
starting with series launch F20 and all following new
productions.
Observe new repair instructions!
 
Further introduction date:

F01, F02, F03, F06, F07, F10, F11, F12, F13, 07/2012
F18

F25 03/2012

Note:
If the document for the selected model is not required or not
approved, the following message will be displayed when
clicking on the "cross-reference": "No documents with further
information available for the currently selected vehicle context".

Distinguishing feature:
(A) old version, small mirror base (1) with round base plate on
windscreen
(B) new version, large mirror base (2) with square base plate
on windscreen
Note:
Dismantling of mirror cap is identical on both versions.

Version with mirror arm end cap:

 old version
 4/30/2016 2/3

Version with mirror arm end cap:

 new version

Version with rain sensor:

 old version
 new version

Version with Autobeam:

 old version
 new version
 4/30/2016 3/3

Version with Toll interior mirror for Japan:

 old version
 new version
 4/30/2016 1/2

51 16 063 Removing and installing/replacing inside

mirror (from 07/2011)

Important!
Work may only be carried out at a room/object
temperature of 18 ... 28 °C.
If this can not be guaranteed (cold/hot countries), it is
necessary to equalise the temperature of the windscreen,
mirror base and inside mirror (e.g. vehicle left to stand
indoors or in the shade for at least 30 minutes).

Important!
To avoid windscreen breakage:
When removing mirror base, never turn or disengage
towards front or rear.

Use suitable tool to unclip end cap (1) in direction of arrow and
remove.

Installation note:
Latch mechanisms (1) and guides (2) on both end caps (3)
must not be damaged.
For end caps (3) with tabs (4), the spacers must be bonded
onto the tabs (4).
 4/30/2016 2/2

Important!
Risk of damage!
When removing mirror base, never turn or disengage
towards front or rear.
Inside mirror is held on mirror socket (2) by clamp (3) and
latch mechanism in area (A).

If necessary, disconnect plug connection on inside mirror (1).

Jerkily pull off inside mirror (1) parallel to windscreen from
mirror socket (2).
Installation note:
Retaining clips (3) must not be bent or damaged.
Inside mirror (1) in area (A) must be correctly engaged in mirror
socket (2).

Version with compass:

Check compass function if replacing or after disconnecting
inside mirror plug connection or battery.
If necessary, calibrate compass in interior rearview mirror.
Version with high-beam assistant without KAFAS (camera-
based driver support systems):
Normalisation or initialisation is not necessary.
High-Beam Assistant is automatically aligned under the
following conditions:

- Driving on a motorway/ordinary road at night for approx.

50 km and

- Clearly visible road markings

Replacement:
Carry out vehicle programming/coding.
 4/30/2016 1/1

51 45 195 Removing and installing/replacing

instrument panel trim, bottom right

Unfasten screw connection (1).

Note:
Version with knee airbag: Unscrew nuts (1).

Tightening torque 51 45 9AZ.

Release trim panel (2) at clamps (3).
Feed out trim panel (2) in area (A) toward the bottom.
Lower trim panel (2) slightly and disconnect plug connections
behind it.
Installation note:
Feed in trim panel (2) in area (A) correctly behind the centre
console.
Clamps (3) must not be damaged.

Installation note:
Guides (1) must not be damaged or missing.
Feed guides (1) correctly into the corresponding holders on the
vehicle.

Replacement (depending on version):

Remount footwell light (2).
Remount power socket.
 4/30/2016 1/2

62 11 280 Removing and installing/replacing

instrument panel

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point
 Move steering column completely rearwards
 If necessary, tape off cover to protect against
damage

Release screws (1).
Tightening torque 62 11 1AZ.
Pry out instrument panel in direction of arrow.

Detach plug connection (1) and remove instrument panel (2).

Installation note:
 4/30/2016 2/2

Retaining tabs (1) of dashboard (2) must be exactly seated in

mountings of dashboard.

Replacement:
Carry out vehicle programming/encoding.
Check values for Condition Based Service (CBS) and correct if
necessary.
 4/30/2016 1/1

51 48 001 Removing and installing/replacing

insulation lining on engine hood/bonnet

Note:
Example shown on F01: There may be differences in detail in
the case of other vehicle types.

Release all expanding rivets/clips on damping material (1).

Remove damping material (1).
 4/29/2016 1/5

11 31 025 Removing and installing/replacing intake

camshaft (N55)

Special tools required:

 11 4 481

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove intake adjuster.
 Remove intermediate lever.
 Adjust valve timing.

Note:
All bearing caps are identified with numbers from 1 to 6.

The front bearing cap is a thrust bearing and does not have an
identification.
Release screws on thrust bearing cover.
Release screws on all bearing caps 1 to 6.
Set all bearing caps down in special tool  11 4 481 in a neat and
orderly fashion.

Remove intake camshaft (2) towards top.

Installation note:
Clean all bearing positions and lubricate with oil.
 4/29/2016 2/5

Check plain rectangular compression rings (1) for damage.

Metal plain rectangular compression ring:

Important!
Plain rectangular compression rings (1) can easily break.

Only replace plain rectangular compression rings (1) when they

are broken.
The plain rectangular compression rings have catches at the
joint.
Press plain rectangular compression rings (1) apart upwards
and downwards and removed towards front.
Make sure plain rectangular compression rings (1) can move
freely.
Installation note:
When intake camshafts are inserted, no joint must point to a
separating joint.

Plastic plain rectangular compression ring:

Installation note:
The plastic plain rectangular compression ring is maintenance
free and does not have to be replaced.

Insert plastic plain rectangular compression ring (1) into groove

of intake camshaft (2) (see arrow).
Lightly oil plastic plain rectangular compression ring (1) and
rotate in direction of arrow until plastic plain rectangular
compression ring (1) is positioned on the intake camshaft.
 4/29/2016 3/5

Check plastic plain rectangular compression ring (1 and 2) for

freedom of movement.

Important!
Marks of intake and exhaust camshafts are different.
Mixing up the intake and exhaust camshaft will result in engine
damage.
A Exhaust camshaft.
E Intake camshaft

Install intake camshaft so that the latch mechanism of the plain

rectangular compression rings (1) does not point to a contact
point of the bearing cap
Centre latch mechanism of the plain rectangular compression
rings with the bearing cap.
Note:
Image of the exhaust camshaft.

Insert intake camshaft so that data code (1) on mounting flats

points upwards.
 4/29/2016 4/5

Position intake camshaft (1) so that cams point upwards at an

angle and to the left.

Note:
All bearing caps are identified with numbers from 1 to 6.

The front bearing cap is a thrust bearing and does not have an
identification.
Insert screws on all bearing caps 1 to 6.
Insert screws on thrust bearing cover.
Tightening torque 11 31 3AZ.

Assemble engine.
4/29/2016 5/5
 4/29/2016 1/1

13 71 000 Removing and installing/replacing intake

silencer housing (N55)

Necessary preliminary tasks:

 F33 only:
Remove left front strut.

Release connector (1) on hot film air mass meter and

disconnect.
Release clamp (2).
Tightening torque 13 71 1AZ.
Detach intake silencer housing (3) from rubber mount in upward
direction.
Detach intake silencer housing from front rubber mount (4) and
remove toward the top.

Reassemble the vehicle.

 4/30/2016 1/17

34 52 121 Removing and installing/replacing

integrated chassis management control
unit (complete procedure)

Special tools required:

 00 9 327
 00 9 340
 00 9 317

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Important!
Read and comply with notes on handling wiring harnesses
and cables.

Warning!
The sensor system for triggering the airbag is installed in
the ICM control unit!
 4/30/2016 2/17

The battery must be disconnected before removing the

ICM control unit (ICM control unit de-energised)!
There is a risk of the airbag being triggered inadvertently if
this requirement is disregarded!

Warning!
Observe safety instructions for handling vehicle battery.
Follow instructions for disconnecting and connecting
battery!
Observe notes on voltage supply / on intelligent battery
sensor (IBS).

Lift luggage compartment floor.

Loosen nut (1).
Important!
Do not under any circumstances use force to pull off
negative terminal.

Detach battery negative lead with IBS towards top, lay to one

side and secure.

Loosen cover (1) with special tool 00 9 327 from clamps (2).

If necessary, unlock associated plug connections and
disconnect.
Feed out cover (2) to the top/rear.
 4/30/2016 3/17

Partially fit special tool 00 9 340 as pictured.

Lift cover (1) all around and remove upwards.

Release cover (1) at latch mechanisms (2) and clamps (3).

Slightly raise the cover (1) and disconnect associated plug
connection.
Feed out cover (1) toward the top / rear.

Unfasten plug connection (1) and disconnect.

Unfasten screws (2).
Feed storage compartment (3) out of guides (4) and disconnect
the plug connection from charging socket (5).
 4/30/2016 4/17

Loosen the latch mechanisms (1) left/right from the bottom with

special tool 00 9 327.
Unclip cover (2) towards rear.
If necessary, unlock associated plug connections and
disconnect.
Remove cover (2).

Warning!
Read and comply with safety regulations for handling
airbag modules and pyrotechnical belt tensioners.

Important!
Operations on pyrotechnical devices may only be carried
out by authorised experts.
Improper, unauthorised operations may result in serious
dangers.
Unauthorised persons are strictly prohibited from
performing any operations on this system.
 4/30/2016 5/17

Release screw connection (1).

Release trim panel for pedal mechanism (2) at clamps (3).
Slightly lower trim panel for pedal mechanism (2) and
disconnect plug connections behind.

Release screw connection (1).

Release passenger side trim panel (2) at clamps (3).
Feed out passenger side trim panel (2) in area (A) towards
bottom.
Slightly lower passenger side trim panel (2) and disconnect plug
connection behind.

Unclip gaiter (1), top, with special tool 00 9 317, if applicable.

 4/30/2016 6/17

Pull gaiter (2) over parking brake lever.

Cut cable ties (1) and remove gaiter.

Release screws (1).

Lift gear selector switch (2), then unlock plug connection (1) at

gear selector switch (2) and disconnect.
 4/30/2016 7/17

Unscrew nuts (1).

Disconnect plug connections (2), depending on version.

Release screws (1 and 2).

Detach wiring harness (3) from central console mount.

Raise the centre console (1) rear and feed out gaiter (2).

Remove centre console (1) to the rear/top.
If applicable, note other plug connections and cable clips.
 4/30/2016 8/17

Warning!
Make sure that the negative battery lead is disconnected!
There is a risk of the airbag being triggered inadvertently!

Disconnect plug connection (1).

Release nuts (2) and remove ICM control unit (3).
 
 

Installation:                                                                 

Important!
Do not trap any electrical wires when installing ICM control
unit!

Insert integrated chassis management control unit.

Renew and tighten self-locking nuts.
Tightening torque 34 51 2AZ.
Connect plug connection (1).

Position centre console (1) over gearshift lever and gaiter (2)

from rear/top.
Feed centre console (1) correctly into dashboard including
guides (4).
Make sure wiring harness (3) is in correct position.
 4/30/2016 9/17

Tighten down screws (1).

Tightening torque 51 16 4AZ.
Tighten down screws (2).
Tightening torque 51 16 3AZ.
Secure wiring harness (3) to centre console mounting.

Tighten down nuts (1).

Tightening torque 51 16 3AZ.
Connect plug connections (2), depending on version.

Connect plug connection (1) to gear selector switch (2).

 4/30/2016 10/17

Insert gear selector switch (2) correctly in front and rear fixation

of centre console support (3).
Tighten down screws (1).
Tightening torque 61 31 1AZ.

Pull gaiter (2) over parking brake lever and secure with cable
strap (1).
Eye of cable strap must point towards bottom.

First insert the gaiter (1) on the bottom and then clip in on the
top.
 4/30/2016 11/17

Guides (1) must not be damaged or missing.

Insert guides (1) correctly into the corresponding holders in the
vehicle.

Clamps (3) must not be damaged.

Connect plug connection to trim panel (2).
Feed in trim panel (2) in area (A) correctly behind the centre
console.
Clip in trim panel (2) with clamps (3).
Tighten screw connection (1).
Tightening torque 51 45 9AZ.

Clamps (1) and guides  (2) must not be damaged.

Feed guides (2) correctly into the corresponding holder in the
vehicle.
 4/30/2016 12/17

Slightly insert trim panel (2) and connect related plug

connections.
Clip in trim panel (2) with clamps (3).
Tighten screw connection (1).
Tightening torque 51 45 8AZ.

Latch mechanisms (1) on cover (2) must not be damaged or

missing.

Position cover (2) from rear and if required connect related plug

connections.
Clip in cover (2).
 4/30/2016 13/17

Guides (1) must not be damaged.

Connect plug connection to power socket (5).

Feed in storage compartment (3) and check guides (4) are
correctly fitted.
Connect plug connection (1).
Tighten down screws (2).

Note:
The following parts must not be damaged or missing:

- Guides (1)

- Latch mechanisms (2)

 4/30/2016 14/17

- Clamps (3)

Feed in cover (1) from top/rear and connect related plug

connection.
Clip in cover (1) at latch mechanisms (2) and clamps (3).

Latch mechanisms (1) on cover (2) must not be damaged or

missing.

Clip in cover (1) from top.

 4/30/2016 15/17

Note:
Clamps (1) and guide (2) must not be damaged or missing.
Feed guide (2) correctly into centre console.

Feed in cover (2) from top/rear.

If necessary, connect related plug connections.
Clip in cover (1) with clamps (2).

Connect battery earth lead with IBS to battery.

Tighten nut (1).
Tightening torque 61 21 1AZ.
 4/30/2016 16/17

Connect vehicle to BMW diagnosis system.

Select and carry out start-up of ICM control unit under Service
functions.

Replacement:
After completing repairs, use BMW Diagnosis and Information
System to

- Switch the ignition on.

- carry out programming/encoding

- Connect BMW diagnosis system

- Carry out ride height adjustment (menu item: ”Service

function”)
Important!
Following ride height adjustment, for vehicles with:
 Run Flat Indicator:
Initialise Run Flat Indicator
 Tyre Pressure Monitor:
Resetting Tyre Pressure Monitor
 4/30/2016 17/17

- Select and carry out start-up of integrated chassis

management control unit under Service functions
 4/30/2016 1/1

61 35 953 Removing and installing/replacing

interior aerial for Comfort Access (front
storage compartment)

Necessary preliminary tasks:

 Remove front storage compartment

Note:
Similar to graphic.

Disconnect plug connection (1).

Release screw (2).
Remove interior aerial (3).
Installation note:
Make sure interior aerial (3) is correctly fitted.
Make sure plug connection (1) is correctly seated.
 4/30/2016 1/1

61 35 954 Removing and installing/replacing

interior aerial for comfort access system
(rear centre console)

Necessary preliminary tasks:

 Remove rear centre console trim

Note:
Work shown on the F30 by way of example, deviations in detail
are possible in other models.

Depending on the equipment specification, if necessary release

cable clips (1) at latches (arrow) and set down.
Installation note:
Make sure cable clip (1) is correctly seated.

Note:
Similar to graphic.

Unfasten plug connection (1) and disconnect.

Release screw (2) and remove interior aerial (3).
Tightening torque 61 35 7AZ.
Installation note:
Make sure plug connection (1) and interior aerial (3) are
correctly seated.
 4/29/2016 1/12

11 37 010 Removing and installing/replacing

intermediate levers (N55)

Special tools required:

 11 4 450
 11 4 481
 11 7 110

Warning!
Risk of injury in event of incorrect use.

Important!
Improper handling. Risk of damage!

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove all ignition coils and injector shafts.
 4/29/2016 2/12

 Remove console for windscreen wiper (only E7x).

Slowly adjust eccentric shaft in direction of arrow to minimum

stroke via the servomotor with a 4-mm hexagon socket
wrench (2) and an open-end spanner (1).
Important!
Secure eccentric shaft with open-end spanner (1) (risk of
return stroke).

Release bolt (1) on the oil spray nozzle.

Tightening torque: 11 37 4AZ.
Unclip oil spray nozzle (2) from the bracket on the actuator
drive (3) in direction of arrow.

Position special tool 11 7 110 on return spring (1) (see arrows).

 4/29/2016 3/12

Warning!
Risk of injury in event of incorrect use.

Important!
Improper handling. Risk of damage!

Place special tool 11 7 110 flat on cylinder head.

Turn knurled screw (1) in direction of arrow until both clamping
levers secure return spring in gate.

Return spring is correctly preloaded when both clamping levers

are parallel to guide block.

Important!
Risk of damage!

Left and right return springs (1) must be positioned in lateral

guide of special tool 11 7 110.
 4/29/2016 4/12

Preload return spring with lever (1) on special tool 11 7 110 in

direction of arrow.

Lock special tool 11 7 110 with latching hook on lever (1).

Important!
Screw connection on return spring can first be released
with secured special tool 11 7 110.

Release screw (1).
 4/29/2016 5/12

Warning!
Risk of injury in event of incorrect use.
Lever (1) is preloaded.

Important!
Improper handling. Risk of damage!

Secure lever (1).

Press back latching hook (2).
Return spring tension can now be released.

Release knurled screw (1) on special tool 11 7 110 in direction

of arrow.

Release special tool 11 7 110 in direction of arrow from return

spring (1).
 4/29/2016 6/12

Press return spring (1) apart.

Remove return spring (1) upward.

Important!
Uniform distribution must not be changed.
Place all components in clean and orderly condition in
special tool 11 4 481.

All components must be reinstalled in the same positions in an

engine which has already been in use.
1 Eccentric shaft with bearing
2 Bearing caps of eccentric shaft (set out in order)
3 Intake camshaft
4 Bearing caps of intake camshaft (set out in order)
5 Intake valves with valve springs
6 Valve heads and valve keys
7 Rocker arms with hydraulic valve clearance compensating
elements (in neat order).
8 Return springs.
9 Gates (set out in order)
 4/29/2016 7/12

10 Intermediate levers (set out in order)

Release screws (1) on gate (2).

Tightening torque 11 37 1AZ.
Place all gates (2) in neat order in special tool 11 4 481.
Installation note:
Mixing up the gates (2) will cause the engine to suffer idle-
speed fluctuations.
This will result in maladjustment of uniform distribution.

Installation note:
All contact surfaces (1) of gates must be clean and free from oil
and grease. If necessary, clean contact surfaces (1).

Lift out intermediate levers (1).

Place all intermediate levers (1) in neat order in special tool
11 4 481.
Installation note:
Mixing up the intermediate levers (1) will cause the engine to
suffer idle-speed fluctuations.

Installation note:
All contact surfaces must be clean and free of oil and grease. If
necessary, clean contact surfaces.

All intermediate levers are classified.

All intermediate levers must be reinstalled in the same positions
in an engine which has already been in use.
 4/29/2016 8/12

Intermediate levers are classified from 1 to 5.

Important!
Before installing intermediate levers (1), make sure rocker
arms are correctly positioned.
Risk of damage!

Install intermediate levers (1).

Fit gate (2) cleanly into recess.

Tighten screws (1) hand-tight.
Check that intermediate levers are in correct installation
position.
Release screws (1) by a 1/4 turn.
 4/29/2016 9/12

Secure special tool 11 4 450 on screw connection (1) of

eccentric shaft and set adjusting screw on special tool 11 4 450
if necessary.
Turn eccentric lever on special tool 11 4 450 in direction of
arrow.
Gate is now preloaded.
Insert screws (1) of gates.
Tightening torque 11 37 1AZ.
Installation note:
At cylinder no. 3, the gate can be pre-installed with one
screw (internal) only.
Oil spray nozzle is fitted only after return spring has been
installed.

Press return spring (1) apart.

Install return spring (1).

Install return spring (2) on gate.

Installation note:
 4/29/2016 10/12

Insert return spring (2) in intermediate lever (1) (see arrow).

Check that rocker arm (3) is in correct installation position.

Position special tool 11 7 110 on return spring.

Clamp return spring with knurled screw (1) in direction of arrow.

Return spring (1) is positioned correctly when latching hooks

surround return spring (1).
 4/29/2016 11/12

Warning!
Risk of injury in event of incorrect use.

Important!
Improper handling. Risk of damage!
Check return spring on intermediate lever to ensure
correct installation position.

Press special tool 11 7 110 to stop in direction of arrow.

Important!
Pay attention to thread on cylinder head. Risk of damage!

Tighten bolt (1).

Tightening torque 11 37 2AZ.

Retract oil spray nozzle (2) on actuator drive (3).

Engage bolt (1) and release back to 90°.
For exact positioning of the oil spray nozzle (2) audibly clip it in
at the top.
Tightening torque 11 37 4AZ.
 4/29/2016 12/12

Assemble engine.
 4/30/2016 1/1

63 31 187 Removing and installing/replacing LED

for left or right door post trim panel

Necessary preliminary tasks:

 Partially remove trim panel for top of door post

Note:
Work shown on the F30 by way of example, deviations in detail
are possible in other models.

Unlock and disconnect plug connection (1) on door post.

Lever out cable at cable clip (2) from door post.

Note:
Work shown on the F30 by way of example, deviations in detail
are possible in other models.
Graphic shows trim panel (3) removed.

Carefully lever out LED module (1) from holder (2) with a

suitable tool.
Lever out cable at cable clip (4) from trim panel (3) and remove
LED module (1).
Installation note:
Make sure LED module (1) is correctly fitted in holder (2).
Cable clips (4) must not be missing or damaged.
Ensure correct cable routing.
 4/30/2016 1/1

51 23 110 Removing and installing/replacing left

engine compartment lid lock.

Necessary preliminary work (only F33):

 Remove left front-end strut

Detach plug connection (1) by twisting from catch carrier.

Unfasten plug connection (1) and disconnect.
Release screws (2) and feed out engine compartment lid lock
(3).
Tightening torque 51 23 1AZ.

Unclip grommet (1).
Unhook Bowden cable (2) from engine compartment lid lock (3).
 4/30/2016 1/2

63 17 070 Removing and installing/replacing left

fog light

Important!
Follow instructions for handling light bulbs (exterior lights)

Necessary preliminary tasks:

 Partially release wheel arch cover front (front
section)

Fold wheel arch cover (1) back.

Unfasten plug connection (2) and disconnect.

Release screw (1).
Tightening torque 63 12 2AZ.
Remove fog light (2) out of bumper panel (3) in direction of
arrow.

Installation note:
Guides (1) on fog light (2) must not be damaged or missing.
 4/30/2016 2/2

On replacement of fog light or bumper panel at front:

- If necessary, remount bulb

- Adjust fog lights

 4/30/2016 1/1

51 47 151 Removing and installing/replacing left

luggage compartment wheel arch panel

Necessary preliminary work:

 Remove storage shelf
 Remove cover on tail panel
 Fold left rear seat backrest forward

Version with lashing eye:

Lever out cover (1) and release screw underneath.
Tightening torque 51 47 1AZ.
Remove lashing eye (2).

Manoeuvre out luggage compartment wheel arch panel (2) in

direction of arrow
Installation note:
Luggage compartment wheel arch panel must be fitted correctly
under tailgate rubber seal (1).
 4/30/2016 1/1

33 32 188 Removing and installing/replacing left or

right camber arm cover

Unscrew nuts (1).

Tightening torque 33 32 11AZ.
Remove cover (2).
Installation note:
Replace nuts.
Observe positions of marks for L (left) and R (right).
The arrow on the cover points toward the front of the vehicle.
 4/30/2016 1/2

33 32 190 Removing and installing/replacing left or

right camber arm

Note:
If the camber arm is detached from the rear axle support/wheel
carrier, it is necessary after installation to carry out a wheel
alignment.

Necessary preliminary work:

 Remove coil spring, rear .
 Remove camber arm cover.

Only on left side at ride-height sensor:

Release screw (1) and remove holder (2) with jointed rod.
Tightening torque 37 14 3AZ.
Installation note:
Replace screw.

Secure camber arm against falling off.

 
Mark position of eccentric adjustment washer to rear axle
support to simplify subsequent adjustment of rear axle.
 4/30/2016 2/2

Release nut (1) and remove eccentric bolt.

Tightening torque 33 32 9AZ.
Installation note:
Note insertion direction of eccentric screw.
Replace nut.
Tighten down screw connection in normal position.

 
Release nut (2) and remove screw.
Tightening torque 33 32 10AZ.
Installation note:
Note direction of insertion of screw.
Replace nut.

 
Release nut (3) and remove screw.
Tightening torque 33 52 3AZ.
Installation note:
Note direction of insertion of bolts.
Replace screw and nut.
Tighten down screw connection in normal position.

After installation:
 Carry out wheel alignment procedure.
 4/30/2016 1/2

51 47 156 Removing and installing/replacing left or

right capping in luggage compartment

Necessary preliminary work:

 Remove luggage compartment wheel arch panel
 Remove panel for roof pillar at rear

Unlock plug connection (1) and disconnect.

Unfasten screws (2).

Release screws (1).
Remove capping (2) toward the inside and feed out seat belt.
Installation note:
Make sure capping (2) is correctly seated on edge
protection (3).

Replacement:
Unclip speaker (1).
Release screws (2) and remove speaker (3).
4/30/2016 2/2
 4/30/2016 1/1

51 11 770 Removing and installing/replacing left or

right deformation element for front
bumper panel

Necessary preliminary tasks:

 Remove front top and bottom supports for bumper
panel
 Remove air intake silencer housing
 Remove headlight
 Release the side of the centre front panel

Release screw (1).
Tightening torque 51 11 7AZ. 
Unfasten screws (2).
Tightening torque 51 11 2AZ.
Release screw (3).
Tightening torque 5111 6AZ.
Release screws (4).
Tightening torque 51 11 3AZ.
Remove deformation element (5).
 

Replacement:
Release screws (1).
Tightening torque 51 11 5AZ.
Modify the deformation element bottom (2).
 4/30/2016 1/2

61 33 050 Removing and installing/replacing left or

right fanfare

Necessary preliminary tasks:

 Release front wheel arch cover at front area

Note:
Graphic displays F20, deviations in detail possible in other
models.

Unfasten plug connection (1) and disconnect.

Slacken nut (2).
Remove fanfare horn (3).

Note:
Electromechanical fanfare is installed as
standard. The electronic fanfare is only installed
in China, India, Russia,
South Africa and Gulf states as of 01/2011.

A: Electromechanical fanfare
B: Electronic fanfare
Distinguishing features:

- Electromechanical fanfare has a black connector (1)

- Electronic fanfare has a white connector (3)

- Only the electromechanical fanfare has no adjusting

screw (2)

- Holder (4) is vehicle-specific and may deviate from the

graphic.
Important!
In vehicles with a production data before 01/2011, both
 4/30/2016 2/2

fanfares must be replaced in the countries listed above.

The electronic fanfare has a different sound pattern.
Combining the mechanical and electronic fanfares is not
permissible.
The connector position may vary slightly.
Pay particular attention to ensuring that the holder is
securely seated on the vehicle and that the fanfare is
securely seated on the holder! This greatly influences the
tone!
If the new part is delivered with a holder included, the
fanfare must be replaced complete with holder!
 4/30/2016 1/2

34 11 020 Removing and installing/replacing left or

right front brake caliper

Necessary preliminary tasks:

 Remove wheels.
 Read and comply with General Information.

After completing work: Bleed brake system.

Press brake pedal down to floor and secure with pedal support.
Note:
The pedal support may only be released when the brake lines
are reconnected.
This prevents brake fluid from emerging from the expansion
tank and air from entering the system when the brake lines are
opened.

If necessary, pull brake hose out of holder (1).

Important!
Grip brake hose at square head (3) to prevent connector
from turning in retaining bracket.

Disconnect brake hose from brake line (2).

Installation note:
Tightening torque 34 32 1AZ.

Detach brake hose from brake caliper (4).

Installation note:
Tightening torque 34 32 2AZ.

Important!
Never twist brake hose when installing it and avoid all
contact with parts attached rigidly to the body.

Note:
 4/30/2016 2/2

First tighten brake hose on brake caliper.

Move wheels into straight-ahead position.
Insert brake hose in bracket and screw onto brake pipe.

Pull brake pad wear sensor (1) towards rear out of pad (left side
only).
If necessary, replace brake pad wear sensor.
Unscrew guide bolts (3).
If necessary, grip at hexagon head (2).
Remove brake caliper by pulling upwards.
Installation note:
Replace guide bolts.

Tightening torque 34 11 5AZ.

 4/30/2016 1/1

51 23 265 Removing and installing/replacing left or

right gas pressure spring for engine
compartment lid

Warning!
Danger of injury and damage!
For the following tasks, you must take the appropriate
measures to support the engine compartment lid.
As an alternative, you can enlist the help of a second
person to hold the engine compartment lid.

Make a written record of the installation position of the gas

pressure spring(s) before removing.
Carry out ball socket removal at both ends (1) of gas pressure
spring (2).
 4/30/2016 1/1

72 12 061 Removing and installing/replacing left or

right head airbag (version with slide/tilt
sunroof)

Important!
Operations on pyrotechnical devices may only be carried
out by authorised experts.
Improper, unauthorised operations may result in serious
dangers.
Unauthorised persons are strictly prohibited from
performing any operations on this system.

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause injury.
A damaged head airbag must be replaced.
A damaged head airbag exhibits an impaired protective
function and in extreme cases loses its protective function
altogether.

Note:
Except for the operations for Removing headlining, this task is
identical to:
 Removing and installing/replacing left or right head airbag
(version without slide/tilt sunroof)
 4/30/2016 1/1

51 16 130 Removing and installing/replacing left or

right knee pad

Special tools required:

 00 9 325

Loosen knee pad (1) with special tool 00 9 325 from clamps (2).

Installation note:
If necessary, replace faulty clamps (2).

Installation note:
Catches (1) and guides (2) must not be damaged or missing.
 4/30/2016 1/1

63 26 000 Removing and installing/replacing left or

right number/license plate light

Special tools required:

 64 1 020

Important!
Follow instructions for handling light bulbs (exterior lights).

Lever out licence plate light (1) with special tool 64 1 020 in

direction of arrow (A) from tailgate (2).
Remove number/license plate light (1) in direction of arrow (B).
Disconnect plug connection underneath.
 
Replacement:
Note bulb type.
LED technology lights can only be replaced completely!
 4/30/2016 1/2

33 21 000 Removing and installing/replacing left or

right output shaft

Important!
When reinstalling, place a new circlip on the output shaft!
 
The radial shaft seal for the output shaft should be
replaced every time the output shaft is removed and
installed.
 
Observe safety information for raising the vehicle

Necessary preliminary tasks:

- Remove rear wheel.

If necessary, remove visual protection cap (1).

Important!
Expand anti-twist lock sufficiently to avoid damaging
thread when releasing collar nut.

Remove collar nut (1); engage parking brake to do so.

Tightening torque 33 41 1AZ.
Installation note:
Lightly oil the gearing at the shaft journal.
No oil permitted on thread of shaft journal or collar nut.
Replace collar nut and secure by means of positive peening on
 4/30/2016 2/2

flat areas of output shaft.

Remove rear axle final drive.

Important!
Secure output shaft against falling out.
Do not damage dust plates (1) when setting down output
shaft.
 

Press output shaft out of drive flange and remove towards

centre of vehicle.

Installation note:
High installation forces indicate that the output shaft spline teeth
are damaged or deformed!
Check gearing and replace components if damaged.
 

Check dust plate (1) for damage, renew if necessary.

If the previous output shaft is reinstalled, circlip (2) must be
renewed.
Coat contact surface (3) of output shaft with approved final
drive oil.

After installation:
 Check transmission oil level, correct if necessary.
 4/30/2016 1/2

34 21 745 Removing and installing/replacing left or

right rear brake caliper

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove brake pads.
After completing repair work: Bleed brake system.

Press brake pedal down to floor and secure with pedal support.
Note:
The pedal support may only be released when the brake lines
are reconnected.
This prevents brake fluid from emerging from the expansion
tank and air from entering the system when the brake lines are
opened.

Important!
Grip brake hose at square head (2) so that connecting
piece cannot rotate in retaining bracket.

Disconnect brake hose from brake line (1).

Installation note:
Tightening torque 34 32 1AZ.

Detach brake hose from brake caliper (3).

Installation note:
Tightening torque 34 32 3AZ.

Important!
Never twist brake hose when installing it and avoid all
contact with parts attached rigidly to the body.

Note:
First tighten brake hose on brake caliper.
 4/30/2016 2/2

Insert brake hose in bracket and screw onto brake pipe.

 4/30/2016 1/1

61 31 112 Removing and installing/replacing left or

right shift paddle for automatic
transmission

Necessary preliminary tasks:

 Remove airbag unit

Disconnect plug connection (1).

Release screw (3).
Feed out wiring harness (2) and remove shift paddle for
automatic transmission (4) in direction of arrow from steering
wheel (5).
Installation note:
Make sure shift paddle for automatic transmission (4) is
correctly seated on steering wheel (5)
Make sure wiring harness (2) is laid exactly.
 4/30/2016 1/1

51 75 010 Removing and installing/replacing left or

right steering assembly cover

Necessary preliminary tasks:

 Remove front underbody protection

Release screws (1) and feed out cover (2).

Release expanding rivets (3) and feed out cover (4).
Installation note:
Replace faulty expanding rivets (3).
Ensure the correct seating of the covers (2 and 4).
 4/30/2016 1/2

33 32 180 Removing and installing/replacing left or

right toe arm

Note:
If the toe arm is detached from the rear axle support/wheel
carrier, it is necessary after installation to carry out a wheel
alignment.

Necessary preliminary tasks:

 Remove rear wheel.

Release screw (1).
Mark position of eccentric adjustment washer to rear axle
support to simplify subsequent adjustment of rear axle.
Release nut (2), unscrew screw and remove toe arm.

Important!
You must observe the installation sequence and
installation notes!
Failure to comply with these instructions may result in
 4/30/2016 2/2

serious damage to the threads of the wheel carrier!

Do not use an impact screwdriver!
Installation sequence:
Firstly insert toe arm in axle support and do not screw!
Renew screw (1) and position on wheel carrier by hand!
Twist toe arm a little so that screw (1) can be screwed in
by hand without tension!
Insert screw in axle support and renew nut (2)!
Only apply tightening force to both screw connections in
normal position.
Tightening torque 33 32 8AZ.
Tightening torque 33 32 7AZ.

After installation:
 Carry out wheel alignment procedure.
 4/30/2016 1/2

31 12 050 Removing and installing/replacing left or

right trailing link

Necessary preliminary tasks:

 Remove front wheel.

Release screws (1).
Remove cover (2).

Release nut (1), if necessary, grip at inner Torx socket.

Tightening torque 31 12 2AZ.
Installation note:
Replace self-locking nut.
Keep trailing link to swivel bearing connection clean and free
from oil and grease.

Release screw (1).
Tightening torque 31 12 1AZ.
Remove tension strut.
 4/30/2016 2/2

Installation note:
Replace screw (1).
Tighten down screw connection in normal position.
 4/30/2016 1/2

31 12 000 Removing and installing/replacing left or

right wishbone

Note:
If the wishbone is detached from the front axle support, it will be
necessary to carry out the wheel alignment procedure.

Necessary preliminary tasks:

 Remove front wheel.
 Remove front assembly underside protection.
 Remove steering assembly cover. (N47 with rear-
wheel drive only)

Only on ride-height sensor at left:

Release link at wishbone.

Release nut (1), if necessary, grip at inner Torx socket.

Tightening torque 31 12 4AZ.
Installation note:
Keep wishbone to swivel bearing connection clean and free
 4/30/2016 2/2

from oil and grease.

Replace self-locking nut.

Slacken nut (1).

Tightening torque 31 12 3AZ.
Remove screw towards front.
Take off wishbone.
Installation note:
Replace screw and nut.
Bolt head points in direction of travel.
Tighten down screw connection in normal position.

After installation:
 Carry out wheel alignment procedure.
 4/29/2016 1/2

11 61 365 Removing and installing/replacing left-

hand charge air duct (N55 )

Necessary preliminary tasks:

 Remove front underbody protection.
 Release air conditioning compressor (do not draw
off and remove).

(1) Unlocked
(2) Locked
Installation note:
Ensure locking clamps are correctly fitted.
Lock must engage.

Unlock and pull off cable connector (1).

Unlock snap fastener (2).
Pull off charge air duct (3) from throttle body.

Unclip charge air duct (1) from rubber grommet (2).

 4/29/2016 2/2

Unlock snap fastener (1).

Pull off charge air duct (2) from charge air cooler (3).
Installation note:
The seal inside the snap fastener must be coated with anti-
friction agent.
Charge air duct (2) must snap audibly into place!

Assemble engine.
 4/30/2016 1/2

61 31 037 Removing and installing/replacing light

operating facility

Special tools required:

 00 9 325

Note:
When working on trim panel components, make sure that the
sensitive surfaces are not scratched or damaged.

Lever out decorative trim (2) at the retaining points (1) using

special tool 00 9 325.

Unfasten plug connection (1) and disconnect.

Remove decorative trim with lighting operating facility (2).

Replacement:
Unclip lighting operating facility (2) in area (1) and remove from
the decorative trim (3).
Latch mechanisms in area (1) must not be damaged or missing.
4/30/2016 2/2
 4/30/2016 1/2

52 26 311 Removing and installing/replacing lock

for left or right rear seat backrest

Unclip lock finisher (1) in direction of arrow (2) starting with

backrest side section.
Remove lock finisher (1) in direction of arrow (3).

Installation note:
Retaining lugs (1) and (2) of cover must not be damaged.
Replace faulty cover.

Important!
Risk of damage!

Insert plastic wedge from outside between trim (1) and lock.

Carefully lever outer side of trim (1) with plastic wedge upwards
out of catch.
Lever inner side of trim (1) with plastic wedge out of catch.
Remove cover upwards.

Lever out backrest cover (1) in working area.

 4/30/2016 2/2

Release screws and feed door lock (1) out of rear seat

backrest.
Tightening torque 52 26 06AZ.
 4/30/2016 1/1

32 31 020 Removing and installing/replacing lower

section of steering column shroud

Necessary preliminary work:

 Remove upper section of steering column shroud.
 Move steering column in ”top” and ”extended”
position.

Press retaining lugs outwards a little and unclip steering column

shroud downwards.
Installation note:
Align steering column shroud by means of retaining lugs to
steering column and press up as far as it will go.
Press steering column shroud on both sides together a little and
then press upwards completely until retaining lugs snap into
place.
Check installation position, correct if necessary.

Tilt steering column shroud in downward direction.

If necessary, unlock plug connection (1) on steering column
adjustment switch and (2) emergency starting aerial and
disconnect.
Remove lower section of steering column shroud.
 4/29/2016 1/4

11 65 045 Removing and installing/replacing low-

pressure exhaust turbocharger (large
turbocharger) (N47S)

Special tools required:

 11 6 050

Warning!
Risk of burning!
Only perform this repair work on an engine that has cooled
down.

Recycling:
Catch escaping engine oil with suitable auxiliary materials.
Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

 Remove acoustic cover
 Remove air filter housing.
 4/29/2016 2/4

 Remove diesel particulate filter.

 Remove H.P. turbocharger.

Important!
In event of exhaust turbocharger damage:
 Pressure pipes
 Charge air cooler
 Intake plenum
- must be checked for foreign bodies, damage and correct
function.

Release screws (1) on holder.

Release hose clamp (2)

Release bolts (1) on bracket (2).

 4/29/2016 3/4

Release screw (1) on exhaust turbocharger (2) with special

tool 11 6 050 in conjunction with a hinged extension.
Tightening torque 11 65 3AZ.

Important!
Secure turbocharger against falling out.

Release screws (1) on exhaust turbocharger at top with special

tool 11 6 050.
Remove exhaust turbocharger.
Tightening torque 11 65 3AZ.
Installation note:
Apply a thin coating of copper paste to bolt thread.
To avoid damaging the threads and prevent exhaust
turbocharger leakage, insert mounting bolts in 1/2 turns
simultaneously.

Important!
Spacer ring (1) must be fitted without fail.
Clean threads (2) with thread cutter.
 4/29/2016 4/4

Assemble engine.
 4/30/2016 1/1

61 35 970 Removing and installing/replacing

luggage compartment aerial for Comfort
Access

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.
 
Remove luggage compartment floor trim panel (1) in direction of
arrow.

Disconnect plug connection (1).

Unlock and remove luggage compartment aerial (2) from
bracket (3).
 
Installation note:
Make sure luggage compartment aerial (2) is seated correctly in
bracket (3).
 4/30/2016 1/1

51 47 101 Removing and installing/replacing

luggage compartment floor trim panel

Remove luggage compartment floor trim panel (1) in direction of

arrow.
 4/30/2016 1/1

63 31 080 Removing and installing/replacing

luggage compartment light

Important!
Follow notes for handling light bulbs (interior lights).

Lift luggage compartment light (1) out of luggage compartment

trim panel (2) in direction of arrow.
Disconnect associated plug connection and remove luggage
compartment light (1).

Replacement:
 If necessary, modify bulbs, observe  bulb type
Luggage compartment light in LED technology must be
completely replaced!
 4/30/2016 1/3

52 15 055 Removing and installing/replacing

lumbar support on front seat

Necessary preliminary work:

 Remove rear panel on front seat

Detach backrest cover from backrest frame in marked area.

Unlock and disconnect plug connection (1) on lumbar support

pump.
Unlock and disconnect plug connection (3) on valve body.
Release cable strap (2).
Installation note:
Completely remove remnants of cable ties.
Replace faulty cable straps.

Version with backrest width adjustment only.

Unlock and disconnect additional quick connector (4).

Detach valve body (2) from spring wire.

Detach lumbar support (3) from spring wire.
Press padding forward a little.
 4/30/2016 2/3

Carefully pull out lumbar support pump (1) downward with

lumbar support (3) and valve body (2).

Installation note:
Attach lumbar support on second and fifth wire from the bottom.

Installation note:
Check lumbar support at top (1) and bottom (2) for damage.
Air hoses (3) must not be kinked.

Installation note:
Run a function check.
4/30/2016 3/3
 4/30/2016 1/2

52 15 059 Removing and installing/replacing

lumbar support pump with valve body for
lumbar support/backrest width
adjustment

Necessary preliminary tasks:

 Remove rear panel

Cut open cable straps (arrows).

Installation note:
Replace defective cable straps.

Remove lumbar support pump (1) from backrest frame.

Unfasten plug connection (2) and disconnect.
Unclip air hose from holder (3).

Unclip valve body (1) from seat mechanism and feed out from
backrest frame.
Installation note:
Check the valve body (1) for correct fit in the backrest frame
and spring wire.
Air hoses must not be kinked.

Unfasten plug connection (2) and disconnect.

Unlock quick connectors and detach air hoses (1).
 4/30/2016 2/2

Valve body for backrest width adjustment:

1. Lumbar support left/right = hose clear, quick-connector
white
Installation note:
Connections are coded against incorrect assembly.

Note:
Run a function check.
 4/30/2016 1/5

54 12 ... Removing and installing/replacing

mechanism for glass slide/tilt sunroof

Necessary preliminary tasks:

 Remove wind deflector
 Remove glass slide/tilt sunroof panel

Note:
Removal operation is shown on left side, right analogous to
that.

Tape off working area with adhesive tape (1).

Note:
Replace the control gate (1) after disassembly.

Lift one side of the control gate (1) with a screwdriver and press
away from the guide rail.

Lift the other side of the control gate (1) with the screwdriver
and push it out.
 4/30/2016 2/5

Move the mechanism (1) to the end of the guide rail.

Slider must be positioned in the aperture for the control gate
(arrows).
Note:
For the next operation, counter-hold the mechanism at the end
of the guide rail as shown here.

Counter-hold the mechanism (1) at the end of the guide rail and
move the carriage (2) forward until the carriage (2) is positioned
in the aperture of mechanism (1).

Unclip the linkage for the water channel (1) from the
mechanism (2).
Installation note:
Engaging of water channel linkage in gate must be felt.
 4/30/2016 3/5

Lift the mechanism (1) out of the carriage (2) and guide rail.

Hold the left and right of the mechanism (1) raised and move
the carriage (2) back until the aperture for the control gate is
exposed.

Installation note:
Move the carriage forward until it is positioned with the opening
below the cover carrier (1) and can be immersed.
Insert the mechanism (1) outside in the guide rail and inside in
the rear control gate.
 4/30/2016 4/5

Pull the mechanism (1) back to the aperture and turn it out of
the guide rail in the direction of the arrow by 90°.

Lift the mechanism (1) out of the guide rail in the direction of the
arrow.

Note:
Horn cheeks (1) may remain in the guide rail.

Horn cheeks (1) must be mounted correctly on the mechanism.

 4/30/2016 5/5

Installation note:
Keep to installation sequence.
Initialise glass slide/tilt sunroof.
If the movement is stiff, lightly lubricate the guide channel with
lubricating grease RHF1 (Fuchs).
 4/30/2016 1/1

63 31 050 Removing and installing/replacing mirror

light

Special tools required:

 00 9 340

Lift off make-up mirror light (1) from roofliner with special

tool 00 9 340 in direction of arrow.
Disconnect plug connection underneath and remove make-up
mirror light (1).
Note:
Mirror light (1) in LED technology, LED cannot be replaced.
 4/30/2016 1/2

51 16 001 Removing and installing/replacing mirror

on left or right front door

Necessary preliminary work:

 Remove front door trim panel

Release door window frame cover (1) at clamps (2) and remove

partially.
Lift off cover (3).
Installation note:
Ensure cover (3) and door window frame cover (1) are properly
secured.

Important!
Secure mirror against falling off.

Unlock plug connection (1) and disconnect.

Release screws (2) and remove inside mirror.
Tightening torque 51 16 1AZ.
Installation note:
Due to self-tapping screws, the tightening torque of the new
rearview mirror increases by 2 Nm.

Installation note:
The sound insulation (1) must not be damaged or missing.
Run a function check.
 4/30/2016 2/2

Replacement
 Modify mirror glass
 Modify protective cap
 4/30/2016 1/1

34 33 051 Removing and installing/replacing non-

return valve for brake booster

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove the left engine compartment cover.

Note:
Before beginning repair work, fully press the brake pedal
several times to reduce the vacuum pressure in the brake
servo. This makes it easier to remove the non-return valve.

Remove non-return valve (1) from brake servo.

Unlock quick-release coupling (2) and detach vacuum line.
Remove vacuum line.
Installation note:
Check sealing ring in brake servo and replace if necessary.
The snap fastener (2) must be latched correctly.
 4/29/2016 1/1

12 61 280 Removing and installing/replacing oil

pressure sensor (N55)

Necessary preliminary tasks:

 Switch off ignition.
 Remove ignition coil cover.

Warning!
Risk of burning!
Only perform this repair work on an engine that has cooled
down.

Unlock connector (1) and remove.

Release oil pressure sensor (2).
Tightening torque 12 61 1AZ.
Installation note:
Check engine oil level, top up engine oil if necessary.
 4/29/2016 1/5

11 41 000 Removing and installing/replacing oil

pump (N55)

Special tools required:

 2 303 793

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Removing oil sump.
 Remove sealing cap of vacuum pump.
 Remove sealing cap of chain tensioner for the oil pump.

Undo all the aluminium screws (1) along the line.

Installation note:
Replace aluminium screws.
 4/29/2016 2/5

Remove intake pipe with oil deflector.

Installation note:
Replace O-ring.

Important!
Before releasing the central bolt on the oil pump, the
hydraulic chain tensioner must be drained.

Carefully press tensioning rail (1) with a suitable screwdriver (2)

in direction of arrow.
As the oil pressure in the chain tensioner can only be drained
pulsating, the tensioning rail (1) must be pressed several times.

Press the tensioning rail (1) and hold down.

Fix chain tensioner piston in position with a suitable lock pin (2).
Tightening torque: 11 41 7AZ.

Note:
Sprocket must be blocked in order to release central bolt (1).

Secure special tool 2 303 793 to crankcase.

Release oil pump central bolt (1).
Tightening torque 11 41 5AZ.
 4/29/2016 3/5

Release aluminium screws (1).

Tightening torque 11 41 6AZ.
Installation note:
Replace aluminium screws.
Watch mounting flats on oil pump sprocket.

Important!
Observe different screw lengths.

Release aluminium screws (1).

Tightening torque 11 41 2AZ.
Installation note:
Replace aluminium screws.

Detach sprocket (1) in direction of arrow.

Note:
Chain tensioner presses timing chain (3) upwards.
Do not remove sprocket (1).

Remove oil pump (2) in direction of arrow.

 4/29/2016 4/5

Installation note:
Check spacer bushes for secure seating and damage; replace if
necessary.

Install oil pump (2).

Align mounting flats (3) on oil pump (2) to sprocket (4).

Install intake pipe with oil deflector.

Installation note:
Replace O-ring.

Insert all the aluminium screws (1) along the line.

Installation note:
 4/29/2016 5/5

Replace aluminium screws.

Tightening torque 11 41 1AZ.

Assemble engine.
 4/29/2016 1/2

13 62 582 Removing and installing/replacing oil

temperature sensor (N55)

Warning!
Risk of burning!
Only perform this repair work on an engine that has cooled
down.

Necessary preliminary tasks:

 Switch off ignition.
 Remove throttle valve assembly.

Recycling:
Catch and dispose of emerging engine oil.
Observe country-specific waste disposal regulations.

Unlock connector (1) and remove.

Release oil temperature sensor (2).
Tightening torque 13 62 8AZ.
 4/29/2016 2/2

Note:
Add final details to vehicle
Check engine oil level. Top up engine oil if necessary.
 4/30/2016 1/1

66 20 534 Removing and installing/replacing one

rear left ultrasonic sensor

Warning!
Risk of burning!
Work on the exhaust system may only be carried out when
it has cooled down!

Note:
Diagram similar.
Ultrasonic transducers (3) can be reached from below with
bumper installed.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (2)
out of bracket.
Installation note:
Before installation of ultrasonic sensor (3) on wiring harness,
clean plug connection!
Retaining tabs (2) must not be damaged!
Make sure ultrasonic sensor is securely seated.

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
 4/30/2016 1/2

66 20 537 Removing and installing/replacing one

rear middle right ultrasonic sensor

Necessary preliminary tasks:

 Remove rear bumper panel

Note:
Diagram similar.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.

Installation note:
Before installation of ultrasonic sensor (3) on wiring
harness, clean plug connection!
Retaining tabs (2) must not be damaged!
Make sure ultrasonic transducer (3) is securely seated.

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
4/30/2016 2/2
 4/30/2016 1/1

51 11 180 Removing and installing/replacing

ornamental grille for bumper panel
(centre)

Necessary preliminary work:

 Remove front bumper panel

Release expansion rivet (1).

Release all retaining lugs from ornamental grille (2).
Remove ornamental grille (2).

Installation note:
Latch mechanisms (1) on bumper panel (2) must not be
damaged or missing.
 4/30/2016 1/2

52 14 040 Removing and installing/replacing outer

cover on left or right front seat
(normal/electric)

Move backrest to full rearward position.

Grip end fitting cover centrally between seat belt strap and
cover.
Unclip end fitting cover in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with rear guide in covering.

2. Insert cover in direction of arrow downwards in covering
3. Engage top left of cover in covering.

Release screw (1).
Lever latch mechanism (3) of the cover (2) out of seat
mechanism.
Remove cover (2) in direction of arrow from seat mechanism.
Unlock and disconnect plug connections behind from operating
unit.
Installation note:
Cover must not be damaged.
Replace cover if necessary.

Replacement only:
Remove operating unit for seat adjustment from cover.
4/30/2016 2/2
 4/30/2016 1/2

52 13 040 Removing and installing/replacing outer

cover on left or right front seat

Move backrest to full rearward position.

Grip end fitting cover in marked area between cushion and
cover.
Unclip end fitting cover in direction of arrow (1).
Feed out end fitting cover (2) in direction of arrow.

Installation note:
Install end fitting cover as follows:

1. Insert cover with front guide in cover

2. Insert cover in direction of arrow downwards in covering
3. Engage top cover in marked area in covering.

Pull the handle up and lift up lock (3).

Pull off the handle for the backrest angle adjustment (1) and
handle for seat height adjustment (2).

Release screw (1).
Lever latch mechanism (3) of the cover (2) out of seat
mechanism.
 4/30/2016 2/2

Remove cover (2) in direction of arrow from seat mechanism.

If necessary, unlock plug connection (1) backrest width

adjustment and disconnect.
If necessary, unlock plug connection (2) lumbar support and
disconnect.
Replacement only:
Depending on version, cut-outs for buttons in cover may need
to be reworked.

Replacement:
If necessary, remove switch backrest width adjustment and
switch lumbar support.
Installation note:
Please ensure correct latching of the switch backrest width
adjustment and switch lumbar support.
 4/30/2016 1/2

51 22 170 Removing and installing/replacing outer

door handle on left or right rear door

Necessary preliminary tasks:

 Remove cover on outer door handle

If necessary, lay outer door handle light (1) slightly to one side.

Pull out outer door handle (2) and feed out in direction of arrow.
Version with Comfort Access/CA:
Carefully feed out outer door handle (2) and disconnect
associated plug connection.

Installation note:
Locator (1) must not be damaged.
Version with Comfort Access/CA:
Seal (2) must not be damaged.

Installation note:
Seals (1 and 2) must not be damaged.
In necessary, use string to pull lock actuation (3) outwards and
hold in position.
Install outer door handle and insert correctly into lock
actuator (3).
Remove string.
Mount cover on outer door handle and carry out function check
with open door.
 4/30/2016 2/2

After replacing version with Comfort Access/CA:

Clear fault memory and perform functional check.
 4/30/2016 1/1

65 81 060 Removing and installing/replacing

outside temperature sensor

 Partially remove front wheel arch cover

Pull outside temperature sensor (1) upward out of fixture (3).

Unfasten plug connection (2) and disconnect.
Remove the outside temperature sensor (1).
 4/30/2016 1/1

66 33 008 Removing and installing / replacing park

assist control unit

Necessary preliminary tasks:

 Remove right luggage compartment wheel arch panel

Unlock plug connections (2) and disconnect.

Pull out parking assist control unit (1) towards top.

Replacement:
Carry out programming/encoding.
 4/30/2016 1/2

51 13 ... Removing and installing/replacing

partition wall attachment, right

Turn locks (1) 90° counterclockwise.

Unlock catch (3).
Remove cover (2).

Release clip (1).
Turn snap fastener (2) approx. 90° counterclockwise.
Disconnect plug connection (3) and feed out cable.
Release screws (6) and feed out attachment (5).
 
Replacement:
Twist sensor (4) approx. 90° anticlockwise and remove.

Installation note:
The following versions may be fitted:

- Attachment (1) without air filter

- Attachment (1) with air filter (2)

- Attachment (1) with air filters (2 and 3)

Attachment (1) must only be fitted with air filter (2).
If necessary, remove air filter (3) and/or attach air filter (2) at
position illustrated.

Installation note:
Grille (1) on sealing frame (2) must be fitted.
 4/30/2016 2/2

If necessary attach new grille (1).

Grille (1) is pressed onto sealing frame (2) by air filter on
attachment.
Grille (1) in conjunction with the air filter on the attachment
prevents foreign objects entering.
 4/30/2016 1/3

61 12 ... Removing and installing / replacing

positive battery cable at partition seal
(engine compartment)

Warning!
Observe safety informations for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.

Turn locks (1) 90° counterclockwise.

Unlock catch (3).
Remove cover (2).

Slacken nut (1).

Tightening torque 61 21 4AZ.
Slacken nut (2).
Tightening torque 61 21 4AZ.
Remove positive battery cable (3).

Check that the positive battery cable subsurface (1) is correctly

positioned.
Positive battery cable subsurface (1) must face away from
partition seal as shown.
 4/30/2016 2/3

In case of incorrect installation position:

Release nut (2) and correct installation position of positive
battery cable subsurface (1).
Tightening torque 61 21 7AZ.

Installation note:
Coat positive battery cables (1) at partition seal with contact
protection grease.
(Contact protection grease BMW part number 83 19 2 295 229.)
Use a standard flat brush with a width of approx. 2.5 cm to
apply the grease.

Unclip cover (1).

Installation note:
Guide and retaining lugs on cover (1) must not be damaged or
missing.
 4/30/2016 3/3

Installation note:
Coat positive battery cables (1) at partition seal with contact
protection grease.
(Contact protection grease BMW part number 83 19 2 295 229.)
Use a standard flat brush with a width of approx. 2.5 cm to
apply the grease.
 4/30/2016 1/1

61 31 117 Removing and installing/replacing power

window switch (driver's side)

Necessary preliminary tasks:

 Remove switch cover on front door trim panel

Release catches (1) on both sides.

Remove switch (2) from cover (3).
Installation note:
Latch mechanisms (1) must not be damaged or missing.
 4/29/2016 1/4

13 53 334 Removing and installing/replacing

pressure line (N55)

Special tools required:

 11 8 610
 13 5 020
 32 1 270

Warning!
Observe warning on cylinder head cover.
Disconnect negative battery terminal (risk of fire due to
short-circuiting on removal).
Electric fuel pump starts up automatically when door is
opened!
Carry out installation work on fuel system only with coolant
temperature below 40 °C.

Important!
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the
high pressure line is released!

Important!
Adhere to conditions of absolute cleanliness when working
on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the
 4/29/2016 2/4

system!
 Do not allow any dirt particles or foreign bodies to
get into the system.
 Remove all traces of dirt before removing lines or
separate components.
 Use only fluff-free cloths.
 Seal all fuel system openings with protective caps or
plugs.
 High pressure lines may be rescrewed a maximum
of 10 times.

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel in a suitable container.
Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

 Remove intake plenum.

Release nuts (1 and 2).

Remove H.P. line.
Seal connections of high pressure line and the high pressure
pump with matching plugs from special tool set 32 1 270.
 4/29/2016 3/4

Fit high pressure line.

When reinstalling lines, lubricate the thread and bearing face of
the ball with a little transmission oil or grease! When they are
installed for the first time the nuts have a coating of lubricant
(only effective once). Penetration of lubricant into the fuel-
conducting area should be avoided.
Important!
Adhere to the installation procedure!
Lay the high pressure line with the ball bush (1) to the high
pressure pump. When doing so, the ball bush (2) of the
high pressure line must lie in the centre of the cone on the
rail. If the ball bush (2) does not lie in the centre of the
cone, the installation position of the rail must be adjusted.
To do this the following fuel system components must be
released:

- Release pressure lines on injectors and on rail.

- Release mounting bolts on rail.

Follow sequence of screw connections:
1. Fit high pressure line on high pressure pump and
on rail hand-tight.
2. Fit high pressure lines between the injectors and
the rail hand-tight.
3. Fit mounting bolts on the rail and cylinder head
hand-tight.
4. Tighten mounting bolts on rail and cylinder head.
Tightening torque 13 53 2AZ.
5. Tighten high pressure line on injectors.
Tightening torque 13 53 9AZ.
 4/29/2016 4/4

6. Tighten high pressure line (injector line) on rail.

Tightening torque 13 53 9AZ.
7. Tighten high pressure line (high pressure line
between rail and high pressure pump) on rail.
Tightening torque 13 53 8AZ.
8. Tighten high pressure line on high pressure pump.
Tightening torque 13 53 8AZ.

Assemble engine.
Check fuel system for tightness.
Check function of DME.
 4/30/2016 1/2

51 23 211 Removing and installing/replacing pull

cable for hood/bonnet locks at front

Necessary preliminary work:

 Remove left/right engine compartment lock

Unclip clutch housing Bowden cable (1) at marked points.

Installation note:
Clips must not be damaged.

To open up clutch housing cover, lever up cover (2) in direction

of arrow.

Feed rear Bowden cable (2) out of holder (1) and clutch

housing (3).

Release Bowden cable (1) on holder (2).

Feed out Bowden cable (1).
4/30/2016 2/2
 4/30/2016 1/1

31 35 005 Removing and installing/replacing push

rod (anti-roll bar link) for left/right anti-roll
bar

Risk of damage!
- Avoid bending the head of the anti-roll bar during
assembly!

- An impact screwdriver must not be used!

Necessary preliminary tasks:

 Remove front wheel.

Important!
It is important to counterhold Torx socket when loosening
push rod screw connection (1).

 
Unscrew nuts (1).
Tightening torque 31 35 2AZ.
Remove anti-roll bar link (2).
Installation note:
Replace self-locking nuts.
 4/30/2016 1/2

65 11 080 Removing and installing/replacing radio

receiver

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Carry out installation in a dust-free workshop area only.
To avoid damage, do not touch or dirty the display field.

Necessary preliminary tasks:

 Remove control panel for heating - Air conditioning

Release screws (1).
Pull out radio receiver (2) and unlock and disconnected
associated plug connections.
4/30/2016 2/2
 4/29/2016 1/6

13 53 158 Removing and installing/replacing rail

(Bosch high pressure pump) (N55)

Special tools required:

 13 0 160

Warning!
Observe warning on cylinder head cover.
Disconnect negative battery terminal (risk of fire due to
short circuit on dismantling).
Electric fuel pump starts up automatically when door is
opened!
Carry out installation work on fuel system only with coolant
temperature below 40 °C.

Important!
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the
high pressure line is released!

Important!
Adhere to conditions of absolute cleanliness when working
on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the
system!
 Do not allow any dirt particles or foreign bodies to
get into the system.
 Remove all traces of dirt before removing lines or
separate components.
 Use only fluff-free cloths.
 Seal all fuel system openings with protective caps or
plugs.
 4/29/2016 2/6

Important!
When working on the oil, coolant or fuel circuit, you must
protect the alternator against dirt contamination.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an
alternator malfunction.

Necessary preliminary work:

 Disconnect pressure lines.
 Remove rear ignition coil cover.

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Release wiring harnesses (1) from rail and lay to one side.
Undo clamps (2) from rail.
 4/29/2016 3/6

Slacken nut (1).

Unlock and disconnect plug (2) on high-pressure sensor.
Release screws (3).
Remove rail (4).

Installing the rail:

Rail installation is described separately from removal.
If an injector line is being replaced, the corresponding injector
hold-down device must be released (see Removing and
installing injector).

Installation note:
Before reinstalling the rail, the decoupling element and
sleeves (1) must be replaced.
 4/29/2016 4/6

Install rail (4) while tightening nuts (1) and bolts (3) hand-tight

only.
Note:
 Rail must still be displaceable on cylinder head.
 Nut (1) must be able to be screwed on easily by hand.

Important!
Connect pressure line (1) without tension only.
To ensure distortion-free installation of the pressure line
and to avoid damaging the thread, it must be possible for
both nuts to be screwed on easily by hand!

Fitting pressure lines:

(Same procedure for all pressure lines)
Install pressure line (1). Tighten nuts (2) hand-tight only.
When reinstalling lines, lubricate the thread and the nut facing
of the ball! When they are installed for the first time the nuts
have a coating of lubricant (only effective once). Penetration of
lubricant into the fuel-conducting area should be avoided.
Reinstall rubber mount (3).

Procedure for loose injector hold-down device (this operation

can be skipped if the injector hold-down device has not been
 4/29/2016 5/6

loosened).
Firstly tighten screw (1).
Tightening torque 13 53 6AZ.
Then tighten down screw (2).
Tightening torque 13 53 6AZ.

Adhere to tightening sequence:

- 1. Tighten screws (1).
Tightening torque 13 53 2AZ.

Important!
Reset special tool in early to avoid bending pressure lines.
Tighten down nuts with special tool 313 0 160.

Adhere to tightening sequence:

- 2. First tighten nut (1) on injector.

- 3. Then tighten nut (2) on rail.

Tightening torque 13 53 9AZ.

- 4. Tighten nut (2).
5. Tighten nut (1).
Tightening torque 13 53 8AZ.
Push connector for high pressure sensor on.
 4/29/2016 6/6

Assemble engine.
Check fuel system for tightness.
Check function of DME.
 4/30/2016 1/5

36 11 533 Removing and installing/replacing RDC

wheel electronics (2nd generation/3rd
generation)

Important!
Before removing and installing, check which generation of
RDC wheel electronics module is installed! (see BMW
Spare Parts Catalogue).
If the wheel electronics have been removed, the complete
valve must be replaced.

Note:
There are two different wheel electronics. The SP303 wheel
electronics module must be used with RDC-01 and RDC-02
from model year 03/06.
The Gen3 wheel electronics must be used with the RDC-LC
from model year 09/2010 (all F0x/F1x vehicles).
 
If a tyre sealant has been used, replace the wheel electronics.
 
When a tyre has been removed, do not clean the rim with
installed wheel electronics with high-pressure cleaning
equipment.
 
Before the installation of new wheel electronics with valve,
thoroughly clean the valve bore of the wheel rim.
Do not treat wheel electronics with solvents, cleaning agents
etc. If dirt contaminationy, wipe with a clean cloth only.
 
Do not clean wheel electronics with compressed air.

Necessary preliminary tasks:

 Remove tyre
 4/30/2016 2/5

Labelling of generation 2.3 wheel electronics

1 Transmission frequency of wheel electronics
2 Large Torx socket screw
3 BMW part number
4 Tightening torque of Torx screw and union nut
5 Width across flats of union nut
6 Serial number of wheel electronics
7 Production date of wheel electronics

Labelling of generation 2.4 and 3.3 wheel electronics

1. Data Matrixcode
2. BMW part number
3. FCC ID = radio authorisation
4. Wheel electronics ID
5. Transmission frequency
6. Pressure sensor
7. Production date of wheel electronics
8. Tightening torque
9. Width across flats of union nut

Labelling of generation 3.4/3.41 wheel electronics

1. FCC ID = radio authorisation
2. Tightening torque
3. Pressure sensor
4. Data Matrixcode
 4/30/2016 3/5

5. Production date of wheel electronics

6. Transmission frequency
7. Wheel electronics ID
8. Width across flats of union nut
9. BMW part number

Note:
The following illustrations only show removal and refitting of the
3rd generation wheel electronics module. The instructions also
apply without alteration to the 2nd generation wheel electronics.

Removing wheel electronics

Release union nut (1).

Remove wheel electronics and valve (1) from valve hole.

 4/30/2016 4/5

Using suitable pliers (2), unscrew valve (1) from the thread of
the square-head bolt (3), while holding the wheel electronics
module (4) firm. Completely unscrew valve (1).
Remove square head screw from fixture for wheel electronics
module.
Installation note:
The valve must be renewed!
Failure to replace the part leads to leaks!

Important!
Before the installation of new wheel electronics with valve,
thoroughly clean the valve bore of the wheel rim!
Also make sure that the valve bore is free of burrs

Installing wheel electronics

Insert new square-head bolt (1) in wheel electronics module (2).
Screw single-use valve insert (3) three turns onto square-head
bolt (1).
Note:
Make sure the square bolt head (1) fits exactly in the fixture for
 4/30/2016 5/5

the wheel electronics module!

Insert valve insert with wheel electronics into cleaned valve

bore.
Both outer feet on the underside of the wheel electronics
module must be resting against the rim wall.

Screw on union nut (1) by hand as far as it will go.

Tighten union nut until the inner strip-off ring breaks. Breakage
is perceptible audibly and tangibly (momentary drop in torque
resistance).
Then fully tighten union nut (1).
Tightening torque 36 11 1AZ.
Important!
Fixing must not under any circumstances be retightened!
The square-head bolt should be located precisely in the
wheel electronics module fixture.
After tightening, the wheel electronics module must fit
snugly on the wheel rim!
 4/30/2016 1/1

51 47 030 Removing and installing/replacing rear

(inside) left or right door sill cover strip

Special tools required:

 00 9 317

Necessary preliminary tasks:

 Release rear seat

Release expansion rivet (1).

Release clips (2) on door sill cover strip (3) with special
tool 00 9 317.
Pull door sill cover strip (3) up and remove.

Installation note:
Replace faulty clips (1).
Fit door sill cover strip (2) with preinstalled clips (1).
 4/30/2016 1/1

33 55 000 Removing and installing/replacing rear

anti-roll bar

Necessary preliminary work:

 Undo anti-roll bar links at the anti-roll bar.
 Lower rear axle support.

Release screw (1). (Left side only.)

Tightening torque 33 32 6AZ.
Installation note:
Replace screw.
Tighten down screw connection in normal position.

Note:
To simplify the graphic, anti-roll bar removal is shown on the
removed rear axle.
 

Release screws (1).
Tightening torque 33 55 1AZ.
Remove both rubber mounts from anti-roll bar.
Turn anti-roll bar (2) and remove toward the left side.
Installation note:
Check both rubber mounts for damage and replace if
necessary.
 4/30/2016 1/2

51 14 010 Removing and installing/replacing rear

BMW badge

Special tools required:

 00 9 322

Important!
The notes on component bonding with double-sided
adhesive tape serve as the basis for this repair instruction
and must be observed without fail.

Carefully heat BMW badge (1) with hot air blower and lever out
with special tool 00 9 322.

Installation note:
Pull liner* off adhesive tape (1).
Position plate over guides (2 and 3) and press down firmly.
* Liner is the protective film on a new badge.
4/30/2016 2/2
 4/30/2016 1/1

64 22 191 Removing and installing/replacing rear

cabin fresh air grille (High A/C system)

Necessary preliminary tasks:

 Remove rear centre console trim

Unclip the retaining lugs (1) of the fresh air grille (2) toward the
bottom.
Remove the fresh air grille (2) from the cover (3) toward the
front.
Installation note:
Retaining lugs (1) must not be damaged.
 4/30/2016 1/2

51 16 163 Removing and installing/replacing rear

centre console cover

Special tools required:

 00 9 327

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Loosen the latch mechanisms (1) left/right from the bottom with

special tool 00 9 327.
Unclip cover (2) towards rear.
If necessary, unlock associated plug connections and
disconnect.
Remove cover (2).

Installation note:
Latch mechanisms (1) on cover (2) must not be damaged or
missing.
 4/30/2016 2/2

 
Replacement (depending on version):
 Modify the tray (3).
 Modify fresh air grille in rear passenger compartment
 If applicable, modify the 12 V charging socket
 4/30/2016 1/2

72 11 097 Removing and installing/replacing rear

centre lower straps

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.

Necessary preliminary tasks:

 Remove rear seat

Removal of middle lower strap:

Note:
Remove the middle lower strap only in combination with the
right lower strap.

Release screw (1).

Tightening torque 72 11 23AZ.
Unlock plug connections (2) and disconnect.
Remove lower strap (3).
Installation note:
Lower strap is encoded against incorrect assembly (3).

Lower strap with belt tensioner:

Note:
Middle lower strap (5) can only be removed in conjunction with
right lower strap.
Removal is depicted for the left lower strap; the right strap is
removed in the same manner.

Unfasten plug connection (2) and disconnect.

Release screw (1).
Tightening torque 72 11 23AZ.
Remove lower strap (3).
Installation note:
Coding (4) determines the installation position and prevents the
 4/30/2016 2/2

lower strap (3) from turning.

 4/30/2016 1/2

72 11 101 Removing and installing/replacing rear

centre seat belt

Note:
 Remove left backrest for rear seat
 Remove rear panel on rear seat backrest, left
 Remove rear seat

Release screw.
Grip in the marked area between the seat belt finisher strip and
backrest cover.
Pull and remove seat belt finisher strip upwards in direction of
arrow.

Feed seat belt strap out of seat belt finisher strip.

Note:
Shown here without backrest cover and upholstery for a better
overview.

Move backrest cover with upholstery upwards.

Release screw (1) on rear side of backrest.
Remove inertia reel (2) from back rest frame in direction of
arrow.
 4/30/2016 2/2

Installation note:
Replace microencapsulated screws.
Tightening torque 72 12 21AZ.
Automatic reel is coded against incorrect installation.
 4/30/2016 1/2

REP-REP-RAF0126-2611090H   Removing and installing/replacing rear centring mount for propeller

shaft

VIN: XXXXXXX Vehicle: 1'/F20/5-

DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System 3.42.40.11060 Data R3.42.40.11060

Version: Version:

26 11 090 Removing and installing/replacing

rear centring mount for propeller
shaft

Special tools required:

 00 5 500
 11 1 310
 11 2 030

Necessary preliminary tasks:

 Remove propeller shaft.

Completely fill centring bore hole (1) with viscous grease.

Drive special tool 11 1 310 with a plastic hammer into
centring bore hole.
The centring bearing (1) is forced out of the propeller
shaft by the pressure on the grease filling.
 4/30/2016 2/2

If necessary, top up grease repeatedly.

Note:
To drive out the bearing, you can also fill the
centring bore hole with water instead of grease.

Installation note:
Grease or water must be removed from the bearing bore.
Drive in centring mount (1) with special tools 11 2 030
and 00 5 500 into propeller shaft (observe protrusion).

Important!
Plastic centring mount must not be greased.

Installation note:
+2
Observe protrusion A = 4 mm of centring (1).
 4/29/2016 1/1

12 .. ... Removing and installing/replacing rear

ignition coil cover (N55)

Necessary preliminary tasks:

 Remove sound insulation bulkhead upper part,
centre.

Pull off ignition coil cover (1) upward and remove.

 4/30/2016 1/1

34 21 280 Removing and installing/replacing rear

left (or right) protective plate

Necessary preliminary tasks:

 Removing the retaining ring.

Removing the brake anchor plate (1).

Installation note:
If applicable, clean the contact surface on the wheel carrier.
 4/30/2016 1/2

72 11 096 Removing and installing/replacing rear

left or right lower straps

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.

Necessary preliminary tasks:

 Remove rear seat

Removal of left lower strap:

Release screw (1).
Tightening torque 72 11 23AZ.
Unfasten plug connection (2) and disconnect.
Remove lower strap (3).
Installation note:
Lower strap is coded against incorrect assembly.

Removal of right lower strap:

Note:
Remove the middle lower strap only in combination with the
right lower strap.

Release screw (1).

Tightening torque 72 11 23AZ.
Unlock plug connections (2) and disconnect.
Remove lower strap (3).
Installation note:
Lower strap is encoded against incorrect assembly (3).

Lower strap with belt tensioner:

Removal is depicted for the left lower strap; the right strap is
 4/30/2016 2/2

removed in the same manner.

Unfasten plug connection (2) and disconnect.
Release screw (1).
Tightening torque 72 11 23AZ.
Remove lower strap (3).
Installation note:
Coding (4) determines the installation position and prevents the
lower strap (3) from turning.

Note:
Only remove the right lower strap (5) in combination with the
middle lower strap.
 4/30/2016 1/1

51 71 041 Removing and installing/replacing rear

left or right wheel arch cover

Necessary preliminary work:

 Remove rear wheel

Release expanding rivets (1).

Release all nuts (2).
Tightening torque 51 75 2AZ.
Remove wheel arch cover (3).
Installation note:
Ensure wheel arch cover (3) is correctly seated.
 4/30/2016 1/2

52 26 200 Removing and installing/replacing rear

panel on right rear seat backrest

Unclip lock finisher (1) in direction of arrow (2) starting with

backrest side section.
Remove lock finisher (1) in direction of arrow (3).

Installation note:
Retaining lugs (1) and (2) of cover must not be damaged.
Replace faulty cover.

Release screw (1).
Remove lashing eye (2) from backrest.
Tightening torque 52 26 05AZ.

Lever backrest cover all round out of backrest frame.

Remove rear panel from backrest.
Installation note:
 4/30/2016 2/2

Insert the rear panel in the backrest frame first.

Press the welt from the backrest cover into the frame.
 4/30/2016 1/1

61 14 040 Removing and installing/replacing rear

positive battery cable distributor

Warning!
Observe safety information for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Release latch mechanisms (1) and fold cover (2) open.

Release and disconnect all plug connections in area (3).
Installation note:
Latches (1) on cover (2) must not be missing or damaged.
Make sure plug connections are correctly locked.

Release nut (1) and disconnect positive wire.

Tightening torque 61 21 4AZ.
Release nuts (2) and remove power distribution box (3).
Tightening torque 61 21 2AZ.
 4/30/2016 1/1

66 20 535 Removing and installing/replacing rear

right ultrasonic sensor

Warning!
Risk of burning!
Work on the exhaust system may only be carried out when
it has cooled down!

Note:
Diagram similar.
Ultrasonic transducers (3) can be reached from below with
bumper installed.

Unlock plug connection (1) and disconnect.

Unlock latch mechanisms (2) and pull ultrasonic transducer (3)
out of bracket.
Installation note:
Before installation of ultrasonic sensor (3) on wiring harness,
clean plug connection!
Retaining tabs (2) must not be damaged!
Make sure ultrasonic sensor is securely seated.

Installation note:
Make sure rubber ring (1) is correctly seated on ultrasonic
sensor (2).
 4/30/2016 1/1

51 47 491 Removing and installing/replacing rear

underbody protection

Note:
Illustration only an example. There may be differences in detail
in the case of other models.

Release screws along line (1) and remove underbody

protection (2).
Tightening torque 51 75 1AZ
 4/30/2016 1/1

61 62 020 Removing and installing/replacing rear

window wiper blade

Fold wiper arm (1) away from rear window.

Press lock (2) and remove wiper blade (3) in direction of arrow.
Installation note:
Make sure guide (4) is correctly seated in wiper blade (3).
 4/30/2016 1/4

51 31 200 Removing and installing/replacing rear

window

Important!
The following notes form the basis for these repair
instructions and must be adhered to at all times:
 Notes on window bonding
 General procedure for dismantling/installing bonded
window glass

When reusing the rear window:

Avoid damaging lines for heated rear window / -aerial.
Note:
Removal is performed with Roll Out 2000.

The following new parts / consumables are required (sourcing

reference BMW Parts Department).

Material Quantity

Rear window (with replacement) 1

Spacer buffer 5x5x20 mm 7

Small repair kit 1

Wire from Roll Out 2000 7 m

Necessary preliminary work:

 Remove trim for rear lid
 Remove wiper arm

Disconnect plug connection (1).

 4/30/2016 2/4

Release screws (2) and remove earth cable.

Secure electric cable with adhesive tape to rear window (3).

Important!
Tape off body in area of piercing point with fabric adhesive
tape (risk of damage).

Push wire from Roll Out 2000 at line (1) through adhesive bead.
For details on how to proceed, refer to: Window removal with
Roll Out 2000.
Because of the window geometry and adhesive strength, make
sure that the cutting wire is always at an acute angle to the
adhesive bead.
If necessary, reposition the suction cup several times that is
used as the deflection point.

Fitting spacer buffers (spacers):

Important!
Spacer buffers are installed to avoid rear window
breakage.
Completely remove old spacer buffers (1 and 2).
Stick new spacer buffers (1) centrally onto moulding.
Bond new spacer buffers (2) within the tabs.
Spacer buffers (2) must not extend over sheet metal edge.

Overview of rear window bonding:

 4/30/2016 3/4

Cut A - A B - B C - C

a [mm] = Position adhesive bead 6 +2 25 +2 5 ±2

b [mm] = Width adhesive bead 8 ±2 8 ±2 8 ±2

h [mm] = Height adhesive bead 12 -2 12 -2 12 -2

Note:
A tolerance band is printed on the ceramic (two dashed lines) that marks the position of the adhesive bead.
Adhesive bead (1) must be applied centred on tolerance band.
Prepare the body and rear window.
x = approx. 250 mm (bead joint distance (1) to rear window outer edge)

Note:
Adhesive area for plastic adhesive tapes (2) must be free from
grease and dust.

Perform the following steps carefully on the rear window (1)

using the siphon (3):
 4/30/2016 4/4

- Position at distance (A) at the top

- Align sides evenly

- Place at distance (B) at bottom and press in

- If necessary, adjust gap dimension (A and B)

- Secure in terms of height in this position at top with yellow

plastic adhesive tapes (2)
A = 2.5 ± 1 mm
B = 3.5 ± 1.4 mm
 4/30/2016 1/2

61 62 150 Removing and installing/replacing rear

windscreen washer pump for
windscreen washer system

Necessary preliminary tasks:

 Detach washer fluid reservoir and pull forwards

Overview of washer pumps:

(1) Windscreen washer pump of window washer system.
(2) Windscreen washer pump of rear window washer system
(not F30).
(3) Washer pump for headlight cleaning system.

Note:
Graphic shows by way of example the washer pump for the
headlight cleaning system!
 

Catch any escaping washer fluid if necessary.

Unfasten plug connection (1) and disconnect.
Unlock latch (3) and detach hose pipe (2) from washer
pump (4).
Turn washer pump (4) if necessary and pull out of washer fluid
reservoir (5).

Note:
Graphic shows an example of the strainer for windscreen
washer pump.

Remove and replace strainer (2) of windscreen washer pump

(1) or washer fluid reservoir (3).
 4/30/2016 2/2

Installation note:
 Coat sealing ring of washer pump with lubricant
 Lay hose pipe of washer pump without kinks
 Topping up washer fluid
 4/30/2016 1/1

61 62 060 Removing and installing/replacing rear

wiper motor

Necessary preliminary tasks:

 Remove rear window wiper arm
 Remove trim for rear lid

Disconnect plug connection (1).

Unfasten screws (2).
Tightening torque 61 62 2AZ.
Remove the rear wiper motor.
 4/30/2016 1/2

61 36 605 Removing and installing/replacing relay

for fan control

Warning!
Observe safety information for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Note:
Graphics shown on the F20 by way of example, deviations in
detail are possible in other models.

Turn locks (1) 90° counterclockwise.

Unlock catch (3).
Remove cover (2).

Release latch mechanism (arrow) and pull relay carrier (1) up

and out of power distribution box (2).

Release latch mechanism (1) from relay carrier (2) and pull

relay (3) off of relay carrier (2).
Installation note:
Ensure that relay carrier (2) and relay (3) are properly engaged.
 4/30/2016 2/2

For hot-climate version:

Unfasten plug connection (1) and disconnect.
Release nuts (2) and attach cable to the side.
Tightening torque 61 21 1AZ.
Loosen screws on relay (3) and remove relay.
Tightening torque 61 36 1AZ.
Installation note:
Ensure that cable (2) and relay (3) are screwed on properly.
 4/30/2016 1/2

66 53 020 Removing and installing/replacing

reversing camera (M Aerodynamics
package)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove rear bumper panel

Unlock latches at marked points. 

Remove reversing camera (1) with holder (2) towards top.

Replacement:
Release screws (1).
 4/30/2016 2/2

Remove holder (2) from reversing camera (3).

After installation:
 Carry out reversing camera function check
 Calibrate reversing camera
 4/29/2016 1/2

11 61 362 Removing and installing/replacing right

charge-air duct (N55)

Necessary preliminary tasks:

 Remove front underbody protection

Unscrew screw (1) and set expansion tank aside.

Release lock (1) of charge air duct.

Pull charge air duct (2) off of exhaust turbocharger.

Release lock (1) of charge air duct.

Detach charge air duct (2) from charge air cooler.
Feed out charge air duct (2).
 4/29/2016 2/2

Assemble engine.
Check DME control unit (exhaust turbocharger) for correct
operation.
 4/30/2016 1/1

51 23 100 Removing and installing/replacing right

engine compartment lid lock.

Necessary preliminary work (only F33):

 Remove right front-end strut

Release screws (1) and feed out engine compartment lid lock

(2).
Tightening torque 51 23 1AZ 

Unclip grommet (1).
Unhook Bowden cable (2) from engine compartment lid lock (3).
 4/30/2016 1/2

63 17 075 Removing and installing/replacing right

front fog light

Warning!
Follow instructions for handling light bulbs (exterior lights)

Necessary preliminary tasks:

Version with right wheel arch auxiliary radiator:
 Partially release auxiliary radiator
On all other versions:
 Partially release wheel arch cover front (front
section)

Note:
Perform operations on right side the same as the left side
shown, use graphics in mirror image.

Fold wheel arch cover (1) back.

Unfasten plug connection (2) and disconnect.

Release screw (1).
Tightening torque 63 12 2AZ.
Remove fog light (2) out of bumper panel (3) in direction of
arrow.
 4/30/2016 2/2

Installation note:
Guides (1) on fog light (2) must not be damaged or missing.

On replacement of fog light or bumper panel at front:

- If necessary, remount bulb

- Adjust fog lights

 4/30/2016 1/3

51 16 366 Removing and installing/replacing right

glove box with housing

When working on trim panel components, make sure that visible surfaces are not scratched or
damaged (e.g. by sharp-edged tools).

Necessary preliminary tasks:

 Remove trim for instrument panel, bottom left
 Remove side panel on dashboard on right
 Remove decorative strip on dashboard on right

Release screws (1).
Tightening torque 51 16 2AZ.
Installation note:
Ensure the glove box is correctly seat on the holder (2).

Release screws (1).
Tightening torque 51 16 2AZ.
 4/30/2016 2/3

Release screw (1).
Tightening torque 51 16 2AZ

Pull glove box (1) out slightly and unlock and disconnect

depending on the plug connection versions (2).
Remove glove box (1).

Installation note:
To avoid straining the glove box and causing annoying noises,
screw it in place in the specified order (1 to 9).
This also helps achieve optimal gap spacing.

When replacing, remount the following parts depending on the

version:
 Glove box damper
 Glove box cover
 Glovebox light
Depending on version:
 4/30/2016 3/3

 USB interface connecting socket/blind plate

 Hotel position switch/blind plate
 4/30/2016 1/3

51 47 161 Removing and installing/replacing right

luggage compartment wheel arch panel

Special tools required:

 00 9 325

Necessary preliminary work:

 Remove storage shelf
 Remove cover from tail panel
 Remove luggage compartment light
 Fold down backrest of right rear seat

Version with lashing eye:

Lever out cover (1) and release screw underneath.
Tightening torque 51 47 1AZ.
Remove lashing eye (2).

Version with charging socket:

Lever out charging socket (1) in direction of arrow and
disconnect plug connection.
 4/30/2016 2/3

Version with oddments tray:

Unclip oddments tray (2) from wheel arch panel (1) using
special tool 00 9 325.

Pull out and detach fuel tank release (1).

Feed out wheel arch panel (3) in direction of arrow.
Installation note:
Wheel arch panel must be seated correctly under tailgate
rubber seal (2).

Replacement (depending on version):

Unclip tensioning strap (1).
Detach luggage compartment net (2) at holder (3).
Release lock washer (4) and feed out luggage compartment net
(2).
Unscrew holder (3).
4/30/2016 3/3
 4/30/2016 1/1

51 47 065 Removing and installing/replacing rocker

panel trim on front left or right entrance
(outer)

Special tools required:

 00 9 317

Lift cover panel (2) up and out at clips (1) using special
tool 00 9 317.
Remove cover (2).

Installation note:
If necessary, remove clips (1) from entrance with a suitable tool.
Replace faulty clamps (1).
 4/30/2016 1/1

54 12 ... Removing and installing/replacing

screen panel for glass slide/tilt sunroof

Necessary preliminary tasks:

 Remove complete glass slide/tilt sunroof

Press screen panel (3) towards inside of vehicle and

simultaneously slide forwards in direction of arrow (2).
Remove screen panel (3) upwards in direction of arrow (1).
 4/29/2016 1/3

11 14 015 Removing and installing/replacing

sealing cap for oil pump chain tensioner
(N55)

Special tools required:

 11 8 530
 11 8 531
 11 8 532
 11 8 533
 11 8 534
 11 8 535
 11 8 537
 2 318 118
 2 318 119

Necessary preliminary work:

 Remove fan cowl.
 Remove drive belt for alternator.
 Remove both drive belt tensioning devices (hybrid car).
 Remove vibration damper.

Drive out sealing cap (1) with a suitable punch (2) in direction of

arrow.
Note:
The sealing cap is driven out diagonally during this operation.

Removing sealing cap:

 4/29/2016 2/3

Prepare special tool 11 8 530.

Remove special tool 11 8 533 from special tool 11 8 532 and 11
8 534 .
Special tool 11 8 536 is not required.

Special tool 2 318 118 is magnetic.

Secure special tool 2 318 118 on special tool 11 8 531 (refer to
graphic).

Screw back screw (2) on special tool 2 318 119 .

Install special tool 2 318 119 with screw (1) on special
tool 11 8 531.

Position sealing cap (1) on crankcase (2).

 4/29/2016 3/3

Installing sealing cap:

Screw in screw (1) on special tool 2 318 119 up to limit position.
Tightening torque 20 Nm.

Assemble engine.
 4/30/2016 1/1

67 31 520 Removing and installing/replacing seat

height adjustment drive unit

Necessary preliminary tasks:

 Remove driver's or front passenger seat

Set down front seat sideways on a suitable surface.

Unfasten plug connection (1) and disconnect.
Release screws (3).
Tightening torque 67 31 1AZ.
Feed out seat height adjustment drive unit (2) and remove.

Note:
Carry out a function check.

Replacement:
Initialise seat height adjustment drive unit.
 4/30/2016 1/1

64 11 991 Removing and installing/replacing

sensor for automatic recirculated air
control (AUC)

Release locks (1).

Unlock catch (3).
Remove cover (2).

Unfasten plug connection (1) and disconnect.

Unscrew automatic air recirculation control sensor (2) in
direction of arrow and remove.
Installation note:
Make sure retaining lug (3) is correctly seated in trim panel.
 4/29/2016 1/6

11 37 020 Removing and installing/replacing

servomotor for eccentric shaft (N55)

Warning!
The preloading on the throttle return springs increases as
the rotation on the worm gear increases. Danger of injury!
The eccentric shaft may only be twisted on the mounting
flats for protection.
Risk of damage to the eccentric shaft gearing and to the
servomotor worm drive.
The eccentric shaft must not spring back to the minimum
stroke stop. Risk of damage!

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove ignition coils and injector shafts of cylinders
1 to 4.

Warning!
Heed stop installation instructions.

The eccentric shaft on the mounting flats (2) must only be

turned with an open-end spanner (1) for support.
Heed the following work instructions.
After the motor stops, the eccentric shaft is in the maximum
stroke position.
If the actuator drive is defective, the eccentric shaft is located in
an undetermined position.

Release bolt (1) on the oil spray nozzle.

Tightening torque: 11 37 4AZ.
Unclip oil spray nozzle (2) from the bracket on the actuator
 4/29/2016 2/6

drive (3) in direction of arrow.

If the eccentric shaft is not on maximum stroke, the eccentric

shaft must be adjusted to maximum stroke.
Important!
Fix eccentric shaft with an open-end spanner (kickback
danger)
Adjust eccentric shaft only on the hexagon socket of the
actuator drive (preload).

Remove minimum stroke stop (1).

Turn 4-mm hexagon socket wrench (1) clockwise in direction of

arrow (maximum stroke).
Secure eccentric shaft with an open-end spanner (2) for support
in direction of arrow.
Fix eccentric shaft with an open-end spanner (2) (kickback
danger)

Remove minimum stroke stop (1).

Tightening torque: 11 37 5AZ.
 4/29/2016 3/6

Adjust eccentric shaft (1) to minimum stroke in direction of

arrow via servomotor.
Important!
Secure eccentric shaft with an open-end spanner
(kickback danger)

Slowly adjust eccentric shaft in direction of arrow to minimum

stroke via the servomotor with a 4-mm hexagon socket
wrench (2) and an open-end spanner (1).
Important!
Secure eccentric shaft with an open-end spanner (1)
(kickback danger)

Release gearing of the eccentric shaft from worm drive.

Important!
Eccentric shaft (2) is no longer connected to the worm
drive of the servomotor in this working position.

Turn eccentric shaft (2) approximately 90° further with an open-

end spanner (1).
Secure eccentric shaft (2) against kickback with the assistance
 4/29/2016 4/6

of a second person.

Important!
Eccentric shaft (1) is located in a relaxed position.
Secure eccentric shaft (1) against kickback with the
assistance of a second person.

Unfasten screws (2).

Remove servomotor (1) upward in direction of arrow.

Installation note:
Clean blind holes with compressed air.
Install servomotor (1) downward in direction of arrow.
Secure eccentric shaft against kickback with the assistance of a
second person.

Installation note:
The gearing of the eccentric shaft and the worm gear must be
greased with Long-time PD 1 (4.1).

Installation note:
Eccentric shaft and worm drive must now be joined.
Carefully mate eccentric shaft gear in the worm shaft of the
servomotor by simultaneously pressing and turning on the
actuator drive.
 4/29/2016 5/6

Insert bolts (2).
Tightening torque: 11 37 3AZ.

Preload eccentric shaft to maximum stroke with a 4-mm

hexagon socket wrench (1) on the servomotor in direction of
arrow.
Fix eccentric shaft with an open-end spanner (2) for support
and secure (kickback danger).

Adjust eccentric shaft (1) back to maximum stroke in direction

of arrow via servomotor.
Important!
Fix eccentric shaft with an open-end spanner and secure.
(kickback danger)

Screw in stop (1) for minimum stroke.

Tightening torque: 11 37 5AZ.
Important!
Fix eccentric shaft with an open-end spanner and secure.
(kickback danger)
 4/29/2016 6/6

Retract oil spray nozzle (2) on actuator drive (3).

Engage bolt (1) and release back to 90°.
For exact positioning of the oil spray nozzle (2) audibly clip it in
at the top.
Secure oil spray nozzle (2) with screw (1).
Tightening torque: 11 37 4AZ.

Remove all special tools.

Assemble engine.
Check function of Digital Engine Electronics.

- Service function.

- Drive.

- Digital Motor Electronics

- Valvetronic run-in procedure.

 4/30/2016 1/1

51 45 ... Removing and installing/replacing side

panel on dashboard on left or right

Special tools required:

 00 9 327

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Pull off seal (1) in the area of the side panel (2).

Unclip side panel from dashboard (2) in direction of arrow with
special tool 00 9 327 and feed out at a slant to the rear.
If necessary, unlock plug connection on switch for front
passenger airbag deactivation and unplug.

Installation note:
Latch mechanisms (1) and guide tab (2) on side panel (3) must
not be damaged or missing.

Replacement (depending on version):

Remount switch for front passenger airbag deactivation.
 4/30/2016 1/2

51 45 ... Removing and installing/replacing side

panel on dashboard (with switch for front
passenger airbag deactivation) on the
left and right

Special tools required:

 00 9 325

Warning!
Read and comply with safety regulations for handling
airbag modules and pyrotechnical belt tensioner.
Incorrect handling can activate airbag and cause injury.

When working on trim panel components, make sure that the

sensitive surfaces are not scratched or damaged.

Necessary preliminary work:

 Clamp off battery negative lead
 4/30/2016 2/2

Pull off sealing (2) in the area of the dashboard side panel (1).

Unclip side panel from dashboard (1) in direction of arrow with
special tool 00 9 325 and feed out at a slant to the rear.

Installation note:
Retaining clips (4) and guide tab (3) of side panel on
dashboard (1) must not be damaged or missing.

Replacement

- Reinstall retaining clips (4).

- Modify switch for front passenger airbag deactivation (2)

 4/30/2016 1/2

51 43 070 Removing and installing/replacing side

trim panel, footwell, on A-pillar, left

Necessary preliminary tasks:

 Remove front door sill cover strip (inside)
 Remove trim panel for pedal mechanism

Detach edge protection (1) in area of side trim panel (2).

Release screw (3).
Remove engine compartment lid release lever (4) from side trim
panel (2).
Installation note:
Make sure edge protection (1) is correctly seated.

Release screw (1).
Unclip side trim panel (3) in direction of arrow from retaining
points (2).
If necessary, disconnect associated plug connection and
remove side trim panel (3).

Installation note:
If necessary, lever out clamps (1) remaining in bore.
Replace faulty clips (1).
Position side trim panel (2) pre-installed with clips (1) on
associated bore holes and clip into place.

Replacement:
Modify rear lid unlocking switch, if applicable.
4/30/2016 2/2
 4/30/2016 1/1

51 43 075 Removing and installing/replacing side

trim panel, footwell, on A-pillar, right

Necessary preliminary tasks:

 Remove front door sill cover strip (inner), right
 Remove dashboard trim at bottom right

Detach edge protection (1) in area of side trim panel (3).

Pull side trim panel (3) off clips (2) in direction of arrow.
Loosen clips (2) from body and insert in side trim panel (3).
Installation note:
Make sure edge protection (1) is correctly seated.

Installation note:
Clips (1) for side trim panel (2) must not be damaged.
 4/30/2016 1/2

54 12 136 Removing and installing/replacing

sliding head liner for glass slide/tilt
sunroof panel

Special tools required:

 00 9 460

Necessary preliminary tasks:

 Remove glass slide/tilt sunroof panel

Lever out linkage of left and right water channels (1) from

gate (2).
Installation note:
Linkage must audibly engage in gate.

Release left and right screws (1).

Installation note:
Replace micro-encapsulated screws (1).

Tighten down screws (1) with special tool 00 9 460.

Tightening torque 54 12 04AZ.

Slide spring glider (1) inwards and remove in direction of arrow.

Remove headlining frame (2) upwards in direction of arrow.
Installation note:
Make sure spring glider is installed in correct position.
 4/30/2016 2/2

Run a function check.

If headlining frame has stiff movement, apply a light coat of
grease RHF1 (manufactured by Fuchs) to guide duct.
 4/30/2016 1/2

63 21 030 Removing and installing/replacing

socket housing for left rear light

Warning!
Follow instructions for handling light bulbs (exterior lights).

Necessary preliminary work:

 Remove rear light

Release all latch mechanisms.

Remove the socket housing (1) from the rear light (2).
Installation note:
The socket housing seal must not be damaged or missing.
Make sure socket housing (1) is correctly locked.

Replacement:
Carefully press down bulb (1), turn in direction of arrow and
remove from socket housing.
Note bulb type.
4/30/2016 2/2
 4/30/2016 1/3

51 48 060 Removing and installing/replacing sound

insulation in left or right front door

Important!
Instructions for sound insulation are an essential part of
these repair instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every
repair (water ingress).

Necessary preliminary tasks:

 Remove door trim panel

Note:
Position of sealing bead (1).

If necessary, manoeuvre out sound insulation (2) at cable (3).

Important!
When cutting through sealing bead (1), do not damage
sound insulation (2) and if necessary cable.
With a suitable sharp cutting tool (3) cut through sealing
 4/30/2016 2/3

bead (1) of sound insulation (2) in the area to be

detached.

Clean adhesive area with adhesive remover (sourcing

reference: BMW Parts Department).
Air drying time: 1 minute
Important!
Bonding surface must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area
with bare hands.

Note:
Replacement:

Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts

Department) in specified adhesive area.
Heat butyl rope (hot air blower) and press down firmly on sound
insulation all round.
2
Contact pressure with hand roller: approx. 20 N/cm .
2
Manual contact pressure: approx. 10 N/cm .
Note:
2
Firm thumb pressure has approx. 30 N/cm

Note:
Position of butyl rope (1) on sound insulation (2).
 4/30/2016 3/3

Note:
A mark (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
 4/30/2016 1/3

51 48 070 Removing and installing/replacing sound

insulation on left or right rear door

Important!
Instructions for sound insulation are an essential part of
these repair instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every
repair (water ingress).

Necessary preliminary tasks:

 Remove door trim panel

Note:
Position of sealing bead (1).

If necessary, disconnect plug connection (2).

Feed wires (3) out of sound insulation (4).

Important!
When cutting through sealing bead (1), do not damage
sound insulation (2) and if necessary cable.
 4/30/2016 2/3

With a suitable sharp cutting tool (3) cut through sealing

bead (1) of sound insulation (2) in the area to be detached.

Clean adhesive area with adhesive remover (sourcing

reference: BMW Parts Department).
Air drying time: 1 minute
Important!
Bonding surface must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area
with bare hands.

Note:
Replacement:

Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts

Department) in specified adhesive area.
Heat butyl rope (hot air blower) and press down firmly on sound
insulation all round.
2
Contact pressure with hand roller: approx. 20 N/cm
2
Manual contact pressure: approx. 10 N/cm
Note:
2
Firm thumb pressure has approx. 30 N/cm

Note:
Position of butyl rope (1) on sound insulation (2).
 4/30/2016 3/3

Note:
A mark (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
 4/30/2016 1/1

65 13 060 Removing and installing/replacing

speaker (mid-range speaker, in
instrument panel)

Special tools required:

 00 9 327

Unclip trim (1) with special tool 00 9 327 from latch mechanisms

and remove upwards.

Installation note:
Retaining lugs and clamps at marked points must not be
damaged.

Release screws (1).
Remove mid-range speaker (2) upwards from dashboard (3).
Disconnect plug connections underneath.
Remove mid-range speaker (2).
 4/30/2016 1/1

65 13 050 Removing and installing/replacing

speaker (tweeter in mirror triangle)

Necessary preliminary tasks:

 Remove front door trim panel
 Detach cover on door window frame in front area.

Note:
Cover on window frame shown removed for purposes of clarity.

Remove foam wedge (1) in direction of arrow from door window

frame (2).
Installation note:
Position foam wedge (1) exactly above the guide (3).

Unclip speakers (1) from latch mechanisms (2).

Remove associated plug connection and remove speaker (1).
 4/30/2016 1/2

65 13 062 Removing and installing/replacing

speaker (tweeter, in dashboard)

Special tools required:

 00 9 327

Unclip trim (1) with special tool 00 9 327 from latch mechanisms

and remove upwards.

Installation note:
Retaining lugs and clamps at marked points must not be
damaged.

Release screws (1).
Pull out mid-range speaker (2) upwards from dashboard (3).
 4/30/2016 2/2

Disconnect plug connections (2) at mid-range speaker (3).

Release screws (5) on tweeter (4).
Pull out tweeter (4) upwards from dashboard (1).
 4/30/2016 1/1

51 41 ... Removing and installing/replacing

speaker cover on front left or right door
trim panel

Special tools required:

 00 9 327

Detach speaker cover (1) with special tool 00 9 327 from the

bottom starting at latch mechanisms (2).
Feed out speaker cover (1) downwards out of guide (3).
Installation note:
Firstly feed in speaker cover (1) with guide (3), then clip in place
with latch mechanisms (2).

Installation note:
Guide (1) and latch mechanisms (2) must not be damaged.
 4/30/2016 1/1

65 13 070 Removing and installing/replacing

speakers (mid-range speaker, front door
left and right)

Necessary preliminary tasks:

 Remove front door trim panel

Release screws at marked points.

Tightening torque 65 13 01AZ.
Unfasten plug connection (1) and disconnect.
Remove speaker (2) from inner door panel (3).
 4/30/2016 1/1

61 31 014 Removing and installing/replacing

Start/Stop switch

Special tools required:

 00 9 325

Note:
When working on trim panel components, make sure that the
sensitive surfaces are not scratched or damaged.

Pry out Start/Stop switch (1) at the marked retaining points

using special tool 00 9 325.
Disconnect associated plug connection and remove Start/Stop
switch (1).

Installation note:
Retaining clips (1) on Start/Stop switch (2) must not be bent or
damaged.
 4/29/2016 1/2

12 41 020 Removing and installing/replacing

starter motor (N55)

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Disconnect battery negative lead.
 Remove intake plenum.

Unlock connector (1) and remove.

Release nut (2) and disconnect positive battery cable (3).
Tightening torque 12 42 2AZ.
Release bolts (3) and remove starter.
Tightening torque 12 41 1AZ.

Installation note:
Check starter pinion and ring gear for damage, replace starter
motor if necessary.

Only during starter replacement and on vehicles with MSA

(automatic engine start-stop function):
 Use BMW diagnosis system to reset the starter counter.
4/29/2016 2/2
 4/30/2016 1/2

32 31 090 Removing and installing/replacing

steering column

Necessary preliminary tasks:

 Move steering column into ”extended” position
 Disconnect battery earth lead
 Remove airbag
 Remove steering wheel
 Remove trim panel for pedal mechanism
 Remove upper and lower steering column shroud
 Remove steering column control panel
 Unclip wiring harness and place to one side.
 Release electronics box at the spring strut dome and
only lay to the side (only N47)
 Release steering shaft from steering column in
engine compartment

Undo nuts (1) at top of steering column.

Tightening torque 32 31 1AZ.

Secure steering column against falling out.

Undo nuts (1) at bottom of steering column.
Tightening torque 32 31 1AZ.
 4/30/2016 2/2

Installation note:
Align steering shaft and steering column! (encoding at spindle
and joint)
With the assistance of another person, hold the universal joint
in the engine compartment and slide spindle of steering column
at plastic sleeve (1) from the footwell onto the universal joint.
When pushing in the steering shaft (1), ensure that the steering
shaft collar is correctly positioned. Sleeve must be clipped into
the bulkhead.
(see Removing and installing sleeve for steering shaft)

After installation:
 Turn steering wheel in both directions to the limit position.
The airbag indicator light must not light up!
 4/30/2016 1/1

61 31 231 Removing and installing/replacing

steering wheel module (M sports
steering wheel)

Necessary preliminary tasks:

 Remove airbag unit

Release screws (1) on steering wheel.

Release screw (2) on rear side of steering wheel.
Remove design cover.

Disconnect plug connection (1).

Release steering wheel module (2) from bracket.
Release underlying plug connector (3) from bracket and
disconnect.
Remove steering wheel module (2).
Installation note:
Make sure cables are correctly routed.
Make sure the plug connections (1; 3) are correctly locked.
Make sure steering wheel module (2) and plug connection (3)
are correctly seated in bracket.
 4/30/2016 1/2

32 33 000 Removing and installing/replacing

steering wheel

Note:
Chassis / wheel alignment is not necessary after the steering
wheel has been removed and installed or replaced.

Necessary preliminary tasks:

 Remove airbag unit

Move wheels/steering wheel into straight-ahead driving

position.
Disconnect plug connection (1).
Release screw (1) and remove steering wheel.
Tightening torque 32 33 1AZ.

Installation note:
Align steering wheel by way of marking (1) to steering column
marking (2) and attach.
4/30/2016 2/2
 4/30/2016 1/1

51 24 130 Removing and installing/replacing striker

for tailgate lock

Necessary preliminary tasks:

 Remove top cover from tail panel

Release bolts (1) and remove striker (2).

Tightening torque 51 24 2AZ.
Installation note:
Adjust rear lid lock.

Important!
Striker and tailgate lock must not be greased.
 4/30/2016 1/1

51 11 050 Removing and installing/replacing

support for front bumper panel

Necessary preliminary tasks:

 Remove front bumper panel
 Remove the impact absorber from the support
F30/F31/F34/F35 only:
 Remove right/left headlight

Version with ACC:

Release screws/blind rivet (1).
Installation note:
Blind rivet nuts* and associated screws* are used as repair
solution for defective threads or installed blind rivet.
* Sourcing reference: BMW Parts Department.
Observe note on placing blind rivet nuts.

Release screws (1) on left/right.

Tightening torque 51 11 4AZ.
Remove support (2) towards front.
 4/30/2016 1/2

51 11 060 Removing and installing/replacing

support for front lower bumper panel

Necessary preliminary tasks:

 Remove front bumper panel
F20/F21 only:
 Remove front underbody protection in the working
area

Version with air duct:

Unscrew bolts (1) and expanding rivet (2).
Remove air duct (3).
Note:
Schematic diagram shows the right side. Perform repair work
on the left side in the same manner.

Version with ACC:

Release screws/blind rivet (1).
Installation note:
Blind rivet nuts* and associated screws* are used as repair
solution for defective threads or installed blind rivet.
* Sourcing reference: BMW Parts Department.
Adhere to the notes on mounting blind rivet nuts.

Release screws (1).
Tightening torque 51 11 10AZ.
Remove support (2) in direction of arrow.
 4/30/2016 2/2

In the case of replacement ACC version:

Drill out blind rivets (1).
Modify holder (2) with ACC sensor.
Adjust ACC sensor.
 4/30/2016 1/3

51 21 125 Removing and installing/replacing

support for left or right outer door handle
with lock barrel

Necessary preliminary work:

 Close side window if necessary
 Remove outer door handle on front door
 Remove door lock of front door

Remove seals (1) in direction of arrow.

Release screw (2).

If necessary, release cable clip from support (1).

Remove inner support (1) in direction of arrow and feed out of
door.

For version with Comfort Access/light package:

Release cable clip (1) from support (2).
 4/30/2016 2/3

Disconnect plug connection (3).

Installation note:
For it to be possible to install the door lock, locking pin (1) must
be in the installation position on the support (2).

Replacement
Release sound cover (1) at clips (2) and manoeuvre out of
support (3).

Replacement
Unclip Bowden cable (1) in area (A) and manoeuvre out of
support (2).
Installation note:
Ensure that the Bowden cable (1) is correctly routed at
support (2).
 4/30/2016 3/3

For version with Comfort Access/light package:

Modify outside door handle light on front door.
 4/30/2016 1/3

51 21 126 Removing and installing/replacing

support for left or right outer door handle
without lock barrel

Necessary preliminary work:

 Close side window if necessary
 Remove outer door handle on front door
 Release sound insulation on front door in rear part

Disconnect Bowden cable at bottom (1) and top (3) from door

lock (2).
Important!
Door cannot be opened if Bowden cable is incorrectly laid.

Installation note:
Bowden cable must be correctly engaged in locators in door
lock (2).
Bowden cable must be laid without kinks in bend to door
lock (2).
Seal (4) must be correctly fitted on Bowden cable.
Carry out function check with door open.

Remove seals (1) in direction of arrow.

Release screw (2).
 4/30/2016 2/3

If necessary, release cable clip from support (1).

Remove inner support (1) in direction of arrow and feed out of
door.

For version with Comfort Access/light package:

Release cable clip (1) from support (2).
Disconnect plug connection (3).

Replacement:
Release sound cover (1) at clips (2) and manoeuvre out of
support (3).

Replacement:
Unclip Bowden cable (1) in area (A) and manoeuvre out of
support (2).
Installation note:
Ensure that the Bowden cable (1) is correctly routed at
support (2).
 4/30/2016 3/3

For version with Comfort Access/light package:

Modify outside door handle light on front door.
 4/30/2016 1/2

51 22 126 Removing and installing/replacing

support for outer door handle on left or
right rear door

Necessary preliminary work:

 Close side window if necessary
 Remove outer door handle on rear door
 Remove door lock

Remove seals (1) in direction of arrow.

Release screw (2).

If necessary, release cable clip for outer door handle light from
support (1).
Remove support (1) in direction of arrow and feed out.

For version with Comfort Access/light package:

Release cable clip (1) from support (2).
 4/30/2016 2/2

Disconnect plug connection (3).

Replacement:
Release sound cover (1) at clips (2) and manoeuvre out of
support (3).

Replacement:
Unclip Bowden cable (1) in area (A) and manoeuvre out of
support (2).
Installation note:
Ensure that the Bowden cable (1) is correctly routed at
support (2).

For version with Comfort Access/light package:

Modify outside door handle light on rear door.
 4/30/2016 1/1

51 12 050 Removing and installing/replacing

support for rear bumper panel

Necessary preliminary tasks:

 Remove bumper panel

Release screws (1).
Unscrew nuts (2).
Tightening torque 51 12 1AZ.
Remove support (3).
 4/30/2016 1/1

51 41 ... Removing and installing/replacing switch

cover on left or right front door trim
panel

When working on trim panel components, make sure that

visible surfaces are not scratched or damaged (e.g. by sharp-
edged tools).

Necessary preliminary tasks:

 Remove cover on door handle

Use a suitable tool (1) to release latch mechanism (2) of switch

cover (3) in direction of arrow.
Unclip switch cover (3) from door trim panel towards front/top.
Disconnect plug connection and remove switch cover (3).

Installation note:
Following parts must not be missing or damaged:
(1) Catch
(2) Retaining clips
(3) Guides

Replacement:
Remount switch for power window (4).
 4/30/2016 1/1

61 31 079 Removing and installing/replacing switch

for hazard warning flashers/central
locking

Special tools required:

 00 9 340

Carefully lever out switch for hazard warning system/central

locking (1) with special tool 00 9 340 in direction of arrow.
Remove switch for hazard warning system/central locking (1) in
direction of arrow and disconnect plug connection behind.
 4/30/2016 1/1

61 31 208 Removing and installing/replacing switch

for lumbar support

Necessary preliminary tasks:

 Remove outer cover on front seat

Disconnect plug connection (3).

Unlock latch mechanisms (1).
Remove switch for lumbar support (2) in direction of arrow.
 4/30/2016 1/1

61 31 083 Removing and installing/replacing switch

for unlocking tailgate

Special tools required:

 00 9 323

Note:
Graphic similar!

Lever switch for tailgate unlocking (1) sideways out of A-pillar

trim panel (2) using special tool00 9 323.
Disconnect associated plug connection and remove switch for
unlocking rear lid (1).
 4/30/2016 1/1

51 24 105 Removing and installing/replacing

tailgate lock

Necessary preliminary tasks:

 Remove trim for rear lid

Release screws (1).
Tightening torque 51 24 1AZ.
Manoeuvre out rear lid lock (2) and unlock and disconnect plug
connection (3).

Installation note:
Perform a function check of tailgate lock with the tailgate open.
Concluding tasks:
Adjust tailgate catch.
 4/30/2016 1/1

51 75 ... Removing and installing/replacing tank

cover on the left

Release all expanding rivets (1).

Unfasten screws (2).
Tightening torque 51 75 1AZ
Remove tank (3).
 4/30/2016 1/1

51 75 ... Removing and installing/replacing tank

cover on the right

Release all expanding rivets (1).

Unfasten screws (2).
Tightening torque 51 75 1AZ
Remove tank (3).
 4/30/2016 1/1

51 49 015 Removing and installing/replacing the

cover for the rear window frame at top

Special tools required:

 00 9 325

Detach cover (1) with special tool 00 9 325 from clip (2).

Unclip cover (1) at the side from covers (3) and remove.
Installation note:
If necessary, pull off clips (2) from tailgate and insert in
cover (1).

Installation note:
If necessary, replace faulty clips (1).
Guides and latch mechanisms in the area (2) of the cover (3)
must not be damaged or missing.
 4/30/2016 1/2

61 31 132 Removing and installing/replacing the

shift paddles for the transmission (M
sports steering wheel)

Necessary preliminary tasks:

 Remove airbag unit

Release screws (1) on steering wheel.

Release screw (2) on rear side of steering wheel.
Remove design cover.

Note:
Steering wheel is shown removed for purposes of clarity.

Release the screws (1) and feed out the wiring harness (2).

Note:
Steering wheel is shown removed for purposes of clarity.

Pull the steering wheel module (2) out of the steering wheel.

Release the plug connections (1, 3) from the steering wheel
and disconnect.
Installation note:
Make sure electrical wiring is correctly routed.
Make sure the plug connections (1, 3) are correctly seated.
 4/30/2016 2/2

Ensure that the steering wheel module (2) is correctly seated.

Note:
Steering wheel is shown removed for purposes of clarity.

Feed out the cable though the steering wheel spokes (1) and
take off the shift paddles.
Installation note:
Make sure electrical wiring is correctly routed.
Ensure that the shift paddles are correctly seated.
 4/29/2016 1/2

11 42 035 Removing and installing/replacing the

thermostat housing N55

Special tools required:

 11 9 240

Necessary preliminary tasks:

 Remove intake silencer housing.

Release screw (1).
Tightening torque 17 22 4AZ.
Remove engine oil pipe (2).

Release oil filter cover with special tool 11 9 240.

Tightening torque 11 42 1AZ.
Note:
The remaining engine oil can flow back into the oil sump.
 4/29/2016 2/2

Release screws (1).
Tightening torque 11 42 3AZ.
Note:
Catch escaping engine oil with suitable auxiliary materials.
Remove thermostat housing.

Installation note:
Replace gasket.

Assemble engine.
Checking engine oil level:
 Park vehicle on a horizontal surface.
 Allow engine at normal operating temperature to run for
three minutes with increased engine speed (approx. 1100
rpm)
 Read off engine oil level in instrument panel or on Control
Display
 Top up engine oil if necessary.
 4/30/2016 1/1

51 46 050 Removing and installing/replacing top

cover on tail panel

Necessary preliminary tasks:

 Remove luggage compartment floor trim panel
(luggage compartment mat)

Release expanding rivets (1).

Lever out trim (2) inwards/upwards.
Installation note:
Make sure edge protection for tailgate (2) is correctly seated on
cover.
 4/30/2016 1/1

51 71 373 Removing and installing/replacing

trailing link on spring strut dome

Important!
Driving without the trailing link is not permitted.
(risk of damage to the body).

Necessary preliminary tasks:

 Remove cover in engine compartment on the left
and right

Lever out covers (1) and release screws underneath.

Release screws (2) and remove trailing link (3).
Tightening torque 51 61 1AZ
Installation note:
Replace screws and tighten to specified torque and then to
angle of rotation.
 4/30/2016 1/1

22 31 055 Removing and installing/replacing

transmission bearing block

Necessary preliminary tasks:

- Remove rubber mounts for gearbox mounting.

Release screws (1).
Tightening torque 22 32 1AZ.
Remove transmission mounting bracket (2) from transmission.
 4/30/2016 1/1

51 32 420 Removing and installing/replacing trim

cover on front door window frame, left or
right

Necessary preliminary tasks:

 Open side window
 Remove weather strip
 Remove cover on door window frame

Pull rubber window seal (1) out of rear window guide.

Unfasten screws (2).
Push cover (3) down slightly and unfeed rubber window seal (1)
toward the top.
Then feed cover (3) upward out of the door.
Installation note:
if necessary, replace faulty plastic nuts for screws (2).
Wet rubber window seal (1) prior to fitting with
approved lubricant.
Make sure rubber window seal (1) is correctly seated on
cover (3).

Installation note:
Sealing (1) on cover (2) must not be damaged or missing.
 4/30/2016 1/1

51 45 184 Removing and installing/replacing trim

panel for pedal mechanism

Release screw connection (1).

Note:
Version with knee airbag: Unscrew nuts (1).

Tightening torque 51 45 8AZ.

Release trim panel (2) at clamps (3).
Lower trim panel (2) slightly and disconnect plug connections
behind.

Installation note:
Clamps (1) and guides  (2) must not be damaged.
Feed guides (2) correctly into the corresponding holder in the
vehicle.

Replacement (depending on version):

 Remount speaker for hands-free system (3)
 Remount footwell light (4)
 4/30/2016 1/1

51 46 003 Removing and installing/replacing trim

panel for storage shelf

Open tailgate.
Release holding straps (1) on left and right.
Pull storage shelf (3) out of guides (2).
 4/30/2016 1/2

51 13 280 Removing and installing/replacing trim

strip on roof frame at left or right

Special tools required:

 00 9 321

Lever out trim strip (1) at front with special tool 00 9 321.

Unclip trim strip (1) in direction of arrow.

Installation note:
Clips (1), gaskets (2) and end caps (3) must not be damaged or
missing.
The position of the clips (1) is determined with the tabs on the
body.
Place the trim strip onto the roof loosely and check if clips (1)
are correctly positioned with the tabs on the roof.
Replacement:
Do not attach clips (1) until the trim strip has been painted.

Mounting dimensions for clips:

Pull the front end cap (1) out.
Install clips (2) according to dimension (A to H).
 4/30/2016 2/2

Dimension (A) from outer edge of trim strip to centre of clip (2).

Dimensions (B to H) refer to the centre of the clips (2).

A B C D E F G H

Dimensions in 59 173 232 253 236 239 242 159

mm

Installation note:
The front of the trim strip (1) must be flush with the roof outer
skin.
Trim strip (1) must be flush with roof outer skin (max. -2 mm) at
rear.
 4/30/2016 1/1

65 13 195 Removing and installing/replacing

tweeter in rear

Necessary preliminary tasks:

 Remove luggage compartment wheel arch panel

Unfasten plug connection (1) and disconnect.

Feed out associated cable with resistor (2).
Unclip tweeter (3) with suitable tool at marked point.
Remove tweeter (3) from luggage compartment capping (4).
Installation note:
Make sure resistor (2) is correctly seated in the corresponding
bracket.
 4/30/2016 1/1

66 33 010 Removing and installing/replacing

ultrasound sensor for parking assistant

Necessary preliminary tasks:

 Partially remove cover wheel arch, front left or right

Unfasten plug connection (2) and disconnect.

Unlock latch mechanisms where marked and pull ultrasonic
transducer (1) out of bracket (3).
Installation note:
Latch mechanisms must not be damaged!
Make sure ultrasonic sensor is securely seated.
 4/30/2016 1/1

61 31 134 Removing and installing/replacing USB

audio interface connecting socket

Necessary preliminary tasks:

 Remove insert in centre armrest storage
compartment

Release connecting socket (1) from latch mechanism on both

sides.
Remove connecting socket from storage compartment (2).

Installation note:
- Connecting socket latch mechanisms (1) must not be
damaged or missing

- Make sure connecting socket (1) is correctly fitted in

storage compartment
 4/29/2016 1/3

11 66 000 Removing and installing/replacing

vacuum pump (N55)

Special tools required:

 11 0 290
 11 4 120
 11 8 650

Necessary preliminary tasks:

 Remove drive belt.
 Remove tensioner for drive belt.
 Remove sealing cover for vacuum pump.
 Remove sealing cap of chain tensioner for oil pump.
 Remove high pressure pump.
 Disconnect vacuum line from vacuum pump.

Unlock connector (1) on vacuum pump and disconnect.

Rotate crankshaft at central bolt.

Turn sprocket wheel until drilled holes and screws of vacuum
pump match up.
Screw in special tool 11 8 650 .
 4/29/2016 2/3

Secure special tool 11 0 290 in sprocket and to special tool

11 8 650 .
Release screw (1).
Tightening torque 11 66 2AZ.

Carefully press tensioning rail (1) with a suitable screwdriver (2)

in direction of arrow.
As the oil pressure in the chain tensioner can only be drained
pulsating, the tensioning rail (1) must be pressed several times.

Press the tensioning rail (1) and hold down.

Fix chain tensioner piston in position with a suitable lock pin (2).

Release screws (1).
Tightening torque 11 66 1AZ.
Release screws (1).
Secure screws (1) against falling out.
 4/29/2016 3/3

Remove vacuum pump (1) in direction of arrow.

Installation note:
Replace seal.

Assemble engine.
 4/30/2016 1/2

33 31 017 Removing and installing/replacing

vibration absorber

Special tools required:

 2 240 515

Important!
Different vibration absorbers are installed depending on the vehicle equipment and
motorisation.
The vibration absorbers have different nominal frequencies depending on the equipment
and motorisation.
The nominal frequency is noted on the vibration absorber and its observation is
mandatory.

Release screw on vibration absorber (1) with special

tool 2 240 515 and ring spanner (AF 13).
Tightening torque 33 17 3AZ.
Remove vibration absorber (1).

Release screw (1).
Tightening torque 33 17 4AZ.
Remove vibration absorber (2).
4/30/2016 2/2
 4/30/2016 1/1

25 11 250 Removing and installing/replacing

vibration absorber

Necessary preliminary work:

 Remove gaiter (gearshift lever cover) for gearshift lever.

Unlock vibration absorber (1) by turning counterclockwise.

Remove vibration absorber (1) upwards.
Installation note:
Ensure the locking pin (2) is correctly locked in the gate of the
vibration absorber (1).
 4/29/2016 1/3

11 23 010 Removing and installing/replacing

vibration damper (N55)

Special tools required:

 11 8 180
 11 8 660
 11 9 260

Necessary preliminary tasks:

 Remove underbody protection
 Remove drive belt.

Note:
Gearbox removed:

Block crankshaft with special tool 11 9 260.

Note:
Picture of flywheel removal.

Note:
Gearbox installed with manual gearbox:

Block crankshaft with special tool 11 8 180 .

 4/29/2016 2/3

Note:
Gearbox installed with automatic transmission:

Block crankshaft with special tool 11 8 660 .

Important!
Do not release central bolt.
If the central bolt is accidentally loosened, the timing must
be readjusted.

Release screws (1 to 8).

Remove vibration damper (1).
Screws on vibration damper
Tightening torque 11 23 1AZ.
 4/29/2016 3/3

Assemble engine.
 4/30/2016 1/1

51 64 012 Removing and installing/replacing V-

support

Important!
Driving without V-support is not permissible (risk of
damage to body).

Removal of the V-support is explained in the following

operations:
 Remove front bumper panel
 Release the side of the centre front panel
 Remove deformation element for bumper panel on the left
or right
 4/30/2016 1/2

61 67 010 Removing and installing/replacing

washer pump for headlight cleaning
system

Necessary preliminary tasks:

 Detach washer fluid reservoir and pull forwards

Overview of washer pumps:

(1) Windscreen washer pump of window washer system.
(2) Windscreen washer pump of window washer system (F20,
F21, F31 only).
(3) Washer pump for headlight cleaning system.

Note:
Graphic shows by way of example the washer pump for the
headlight cleaning system!

Catch any escaping washer fluid if necessary.

Unfasten plug connection (1) and disconnect.
Unlock latch (3) and detach hose pipe (2) from washer
pump (4).
Turn washer pump (4) if necessary and pull out of washer fluid
reservoir (5).

Note:
Graphic shows an example of the strainer for windscreen
washer pump.

Remove and replace strainer (2) of windscreen washer pump

(1) or washer fluid reservoir (3).
 4/30/2016 2/2

Installation note:
 Coat sealing ring of washer pump with lubricant
 Lay hose pipe of washer pump without kinks
 Topping up washer fluid
 4/30/2016 1/1

65 24 020 Removing and installing/replacing wave

trap

Necessary preliminary tasks:

 Remove trim panel for roof pillar at rear right

Unlock plug connections (1) and disconnect.

Release screw (2).
Remove blocking circuit (3).
 
Installation note:
Ensure rejector circuit (3) is fitted correctly.
 4/30/2016 1/1

51 22 330 Removing and installing/replacing

weather strip on inside rear door

Necessary preliminary tasks:

 Remove rear door trim panel

Pull the weather strip (1) off rear door.

Installation note:
Replace faulty clamps (2).
Pay attention to fitting position of different clips (2).
 4/30/2016 1/1

51 22 300 Removing and installing/replacing

weather strip on outside of rear door

Special tools required:

 00 9 324
 00 9 325

Important!
Weather strip in plastic design cannot be removed without
damage.
 
Observe procedure for using special tool 00 9 324.
The ”Instructions on fitting window guide seals” serve as
the basis for this repair instruction and must be observed
without fail.

Important!
If reusing the existing window cavity cover strip (1), make
sure it is not bent.

Pry out weather strip (1) with special tool  00 9 324 (starting at

B-pillar).
In areas that cannot be reached with special tool 00 9 324,
carefully pry out weather strip (1) using special tool 00 9 325.
Installation note:
Moisten weather strip (1) before installation with
approved lubricant.
Weather strip (1) must lie flush with the door edge at the front
and rear.
 4/30/2016 1/1

54 12 497 Removing and installing/replacing wind

deflector for glass slide/tilt sunroof

Open glass slide/tilt sunroof.

Carefully detach rubber stops from left and right of wind
deflector (1) in direction of arrow.

Raise wind deflector (1) in vertical position in direction of

arrow (A).
Pull left and right wind deflector (1) in direction of arrow (B) out
of slide/tilt sunroof unit.
Installation note:
Make sure rubber stops are installed.
Position wind deflector with rubber stops under roof outer skin.
Make sure spring clamps (2) are correctly fitted in the slide/tilt
sunroof unit.

Replacement only:
Screw wind deflector (1) with wire spring clip (2) on the left and
right.
Tightening torque 54 12 03AZ.
 4/30/2016 1/3

51 31 021 Removing and installing/replacing

windscreen rubber surround

Special tools required:

 2 232 316

Necessary preliminary tasks:

 Remove windscreen

Important!
The glass activator for pre-treating the area of the
windscreen adhesive trace must not encroach upon the
adhesive area for the rubber frame.
The bonding result of the rubber frame is otherwise
compromised.
The rubber frame must therefore be installed prior to
applying the glass activator.
Following instructions for bonding components with
double-sided adhesive tape.

Pull off rubber frame (1).

Remove remnants of adhesive tape (2).
Clean bonding surface.
Air drying time: ≥ 1 minute
Important!
Adhesive area must be dry and free from dust and grease.
Once it has been cleaned, do not touch the adhesive area
with bare hands.

Installation note:
Pre-treat adhesive area with Sika-Aktivator205.
Air drying time: ≥ 1 minute
Sika Activator 205 must not get onto adhesive area of adhesive
bead.
 4/30/2016 2/3

Reposition lever (1) and open special tool 2 232 316.

Pull off protective film (3) in stages from adhesive tape.
Insert rubber frame (2) in guide pulley (4).

Installation note:
The start and end points of the rubber point are marked on the
windscreen with marks (1).

Place special tool with contact rollers (1 and 2) up against

window edge.
Align the rubber frame on the outer window edge.
Reposition lever (3) and close special tool.

Make rubber frame (1) is correctly seated in guide pulleys (2).

Continue to pull off protective film in stages from adhesive tape.
Run special tool with hand wheel over entire window edge.
 4/30/2016 3/3

Guide pulleys (1 and 2) must always be correctly placed at

windscreen (3) and are not to be twisted.

- Guide pulley (1) from top on windscreen (3)

- Side guide pulleys (2) at outer edge of windscreen (3)

 4/30/2016 1/2

61 71 100 Removing and installing/replacing

windscreen washer pump

Necessary preliminary tasks:

 Detach washer fluid reservoir and pull forwards

Overview of washer pumps:

(1) Windscreen washer pump of window washer system.
(2) Windscreen washer pump of window washer system (F20,
F21, F31 only).
(3) Washer pump for headlight cleaning system.

Note:
Graphic shows by way of example the washer pump for the
headlight cleaning system!

Catch any escaping washer fluid if necessary.

Unfasten plug connection (1) and disconnect.
Unlock latch (3) and detach hose pipe (2) from washer
pump (4).
Turn washer pump (4) if necessary and pull out of washer fluid
reservoir (5).

Note:
Graphic shows an example of the strainer for windscreen
washer pump.

Remove and replace strainer (2) of windscreen washer pump

(1) or washer fluid reservoir (3).
 4/30/2016 2/2

Installation note:
 Coat sealing ring of washer pump with lubricant
 Lay hose pipe of washer pump without kinks
 Topping up washer fluid
 4/30/2016 1/2

61 62 030 Removing and installing/replacing wiper

arm on rear window

Special tools required:

 61 6 060

Spread internal latch mechanisms (2) as shown and remove

protective cap (1) in direction of arrow.

Latch mechanisms (1) and fixture (2) of protective cap (3) must

not be damaged.

Erect wiper arm (1).

Slacken nut (2).
Tightening torque 61 62 5AZ.
Press off wiper arm (1) with special tool 61 6 060 and remove.
 4/30/2016 2/2

Installation note:
Before fitting wiper arm, allow wiping system to run two
wipe cycles into wiper park position.
Adjust dimension (A) between wiper arm and rear window
edge.
Measurement (A): 35 ±3 mm.
 4/30/2016 1/2

61 31 043 Removing and installing roof switch

cluster (front)

Special tools required:

 00 9 325

Important!
Follow notes for handling light bulbs (interior lighting).

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Carefully unclip cover (1) with special tool 00 9 325 and

remove.
Installation note:
Ensure cover (1) is correctly seated.

Unlock left/right retaining lugs (1) with screwdriver (2) in

direction of arrow.
Remove roof switch cluster (3).
Unlock plug connections underneath and disconnect.
 
Installation note:
Retaining lugs (1) must not be damaged.
Make sure roof switch cluster (3) is correctly fitted.
If necessary, initialise slide/tilt sunroof.
 4/30/2016 2/2

Important!
Disconnecting the plug connection for the SOS emergency
call button results in fault entries in the telephone control
unit (restriction in the emergency call system).
After installation, read out fault memory and if necessary
delete fault code entry.
 4/29/2016 1/3

11 12 000 Removing and installing/sealing cylinder

head cover (N55)

Necessary preliminary tasks:

 Release positive battery cable from connection point.
 Release engine wire harness in the area of the cylinder
head cover.
 Disconnect pressure lines.
 Remove air duct

Release screws (1).
Remove flange (2).

Press and hold down the unlocking device on the vacuum line
(1) on the vacuum reservoir (cylinder head cover) in the
direction of the arrow.
Detach vacuum line (1) in upward direction.

Important!
Do not loosen the engine vent line (4) on the cylinder head
cover.
 4/29/2016 2/3

To dismantle the engine vent line, loosen the screws on the air
intake system (3).
Note:
When changing a faulty engine vent line, the clutch on the
coupling on the cylinder head cover may be broken open.

Release screws of cylinder head cover from outside inwards in 1/2 turns.

Remove cylinder head cover.

Replace all gaskets.

 4/29/2016 3/3

Fit cylinder head cover.

Insert screws of the cylinder head cover by 1/2 turn.
Tighten fit screws (1) using 8.5 Nm.
Tighten positional screw (2) using 8.5 Nm.
Tighten remaining screws of cylinder head cover in sequence 3 to 23.
Tightening torque: 11 12 4AZ.
 4/29/2016 1/2

13 54 030 Removing and installing/sealing throttle

body (N55)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Switch off ignition.
 Remove charge air duct.

Unlock connector (1) and remove.

Release screws (3).
Tightening torque 13 54 1AZ.
Partially remove throttle body (4) and unlock tank ventilation
line (2) and remove.
Remove throttle body (4).

Installation note:
Replace sealing ring (1) of throttle body (2).
 4/29/2016 2/2

Installation note:
Check stored fault message.
Delete fault memory.
 4/30/2016 1/2

41 62 000 Removing and installing tailgate

Read contents of Body, General.

For stripping and rigging operations, refer to texts on KSD
CD (job number 41 62 000).
Necessary preliminary tasks:
 Remove trim for rear lid.
 Detach gas pressure spring
 Disconnect all plug and socket cable connections on rear
lid

Warning!
Danger of injury!
Support tailgate in fully opened position with suitable
device.

Carry over the work step shown symmetrically to the other side
of the vehicle.
Slacken nut (1).
Tightening torque 41 62 3AZ.
Unfasten screws (2).
Tightening torque 41 62 1AZ.
Remove tailgate.

Installation note:
Install tailgate at screw locations on hinge.
If necessary, adjust trunk lid.
4/30/2016 2/2
 4/30/2016 1/5

26 11 100 Removing and installing three-hole

flange

Special tools required:

 23 0 020
 33 5 040
 33 5 070

Important!
The slide-in nut must be replaced by a new one.
The sunk nut already has a screw locking.
After the propeller shaft has been screwed into the rear
axle final drive (sunk nut), a hardening time of at least 2
hours is absolutely necessary.
The hardening time may be extended at lower
temperatures!
Failure to comply with these instructions may cause
serious damage!

Necessary preliminary tasks:

 Remove propeller shaft

Since the three-hole flange, the flexible disc and the propeller
shaft are balanced as a single unit, the balance quality of the
propeller shaft, flexible disc and three-hole flange may be
 4/30/2016 2/5

compromised slightly when the three-hole flange is replaced.

Important!
Before removing propeller shaft:
The three-hole flange and the propeller shaft must be
reassembled in the same position.
Mark three-hole flange (1), flexible disc (2) and propeller
shaft (3) in one plane.

Installation note:
Replace ZNS bolts and self-locking nuts.

Important!
The sunk nut must be opened against direction of travel in
clockwise direction.
If an attempt is made to open the sunk nut in direction of
travel in clockwise direction, the sunk nut is automatically
screwed in further and the insert collar of the 12-edge
flange nut is severely damaged.
If the insert collar of the flange nut was damaged, the
propeller shaft can no longer be secured using a new sunk
nut and the rear axle differential must be replaced.

Release insert nut against direction of travel in clockwise

direction with special tool 33 5 040 and 33 5 070.
Grip with special tool 23 0 020.
Release three-hole flange (1) from bevel pinion.
Tightening torque 26 11 6AZ.

Remove retaining clip (1) and gasket (2).

 4/30/2016 3/5

Installation note:
Retaining clip and gasket must be replaced.

Remove insert nut (1).

Installation note:
Insert nut must be replaced.

Before installing three-hole flange:

Clean insert collar (1) on flange nut and gearing on bevel
pinion (2).
Fill insert collar (1) with grease.
Grease: BMW Service Operating Fluids.

Important!
Thread of flange hub must not be contaminated with
grease.

Clean thread (1) of flange hub to remove adhesive residues.

Clean hub teeth (2), then coat with grease.
 4/30/2016 4/5

Grease: BMW Service Operating Fluids.

Place flange nut (1) with gasket in insert collar of flange nut.

Install retaining clip (2).

Important!
The bi-hexagonal flange nut must not be used for bracing.
Failure to comply with this instruction may result in serious
damage to the rear axle final drive.

Important!
Insert nut must be screwed into place within 5 minutes.
Tightening torque 26 11 6AZ.

Slide drive flange (1) to the limit position onto insert nut and
secure.
4/30/2016 5/5
 4/30/2016 1/7

23 00 028 Removing and installing transmission

(GS6-45BZ) N55

Special tools required:

  23 4 050
   00 2 030
 00 9 010
 21 2 240
 00 9 120
 00 9 130

Important!
After completion of repair work, check transmission oil
level.
Use only the approved transmission oil.
Failure to comply with this requirement will result in
serious damage to the manual gearbox.

Important!
For vehicles with N54/N55 engine up to production date
09/2012, aluminium bolts for the for the securing of the
transmission are also installed.
As of production date 09/2012, only steel bolts are
installed for the securing of the transmission.
Note:
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).
The aluminium bolts can be optionally replaced by steel
bolts.
 4/30/2016 2/7

Necessary preliminary tasks:

 Remove underbody protection at front and rear.
 Remove complete exhaust system.
 Remove heat shields.
 Partially remove propeller shaft.

- Disconnect propeller shaft at transmission.

- Release centre mount.

- Tie up propeller shaft to underbody.

Note:
Bending the propeller shaft by an excessive
angle can cause premature damage to the
joint/propeller shaft!

 Support engine with jack when removing gearbox

Unscrew nuts (1).

Release holder (2) and ground strap (3) from vehicle
underbody.
Nut (ground strap on body) tightening torque 23 11 8AZ.

Release screws (1).
Remove strut (2).

- Similar to graphic.
 4/30/2016 3/7

Release aluminium screws (1) on transmission.

Tightening torque 23 00 1AZ.
Unscrew nuts (2).
Tightening torque 18 20 1AZ.
Remove bracket (3).
Installation note:
Renew aluminium screws (1).

Supporting transmission:
Support transmission with special tools  23 4 050,  00 2 030.
Secure transmission to mounting with tensioning strap (1).
Tasks are described in Gearbox holder.

Unscrew nut (1) and bolts (2).

Remove gearbox cross member (3).
Tightening torque 22 32 3/4AZ.
Illustration: Automatic
 4/30/2016 4/7

Note:
Pressure line of clutch slave cylinder remains connected.

Important!
Relieve tension on clutch slave cylinder slowly; otherwise
air will be drawn in through sealing cup.

Release nuts and remove clutch slave cylinder.

Tightening torque 21 52 1AZ.

Lift off retainer (2).

Detach gearshift rod (1).
Installation note:
Grease gearshift rod.
Grease, refer to BMW Service Operating Fluids.

Important!
Retaining clip must interlock captively with retaining
web (1) behind gearshift rod pin.
 4/30/2016 5/7

Unlock bearing journal (1) in direction of arrow and remove.

Lift out gearshift arm.
Installation note:
Grease bearing journals (1).
Grease, refer to BMW Service Operating Fluids.

Disconnect plug connection (1) on reverse gear switch.

Release line from holder.

- Similar to graphic.

Disconnect plug connection (1) on zero gear sensor.

Release all lines from holder.
 4/30/2016 6/7

Release screws.
In vehicles with an N54/N55 engine from production date
09/2012, only steel bolts are installed.
Steel screws (1,2,4,5,6,9), tightening torque 23 00 1AZ.
Release aluminium screws with special tool 00 9 010.
Aluminium screws (3,6,7,8), tightening torque 23 00 1AZ.
Important!
Do not allow transmission to hang on transmission input
shaft when removing and installing, as the clutch disc will
be deformed. Pull transmission downwards and remove.
Renew aluminium screws (3,6,7,8).

Installation note:
Check that fitting sleeves are correctly fitted.
Replace damaged fitting sleeves.

Installation note:
Check lubrication of transmission input shaft for sticky
consistency. If grease is sticky, clean input shaft and replace
clutch disc.
 4/30/2016 7/7

Check clutch disc for frictional corrosion in gearing and replace

if necessary.
Remove any grease and lining abrasion from gearing of clutch
disc by mechanical means (with a cloth).

Installation note:
Greasing specification:

- Remove and clean release bearing and release lever.

- Push on grease scraper ring 21 2 240 to the limit position.

- Grease gearing (1) of input shaft with a brush.

Grease, refer to BMW Service Operating Fluids.

- Detach grease scraper ring.

Installation note:
Tighten down screws/bolts to specified torque.

Special angle-of-rotation tool00 9 120 with magnet00 9 130.

Secure to vehicle underbody and screw down aluminium
screws/bolts in accordance with angle of rotation.
Angle of rotation 23 00 1AZ.
 4/30/2016 1/1

51 31 000 Removing and installing windscreen

Up until this point, the work is identical to "Replace

windscreen".
 Rain/light/solar sensor and/or camera remain on the
windscreen; only disconnect the plug connections
 Replace the cover / windscreen rubber surround only in
the event of damage.
 Replace expanding foam tape only if damaged.
 4/29/2016 1/4

11 13 000 Removing and installing, sealing or

replacing oil sump (N55)

Special tools required:

 11 8 780

Important!
Aluminium screws/bolts are permitted with and without
colour coding (blue).
Aluminium screws/bolts must be replaced each time they
are released.
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Drain and add engine oil.
 Remove front axle differential (AWD).
 Removing bearing support (all-wheel drive).
 Lower front axle.

Release bolts (1) on transmission.

Tightening torque 11 13 7AZ.
Disconnect plug connection (2) on oil level sensor.
 4/29/2016 2/4

Release bolts along line (1).

If necessary, remove oil level sensor.

Installation note:
Screw (1) M8x92 mm.
Screws (2) M8x112  mm
Screws (3) M8x92 mm

Installation note:
Screw (1) M8x50 mm.
 4/29/2016 3/4

Installation note:
Replacing all O-rings and seals (1).

Aluminium screws (2) M8x92 mm and M8x112 mm.

Tightening torque 11 13 3 AZ.
Aluminium screw (3) M8x50 mm.
Tightening torque 11 13 4AZ.
Aluminium screws (4) M8x26 mm.
Tightening torque 11 13 2AZ.

Installation note:
Special tool 11 8 780 is only required if gear is not installed as
mechanical stop.

Secure special tool 11 8 780 with two bolts on crankcase.

Installation note:
Engine removed:
Position oil sump (1) with no gaps until it contacts special tool
11 8 780.

Installation note:
Engine installed:
 4/29/2016 4/4

Position oil sump (1) with no gaps until it contacts gearbox

housing.

Bolt on oil sump (1).

Assemble engine.
 4/30/2016 1/2

52 26 020 Removing and refitting/replacing both

rear seat backrests

Necessary preliminary tasks:

 Remove armrest side section
 Remove rear seat

Note:
A helper is required for the removal and installation of the
backrest.

Left backrest:
 Undo screw (1)
Tightening torque 52 26 01AZ.
 Fold backrest forward slightly
 Pull backrest forwards and outwards out of centre mount
Installation note:
Replace screw (1).

Right backrest:
 Undo screw (1)
Tightening torque 52 26 01AZ.
 4/30/2016 2/2

 Fold backrest forward slightly

 Pull backrest forwards and outwards out of centre mount
Installation note:
Replace screw (1).
 4/30/2016 1/2

52 26 315 Removing and refitting/replacing lock for

centre rear seat backrest

Unclip trim cover for lock with a plastic wedge.

Move trim cover for lock a little towards the middle.
Detach trim cover for lock by pulling towards rear.

Installation note:
Retaining lugs on the trim cover for the lock must not be
damaged.
Replace defective trim cover for lock.

Release screws (1) and feed lock (2) out of rear seat backrest.
Tightening torque 52 26 06AZ.

Installation note:
Make sure operating rod (1) is correctly seated in the lock.
Run a function check.
4/30/2016 2/2
 4/30/2016 1/1

51 23 ... Removing/installing ball sockets with clip

Warning!
Danger of injury! When installed, the gas pressurised
shock absorber is under preload. Minimise preload as far
as possible before removing.

Important!
Never lift off ball socket with engaged clamp.

Disassembly/assembly:
1. Push on clamp in direction of groove with screwdriver
2. Lift off ball socket from ball pin
3. Slide clamp back
4. Fit ball socket on ball stud and snap into place with force
Installation note:
Replace overstretched clips.
Pack grease into two opposite positions in socket. The grease
spreads after installation on the ball pin all round in the ball
socket.
 4/30/2016 1/1

41 62 515 Removing/installing/replacing left hinge

for tailgate (tailgate removed)

Read contents of Body, General.

For stripping and rigging operations, refer to texts on KSD
CD (job number 41 62 515).

Release nuts (1) and remove hinge.

Installation note:
Tightening torque 41 62 2AZ.
Adjust hinge together with tailgate.
 4/30/2016 1/1

51 75 030 Removing or installing/replacing the

sound insulation of the upper part of the
bulkhead

Necessary preliminary work:

 Remove trailing link on spring strut dome

Release expansion rivet (1).

Unclip sealing (2) in direction of arrow.

Release screws (1).
Feed out sound insulation of upper part of bulkhead (2).
Installation note:
The gasket at the bottom of the sound insulation of the upper
part of the bulkhead  (2) must not be damaged.
 4/29/2016 1/3

12 14 600 Removing/replacing knock sensors

(N55)

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Remove high pressure pump.

Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.

Unlock connector (1) and remove.

 4/29/2016 2/3

Release screws on both knock sensors (1) and remove knock

sensors (1).
Installation note:
 Replace aluminium screws.
 Tightening torque 13 62 3AZ.

Installation note:
Clean contact surface of knock sensors on engine block.

Note:
Reassemble the vehicle.
Check stored fault messages.
Delete fault memory.
4/29/2016 3/3
 4/30/2016 1/3

23 14 567 Removing/replacing zero gear sensor

Special tools required:

 23 4 050
 00 2 030

Important!
After installing the zero-gear sensor, it is necessary to
teach in the position of the zero-gear sensor again.
Calibration is carried out using the BMW Diagnosis
System "Service Function" (Learn/record zero-gear
sensor).

Necessary preliminary tasks:

 Remove rear underbody protection.
 Remove complete exhaust system.
 Remove heat shields.

Unfasten screws (2).

Tightening torque 26 11 5AZ.
 4/30/2016 2/3

Support transmission with special tools 23 4 050,00 2 030.

Release screws (1).
Tightening torque 18 20 2AZ.
Detach rubber mount of exhaust system.

Release screws (3).
Tightening torque 22 32 3AZ.
Lower transmission.
 4/30/2016 3/3

Disconnect plug connection (1) on zero gear sensor.

Unfasten screws (2).
Remove zero gear sensor.
Installation note:
Replace screws (2).

Tightening torque 23 14 2AZ.

 4/30/2016 1/2

51 21 ... Removing weather strip with special tool

00 9 324 at front or rear

Special tools required:

 00 9 318
 00 9 324

Open side window completely.

 
Front door:
Insert special tool 00 9 324 at front (at A-pillar) in window
cavity (1) (TOP label pointing upwards).
 
Rear door:
Insert special tool 00 9 324 at rear (at C-pillar) in window
cavity (2) (TOP label pointing upwards).

Note:
For purposes of clarity, graphic shows inner door panel and
side window removed.

 
Special tool 00 9 324 must be correctly guided under weather
strip (1).
2 Short leg, bottom
3 Long leg, top (TOP)

Note:
Start at the front or rear, depending on the model.

Important!
 4/30/2016 2/2

Risk of damage!
Raise weather strip (3) no more than 5 mm in each
levering operation, otherwise the strip will be bent.

Position special tool 00 9 318 on door trim panel (1).

Slide suitable tool (2) through hole of special tool 00 9 324 and
in this way lever weather strip (3) in an upward direction by
max. 5 mm.
Guide special tools 00 9 324 and 00 9 318 forward and
backward step by step until weather strip (3) is fully removed.
 4/30/2016 1/6

51 31 ... Removing windows with a "Spider"

Windscreen removal system "Spider"

1 "Spider" separation device 6 Line threader

2 Bit holder 7 Line routing tool

3 Operating instructions 8 Suction anchor

4 Dashboard protection 9 Cord for separating adhesive strips

5 Angular transmission    

Accessories required for operation (not included):

Cordless screwdriver/drill with at least a 10.8 V Li-ion battery or a 18 V Ni-Cd battery and variable speed.
Note: Always use a low gear setting.

Note:
Damage as well as ergonomic and health-endangering damage are minimised with the "Spider"
disassembly system.
Sourcing reference:
 4/30/2016 2/6

See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop Equipment

(Start BMW) - Shop Workshop Equipment or at www.bmwgroup.com

Warning!
Follow safety instructions for working on vehicles with airbag systems (risk of injury).

Important!
Handle sharp-edged tools with care (risk of damage to the head airbag and the window
glass).

Important!
Always keep both suction cups dry and clean to ensure their optimum adhesion on the
windscreen.
Suction cup may not be applied at the damaged point (crack in window glass).
The bearing bushes of the shaft (spindle) must always be lubricated.
Always wear safety goggles and protective gloves for your own safety.

The procedure for disassembly of the windscreen is described below as an example.

Deviations in the work procedure can be found in the vehicle-specific repair instructions.

General
A cord approx. 6.8 m long is used to cut through the adhesive
bead.
The cord length to be used is identified by a short red
mark (A) approx. 5 cm.
The part of the cord laid outside around the window glass
(approx. 5 m) is identified with a long red mark (B)
(approx. 18 cm).
The marks are applied so that the cord has to be pulled from
the inside to the outside.
Preparation
 4/30/2016 3/6

A. Pierce cord from the roller (1) or separation device (2) with cord threader (3) through the adhesive bead
from the inside, protect the area from the inside as required.
B. Pull out cord up to the first red mark (approx. 18 cm long).
C. Lay cord around the window glass, use pulling aid (4) if required.
D. Secure suction anchor (5) outside on window glass, secure cord to suction anchor (5).
If required, unwind cord from roller (1) up to the second red mark (approx. 5 cm long) and cut off.

Make sure the cord lies below the window glass at all four corners.
Check that the cord is not caught on clamps or body.
Secure window glass on outside with adhesive tape against sliding.

Feeding in the cord on the separation device

 4/30/2016 4/6

Normally, the adhesive bead is cut through anticlockwise seen from the passenger compartment.

- This means the cord must be fed into the separation device as shown in graphic A.
When accessibility is not optimal, the opposite cutting direction may be required (comply with vehicle-specific
repair instructions).

- This means the cord must be fed into the separation device as shown in graphic B.
Feed cord into coil and wind it on, at the same time trapping the end of the cord.
When winding the cord, the correct direction of rotation on the separation device must be observed.
 

Cutting out procedure

 4/30/2016 5/6

Optimum cutting is guaranteed when the cord is at an acute angle to the adhesive bead. There is a
risk of the cord ripping if the angle is too obtuse.
The separation device must be positioned correspondingly to achieve the appropriate angle.

A. Fix separation device (1) on window glass at bottom right.

B. Depending on accessibility, attach bit holder (2) or angle gear (3) to cordless screwdriver (4).
C. Place cordless screwdriver (4) on separation device (1) and start winding cord, observe direction of
rotation on separation device.
If required, over trim panel components with plastic protection.
Guide cord with plastic protection around sharp-edged positions.
Cut through adhesive bead up to bottom area of A-pillar.
Turn back cordless screwdriver (4) approx. 2 rotations and remove.
 

Cutting out procedure

 4/30/2016 6/6

A. Discharge vacuum on windscreen removal tool (1) by pressing the tab, remove windscreen removal
tool (1) from window glass.

B. Reset removal tool (1) at illustrated and wind up cord up to the position of windscreen removal tool (1).

C./D. Repeat further resetting, work sequence as given at B.

Additional resetting may be required for very curved window glass.

 

It is possible to reuse the cord. When a cord is used many times the risk of ripping increases.
Dirt contamination must be avoided when a cord is reused.
 4/30/2016 1/3

51 31 ... Removing windows with an oscillating

knife

Warning!
Follow safety instructions for working on vehicles with
airbag systems (risk of injury).

Important!
Handle sharp-edged tools with care (risk of damage to the
head airbag and the window glass).

Important!
Follow the vehicle-specific repair instructions!
Always wear safety goggles and protective gloves for your
own safety.
Cover the working area (side walls, roof-mounted aerial
and if necessary interior equipment) with protective
covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in
areas where the oscillating knife could damage the
window glass or the paint.

Use suction cups (51 3 010) to lift out the window glass.

Always keep both suction cups dry and clean to ensure their
optimum adhesion on the windscreen.
Secure window glass against falling out.

Depending on the area of application, knife 1 or 2 is used.

(1) Straight knife with adjustable thrust roller
 4/30/2016 2/3

(2) U-shaped knife

Dimension (X) on the knife (1) can be adjusted individually, see
vehicle-specific repair instructions.
Note:
Sharpen knife blade before every use on a running machine
with a grinding stone (even with new knife blade).

Removing from the inside:

Guide knife carefully between body and window glass.
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.

Removal from outside:

Guide knife carefully between body and window glass.
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.

Cut through adhesive bead as closely as possible to window

glass.
(1) Body opening
(2) Adhesive bead
(3) Knife
(4) Window
4/30/2016 3/3
 4/30/2016 1/5

54 00 ... Repair instructions for bonded seals

1. General information on handling rubber seal profiles:

- If seals reveal partly detached protective film on delivery, they must not be bonded.

- Store seals at 5 °C to 40 °C.

- If, during the handling, the protective film has come off before bonding, it can still be bonded.

- Bonding at room and object temperature 25° ± 5° C. Temperatures between 40 and 50 °C
significantly increase initial adhesion.

- Seals, which are subjected to temperatures above 80 °C after bonding, will be very difficult to
remove.

- Maximum storage time for replacement: 2 years (expiry date must be indicated on the packaging)

 

2. Damage pattern and repair

2.1 Partially detached bond (rubber-adhesive tape or adhesive tape-paint)

- Up to 120 mm for reworking without auxiliary materials

- Up to 200 mm reworked with pressing-on tools on straight surfaces

a) Cleaning
damaged areas:
- Degrease adhesive area coated side with cleaning agent (cleaning agent R2,
see BMW Parts Department) and clear off other residuals. Never use paint
thinner!

- This will usually partially destroy intact edge adhesive areas.

- When removing, it is important to wipe off the adhesive area of the adhesive
tape with a lint-free disposable cloth. (e.g. Kimtex blue, see BMW Parts
Department)

- Carefully wipe off the adhesive areas.

Note:

Use necessary cotton- or fluff-free paper towel once only.

When using solvent: Observe the air drying time of > 1 minute.
 4/30/2016 2/5

Do not touch the adhesive area after cleaning.

b) Applying
adhesive:
- Apply the adhesive evenly and very thinly to the gasket and then to the painted
area.

- Observe the air drying time of 2-3 minutes.

Note:

Use the rubber profile adhesive (Terokal 2444 and thinner R)

Maximum mixture ratio:

Adhesive: Thinner = 3 : 1

Important:

Avoid contact with skin!

Do not apply adhesive to visible painted surfaces.

c) Pressing on
rubber seal:
- Press down gasket using contact pressure (forced pressure not necessary) for
at least 1 minute.

Important:

Load can only be applied to the bond after a period of 2 minutes. This
waiting time is absolutely essential.

 

2.2 Larger defects (mechanical damage and larger separations of seal)

 4/30/2016 3/5

- Complete replacement of rubber seal necessary

a) Peeling off damaged

rubber seal:
- Beginning at the stop, the gasket with the adhesive tape is slowly
separated from the paint.

The gasket is slowly pulled off at an angle of approx. 20° while applying
constant force.

Pay attention to the constriction of the adhesive tape.

Note:

Make sure the connection between adhesive tape and gasket is

retained.

When the adhesive tape separates from the gasket, the adhesive tape
remaining on the paint must be fully separated at one location by
approx. 10 mm until it is easy to grip.

Pull off the adhesive tape by pulling strongly at an angle of approx.

20°.

When existing gaskets are being peeled off with a hot air blower: Do
not damage paintwork.

Do not detach rubber-adhesive tape connection if at all possible.

b) Cleaning bonding
surface:
- Soak and wipe away adhesive tape left overs with a single-use towel fully
soaked in adhesive cleaner (see BMW Parts Department).

Wear protective gloves.

- Before performing a new bond, degrease and clear away other residuals
from the entire adhesive area with cleaning agent (cleaning agent R2;
see BMW Parts Department). Never use paint thinner!

- Carefully wipe off the adhesive area.

Note:
 4/30/2016 4/5

Use necessary cotton- or fluff-free paper towel once only.

When using solvent: Observe the air drying time of > 2 minutes.

Do not touch the adhesive area after cleaning.

c) Prepare gasket:

d) Detaching protective
film from bonding
- Pull off the protective film off of the new gasket by approx. 15 cm using
surface:
the tab.

Important:

Once the protective film has been removed, do not under any
circumstances touch the exposed bonding surface.

e) Applying rubber seal:

- Attach gasket on roof aperture edge beginning at rear centre. Use upper
lip as reference edge.

Press on the gasket by hand while pulling off the liner at the same time.

Compress the gasket the corners; never stretch it. (critical area)

Note:

If positioned incorrectly, the gasket can still be pulled off, repositioned

and pressed on again.

Always ensure that you do not touch the bonding surface with your
fingers or contaminate it in any way.

f) Establishing sealing
 4/30/2016 5/5

joint:

- Where the beginning and end meet, a mark is created from pressing the
loose end onto the beginning of the gasket.

Cut off the gasket vertically along the marked line (use sharp knife or
special scissors) and press in place.

- Visually check the pre-bonded gasket.

Note:

Small areas of gasket can remain stuck to adhesive tape of loose end.

g) Pressing on gasket:

- Press on the gasket with the hand roller

- Adhesive tape width up to 5 mm Contact pressure approx. 5 N

- Adhesive tape width up to 10 mm Contact pressure approx. 10 N

Slide/tilt sunroof
gasket only:
- Press gasket down firmly with a hand roller. Contact pressure ≥ 70 N.

Note:

2
Firm thumb pressure has approx. 30 N/cm

 

3. Checking rubber seal

- Check the bonded gaskets for correct positioning and perfect adhesion. The bonding can be checked
by pressing back the sealing lip.

- The force required to peel off the gasket immediately after bonding must be greater than 10 N/cm.
 4/30/2016 1/1

31 01 12(833)

Visible corrosion on vehicle add-on parts

Situation:
Since the market introduction of the E65/66 the engine compartment and underbody
preservation has successively been dropped from all model series for environmental
protection reasons. This may result in visible corrosion of machined surfaces such as, for
example, on chassis/suspension components, machined screwing/bolting points, screw
connections, or on surfaces such as, for example, the joints and drive shafts!

To prevent this surface corrosion and/or re-treat it, the dealer organisation must use the
Pfinder corrosion protection, BMW part number 83 19 2 317 997.
Vehicles concerned: E46, E53, E60, E61, E63, E64, E65, E66, E67, E70, E71

E81, E82, E83, E84, E85, E86, E87, E88, E89

E90, E91, E92, E93,

F01, F02, F03, F04, F06, F07, F10, F11, F12, F13, F18

F20, F21, F30, F31, F35,

R50, R52, R53, R56, R57, R58, R59, R60

Procedure: Apply a thin coating of corrosion inhibitor (using only a brush) to the affected areas.

Warning!
Risk of fire!

Do not apply any corrosion inhibitor to the engine or the exhaust system!

 
 4/30/2016 1/2

61 00 ... Repairing airbag cables

 

Important!

Only repair those cables which show visible signs of damage. In the event of visible damage, make
sure there is only one cable repair in effect after the repair work. If no visible damage can be
identified, the entire cable must be replaced. When carrying out repairs to the airbag wiring harness,
you must use the spare parts offered in the Electronic Parts Catalogue (EPC).

Safety regulations for handling components of airbag system.

Instructions for disconnecting and connecting battery.

In event of non-visible damage to wiring harness:

Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the
contacts in succession as there is a risk of mixing up (similar parts)! Cut through one cable after the other at
an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate
cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control
unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with
insulating tape, do not under any circumstances cut through both cables at the same time. Pin contacts of
repair cable for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable
in vehicle parallel to existing airbag lead. Now pin in contacts for airbag control unit or contacts of adapter
plug, assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of
airbag module or of adapter plug. Twist open cables. With the butt connectors and heat-shrink tubings in the
Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colours. Twist cables again,
open length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to
prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and insulating cables.

Repairing a plug connection using butt connectors.

Installing and removing contacts.

In event of visible damage:

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
 4/30/2016 2/2

with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair
cable in vehicle parallel to existing airbag lead up to separation point. Cut off excess length of repair cable.
Twist open cables. Connect cables with butt connectors and heat-shrink tubings in Electronic Parts Catalogue
(EPC), assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed
40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and insulating cables.

Repairing a plug connection using connectors.

Installing and removing contacts.

 4/30/2016 1/2

61 00 ... Repairing airbag cables

 

Important!

Only repair those cables which show visible signs of damage. In the event of visible damage, make
sure there is only one cable repair in effect after the repair work. If no visible damage can be
identified, the entire cable must be replaced. When carrying out repairs to the airbag wiring harness,
you must use the spare parts offered in the Electronic Parts Catalogue (EPC).

Safety regulations for handling components of airbag system.

Instructions for disconnecting and connecting battery.

In event of non-visible damage to wiring harness:

Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the
contacts in succession as there is a risk of mixing up (similar parts)! Cut through one cable after the other at
an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate
cables remaining in wiring harness with insulating tape. Now disconnect plug connection on airbag control
unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with
insulating tape, do not under any circumstances cut through both cables at the same time. Pin contacts of
repair cable for airbag control unit in control unit plug, assignment of repair cables is relevant. Lay repair cable
in vehicle parallel to existing airbag lead. Now pin in contacts for airbag control unit or contacts of adapter
plug, assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of
airbag module or of adapter plug. Twist open cables. With the butt connectors and heat-shrink tubings in the
Electronic Parts Catalogue (EPC), reconnect the cables with the same cable colours. Twist cables again,
open length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to
prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and insulating cables.

Repairing a plug connection using butt connectors.

Installing and removing contacts.

In event of visible damage:

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
 4/30/2016 2/2

with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair
cable in vehicle parallel to existing airbag lead up to separation point. Cut off excess length of repair cable.
Twist open cables. Connect cables with butt connectors and heat-shrink tubings in Electronic Parts Catalogue
(EPC), assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed
40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts:

Cutting off and insulating cables.

Repairing a plug connection using connectors.

Installing and removing contacts.

 4/30/2016 1/2

41 00 ... Repairing plastic components

 

1.0 General notes

- In general, the economic viability must be checked prior to the repair.

- Only the followed painted components are approved for repair in the outer skin area:

 Bumper panels (exception: E52)

 Side sill trim panels

 Side Panels

 Door outer skin

 Hardtop/roof

 Soft top compartment lid

 Rear lid

 

- Prerequisite for a professional repair:

 Only slight deformation (without micro-cracks, as a rule visible in the paint)

 Only slight damage e.g. scrapes, cracks and holes with a length not exceeding 2.5 cm

 No damage (cracks) on the component edge!

 

- Attention!

Not approved for repair are:

 Fuel tank, fluid tank (e.g. window washer system, brake fluid, coolant expansion tank, etc.)

 headlight mount (pedestrian protection)

 
 4/30/2016 2/2

2.0 Reshaping of plastic parts

- A hot air blower can be used to reshape plastic parts.

- When deformation occurs on plastic parts, micro-cracks can be produced in the plastic. After reshaping
and subsequent paintwork of the component, the cracks may still be visible on the surface for some
time.

- The component must be replaced when micro-cracks are identifiable in the area of the deformation.

 

3.0 Bonding of plastic parts

Important!

Conform with safety regulations!

- A plastic repair box is offered (sourcing reference via BMW Parts Department) for inexpensive repair
with fair time values.

- The procedure for repair of plastic parts is included in the plastic repair box.
 4/30/2016 1/2

36 02 06 (279)

Repairing runflat tyres

All models

Situation:
The question is regularly asked whether a repair should be performed on runflat tyres after
a loss of pressure.

Runflat tyres
(also known as ”tyres with
emergency running characteristics”)
can be recognised by a circular
symbol on the side wall bearing the
letters RSC (Runflat System
Component).

Note:
As a general rule, BMW has never recommended repairs on tyres. However,
should individual customers wish to have their tyre repaired, their wishes
may be accommodated.

A list of tyre manufacturers who approve or disapprove of repairs to runflat tyres can be
found in the section headed ”Procedure”.

Procedure: 1. Contact the local representative of the tyre manufacturer

concerned.

2. Please note the following when naming the nearest authorised

tyre dealer for runflat tyres:

Tyre manufacturers who approve of repairs on runflat tyres

(under certain conditions):
 Michelin
 Dunlop
 Goodyear
 Bridgestone

Tyre manufacturers who disapprove of repairs on runflat tyres:

 Pirelli
 4/30/2016 2/2

 Continental
 4/30/2016 1/3

41 21 013 Replace A-pillar, outer left

Procedure Observe repair stage 3!

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (FR number 41 21 013).
Spot-weld bonding is used on this vehicle. Observe specific
procedure.
Use only approved spot-welding apparatus for repairs.

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) A-pillar, outer

Removal A-pillar, outer

 4/30/2016 2/3

Mark severance cuts (1) and (2) and cut according to specification.

Important!
Cut outer panel only for following severance cuts.
Severance cut (1): Dimension a = 200 mm from corner of roof outer skin.
Severance cut (2): through 20 mm dia. bore hole.
Open welded connections in areas (3).
Open spot-welded adhesive joints in area (4).
Release and remove A-pillar from cavity sealing (5).

New part preparation

Mark severance cuts on new parts according to severance cuts
on vehicle and sever.
Prepare reinforcement plates at severance cuts.
Remove superfluous components from new part.
 4/30/2016 3/3

Installation A-pillar, outer

Apply sealant to cavity sealing.
Install and weld new parts and reinforcement plates.

Note:
 Vehicles with slide/tilt sunroof: Make sure water drain
hose (1) is correctly installed (watertightness).
 In vehicle with a normal roof, a grommet is installed
instead of the water drain hose.
Please ensure correct installation of the grommet!
 4/30/2016 1/5

41 21 201 Replace B-pillar with reinforcement on

left

Procedure Observe repair stage 3!

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (FR number 41 21 201).
Use only approved spot-welding apparatus for repairs!
Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts

Catalogue EPC):

- (1) Outer side frame

- (2) Middle side frame

- (3) Shaped part, B-pillar (not shown)

Removal of B-pillar with reinforcement

 4/30/2016 2/5

Mark severance cuts (1) to (3) and cut according to specifications.

Important!
Cut outer panel only for following severance cuts.
Severance cut (1): through 20 mm diameter hole.
Severance cut (2): Dimension a = approx. 120 mm from edge of roof frame.
Severance cut (3): Dimension b = approx. 30 mm in front of 20 mm diameter hole.
Open welded connections in areas (4).
Remove B-pillar (outer skin).
 4/30/2016 3/5

Mark severance cuts in accordance with specified dimensions and cut.

Important!
Cut outer panel only for following severance cuts.
Dimension a = approx. 70 mm behind previous separation cut.
Dimension b = approx. 90 mm below previous severance cut.
Dimension c = approx. 160 mm in front of previous separation cut.
Open welded connections in areas (1) to (3).
Note:
Open welded connections in areas (2) for both outer panels.
Important!
When opening welded connections in areas (3) do not damage panel behind.
The same welding points must be used again when welding the new parts.

View, B-pillar passenger compartment.

Open welded connections in areas (1).
Release B-pillar reinforcement and cavity sealing (2) and
remove.
 4/30/2016 4/5

New part preparation

Mark severance cuts on new parts in accordance with
severance cuts on vehicle and cut.
Prepare reinforcement plates at severance cuts.
Adjust new parts and reinforcements plates with alignment
bracket or universal mount.
Note:
When adjusting, due to the absence of an outer skin, it is
necessary to place a panel of equal thickness in the area of the
door hinges.

Installation of B-pillar with reinforcement

Apply sealing compound to cavity acoustic baffle.
Install new parts and reinforcement plates with alignment
bracket or universal mount and weld.
For installation, due to the absence of an outer skin, it is
necessary to place a panel of equal thickness in the area of the
door hinges.

Note:
In area (1) the floor panel and inner side member are joined by
spot-welding bonding technology.
Apply repair welding spots in area (1) to existing welding spots
on vehicle.
 4/30/2016 5/5

This is necessary because the adhesive between the spot

flanges acts as an insulator.
 4/30/2016 1/1

64 11 879 Replace control panel for heater/air

conditioning system

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Retrofitting must only be done in the supplied installation
cassettes.
Use of supplied gloves is mandatory.
Carry out installation in a dust-free workshop area only.
To avoid damage, do not touch or dirty the display field.

Necessary preliminary tasks:

 Remove control panel for heating - Air conditioning

Unclip AC control panel (1) at marked points with a suitable tool

(e.g. screwdriver - 3 mm blade).
Remove AC control panel (1) from cover (2).
 4/30/2016 1/1

64 11 891 Replace control panel for heater/air

conditioning system

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Important!
Retrofitting must only be done in the supplied installation
cassettes.
Use of supplied gloves is mandatory.
Carry out installation in a dust-free workshop area only.
To avoid damage, do not touch or dirty the display field.

Necessary preliminary tasks:

 Remove radio and IHKA controls

Disconnect plug connection (2).

Unclip AC control panel (1) at marked points with a suitable tool
(e.g. screwdriver - 3 mm blade).
Remove AC control panel (1) from cover (3).
 4/30/2016 1/1

61 31 198 Replace controller chrome ring

Special tools required:

 00 9 340

Lever out "OPTION", "BACK", "MENU" buttons with special tool

00 9 340.

Lever out chrome ring (1) from latch mechanisms with special
tool 00 9 340 and remove upwards.
Installation note:
Retaining lugs on controller must not be damaged.

Check function of the controller.

 4/30/2016 1/1

41 11 311 Replace entrance for front left door.

Observe procedure for repair stage 3.

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 11 311).

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) A-pillar with entrance

Mark severance cuts in accordance with specified dimensions

and cut.
Important!
Cut outer panel only for following severance cuts.

Dimension a = approx. 60 mm behind 20 mm dia. hole.

Dimension b = approx. 25 mm behind 20 mm diameter hole.
Open welded connections in areas (1).
Installation note:
Mark new part in accordance with severance cuts on vehicle
and cut.
Weld in reinforcement plates at severance cuts.
 4/30/2016 1/1

51 45 382 Replace decorative strip on instrument

panel at right

Note:
When working on trim panel components, make sure that the
sensitive surfaces are not scratched or damaged.

Necessary preliminary tasks:

 Remove decorative strip on dashboard on right

Unclip fresh air grille (2) from decorative strip (1) in direction of

arrow.
Installation note:
If necessary, renew faulty clamps of decorative strip (1) and
fresh air grille.
 4/30/2016 1/3

32 13 572 Replace electrical steering box (EPS)

Important!
Connecting line:
In the event of moisture/corrosion inside the two plug
connections, check the insulation of the connecting line. If
the insulation reveals any noticeable/striking features,
partial replacement will be necessary. Otherwise it will be
sufficient to replace the contacts or connector housing.

Note:
In a warranty case you must always provide a fault memory
printout, even where there is no fault entry, with the defective
part.

Necessary preliminary tasks:

 Disconnect battery earth lead
Note: High-current-carrying wiring laid with
permanent positive connection (80 A fuse).
 Remove front wheel on the left and right.
 Remove front underbody protection
 F33Remove : stiffening plate.
 Remove sump guard for steering (sports suspension
only)
 Remove cover of steering assembly (diesel-engine
cars only)
 Release left and right track rod end at swivel bearing
 4/30/2016 2/3

Release clamping bolt (1) of steering shaft from steering gear

and pull off.
Installation note:
Clean screw threads to remove all remnants of screw locking
adhesive.
Replace clamping bolt
Tightening torque 32 31 2AZ.

Unlock plug connections (1) and disconnect.

Unfasten screws (2).
Tightening torque, 32 00 1AZ.

Important!
Risk of damage!
Pay attention to connector housing on steering gear while
removing steering gear.
Remove steering gear toward the front.

Installation note:
Modify track rod end on left and right.
Or check it and renew if necessary.
 4/30/2016 3/3

After installation:
 Carry out programming/encoding
 Teach in end stop software
 Perform chassis / wheel alignment check
 4/29/2016 1/3

18 10 120 Replace front intake pipe (N55)

Warning!
Risk of burning!
Only perform this repair work after engine has cooled
down.
Danger of injury!
Removal of the exhaust system must be carried out with
the assistance of a second person.

Necessary preliminary tasks:

 F21 only:
Remove rear trailing link.

Support front pipe with a suitable jack and secure against falling
down.

Note:
If the separation point is not marked by a punch mark in the
pipe, determine the separation point by means of the pipe
length on the new front pipe.
 4/29/2016 2/3

Carry over separation point to defective front pipe and mark.

Secure front pipe against falling off.
Cut through exhaust pipes at marked point with a suitable tool
and deburr.

If fitted:
Release screws (1).
Tightening torque 18 31 3AZ.
Remove reinforcement plate (2).
Lower and remove front pipe.

If fitted:
Release screws (1).
Tightening torque 18 20 4AZ.
Unfasten screws (2).
Tightening torque 18 20 5AZ.

Installation note:
Adjust new front pipe to fit and connect with clamps.
Align clamping sleeves so that:
 Nuts point downwards.
 Cutting line is in middle of clamping sleeve.
 There is sufficient spacing to adjoining components.
 4/29/2016 3/3

Centre clamp and tighten down.

Tightening torque 18 31 5AZ/6AZ.

Installation note:
Check rubber mount for damage, replace if necessary.
Check exhaust system for leak tightness.
 4/30/2016 1/2

52 15 455 Replace heating elements for front seat

(sport/manual) left or right

Necessary preliminary tasks:

 Remove seat cover
 Remove backrest cover
 Remove thigh support cover

Note:
Heating elements are bonded with the foam part and cannot be
separated from each other without causing damage.
Foam part and heating elements must be replaced.

Check new foam part:

- No obvious damage or material defects

- All trim wires present in foam

- No bubbles in foam part

- No dirt contamination on foam or residual foam

- Pay attention to foam part on left and right

Check new heating mat:

- No obvious damage or material defects

- All tear-off film pieces present

- Note variant by examining label on cable

Guide cable for backrest heating through foam hole.

Stick on main section (1):

- Pull adhesive film pieces off main section (1) and stick to

upper edge of main section foam until flush
Stick on bead section (2):

- Pull adhesive film pieces off bead section (2) and stick on

heating mat along bead section edge.
 4/30/2016 2/2

- Press down evenly in outwards direction

Guide cable for seat heating through foam hole.

Bond the STV heating mat (1):

- Pull off the adhesive film and bond flush with the rear
foam edge
Stick on bead section (2):

- Pull adhesive film pieces off bead section (2) and stick on

heating mat along bead section edge.

- Press down evenly in outwards direction

Stick on main section (3):

- Pull adhesive film pieces off main section (3) and stick to

upper edge of main section foam until flush

Check laying of heating mats:

- Heating mats laid without folds

- Heating mats correctly positioned

- All bonding surfaces stuck on

Note:
Carry out function check
 4/30/2016 1/2

63 11 731 Replace LED module for left daytime

driving lights

Warning!
Follow instructions for handling light bulbs (exterior lights).

Necessary preliminary tasks:

 Remove headlight

Release screws (1).
Lift out LED module (2).

Disconnect plug connection (1).

Remove LED module (2).
If necessary, remove sealant residue from headlight housing.

Installation note:
Sealant (1) on LED module (2) must not be damaged.
 

Replacement:
 4/30/2016 2/2

Always replace LED modules (2) as a pair.

As far as possible, do not touch sealant (1) on new LED module
(2).
 4/30/2016 1/3

41 21 203 Replace outer left B-pillar.

Procedure Observe repair stage 3!

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 21 203).
Use only approved spot-welding apparatus for repairs.

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) A-pillar with entrance

- (2) Shaped part, B-pillar, lower outer (not shown)

Removing the B-pillar

 4/30/2016 2/3

Mark severance cuts (1) to (3) and cut according to specifications.

Important!
Cut outer panel only for following severance cuts.
Severance cut (1): through 20 mm diameter hole.
Severance cut (2): Dimension a = approx. 160 mm from edge of roof frame.
Severance cut (3): Dimension b = approx. 30 mm in front of 20 mm diameter hole.
Open welded connections in areas (4).
Remove B-pillar.

New part preparation

Mark severance cuts on new parts in accordance with
severance cuts on vehicle and cut.
Prepare reinforcement plates at severance cuts.
 4/30/2016 3/3

Installation of B-pillar
Install and weld new parts and reinforcement plates.
 4/30/2016 1/9

41 31 100 Replace roof outer skin with slide/tilt

sunroof

Read contents of Body, General.

Strip down vehicle.

Procedure Observe repair stage 2!

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Roof outer skin, slide/tilt sunroof

- Star screws (4x, Order No. 07 14 7 153 767)

 
Following consumables are required:

Material Quantity

Adhesive K5b 1

Adhesive K5a 1

Punch rivets N4 8
 4/30/2016 2/9

Punch rivets N5 12

EMC screws 2

Cleaning agent R1 1

Sealant D1  

Tools also required:

- Roof pliers set, order number: 81 43 2 158 707

Sourcing reference:
BMW Workshop Equipment Catalogue

Removal

Release 4 screws (1) in roof channel.

 4/30/2016 3/9

Open welded connections in areas (1).

Detach adhesive areas (adhesive) in area (2).
Loosen adhesive area (sealant) in area (3) and remove roof outer skin.

New part preparation

Place roof outer skin in position and fit in conjunction with roof
trim strips.

Important!
Bonding in outer skin area.
Do not grind/sand new part in area of bonding surfaces.
 4/30/2016 4/9

Installation
 4/30/2016 5/9

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.
Apply sealant D1 in areas (1) analogously to Series.
Apply adhesive in areas (2).
Apply a little more adhesive to nodes of A-pillar.
Note:
Excess material at the nodes is later used for spreading to side frame.

Place roof outer skin with helpers evenly and centrally on

vehicle.
Insert 4 star screws (1) hand-tight.

Mount roof pliers (1) and secure with tensioning strap (2).

Note:
 4/30/2016 6/9

To generate an optimum contact pressure, mount roof pliers

according to the graphics as left.

Secure roof outer skin at 2 areas with roof pliers and tensioning
straps (2).
(1) Star screws

In area (1) rivet roof outer skin with 8 N5 punch rivets.

 4/30/2016 7/9

In areas (1) to (3) rivet roof outer skin with punch N4rivets.

In each of areas (4) install one punch rivet N5.

Area Number

1 3

2 3

3 1

In area (1) use one punch rivet N5. Work operation identical on

right side.
 4/30/2016 8/9

Adapt step (1) between roof outer skin (2) and A-pillar with

emerging adhesive. Remove excess adhesive.
Important!
Do not use any cleaning agents containing solvents.

Do not leave any traces of sharp edges as this could

compromise the tightness of the subsequent bond.

Important!
Spread excess adhesive in roof trim strip channel.
Mounting surfaces of clips for roof trim strips must not be
coated with adhesive.
Tighten 4 star screws.
Tightening torque 41 31 1AZ .
Until the adhesive hardens: Mount hinge for tailgate.

Operation is described on the left side. Right side identical.

Fit an EMC screw after adhesive has hardened in position (1).
Dimension a = approx. 165 mm in front of corner of roof outer
skin.

After hardening of the adhesive, seal adhesive areas, star

screws and EMC screws with sealant D1.
Mounting surfaces of clips for roof trim strips must not be
coated with sealant.
4/30/2016 9/9
 4/30/2016 1/1

41 31 000 Replace roof outer skin

Refer to repair instructions Roof outer skin with slide/tilt sunroof

for procedure and carry over schematically to the vehicle.
Strip down vehicle

Installing roof outer skin

Apply sealant in areas (1) in the same way as in series
standard.
Apply adhesive in areas (2).
 4/30/2016 1/4

52 14 400 Replace seat cover for left or right front

seat (normal/electric)

Special tools required:

 52 0 050

Necessary preliminary work:

 Remove front seat
 Remove outer cover on front seat
 Remove inner cover on front seat

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Version with seat heating only:

Unlock plug connection (1) for seat heating and disconnect.
Detach cable strap.
Detach seat heater cable (2) from cable clips on seat
mechanism.
Installation note:
Plug connection is encoded to prevent incorrect connection.
Replace cable strap.
 4/30/2016 2/4

Fully lift welt of seat cover out of seat frame.

Disengage seat cover at rear.

Carefully slide bracing cloth (1) with foam through backrest gap

and seat structure.
If applicable, route cable carefully through seat and backrest
mechanics as the edges of the frame may be sharp.
Installation note:
Slide foam completely through backrest gap and seat structure.
Make sure foam and bracing cloth are correctly fitted.

Remove seat cover (1) with padding towards front/top.

Release all clamps (1) from seat cover (2).

 4/30/2016 3/4

Release all clamps in marked area of trim wires.

Remove seat cover from upholstery.
Important!
Remove all remnants of clamps from seat cover and
upholstery.

Replacement only:
If applicable, pull trim wires out of seat cover.
Cut new seat cover to size and insert trim wires.

Installation note:
Bend new clamps (2) with special tool 52 0 050.
1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in cover
 4/30/2016 4/4

5. Seat cover
 4/30/2016 1/9

41 11 420 Replace sills, left.

Procedure Observe repair stage 3!

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 11 420).
Use only approved spot-welding apparatus for repairs.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Inner side member

- (2) Side frame, outer

- (3) Sill reinforcement plate (rear side panel)

Removal
 4/30/2016 2/9

Mark severance cuts in accordance with specified dimensions and cut.

Important!
Cut outer panel only.
Dimension a = approx. 275 mm from centre point of 20 mm dia. hole.
Dimension b = approx. 140 mm from component edge of sill.
Dimension c = approx. 115 mm before centre point of hole dia. 20 mm.
Open welded connections in areas (1).
 4/30/2016 3/9

Mark severance cut (1) in accordance with dimension a and cut.

Measurement a = approx. 20 mm from component edge.
Carry out severance cut (2) at component edge.
Open welded connections in area (3).

Mark severance cut (1) in accordance with dimension and cut.

Dimension a = approx. 15 mm from component edge.
Open welded connections in areas (2).
Release and remove side sill from cavity sealings.

New part preparation

 4/30/2016 4/9

Inner front side member:

Mark severance cut (1) in accordance with severance cut on vehicle +15 mm extra material and cut.
In area (2) of jacking point, extra material = 5 - 10 mm.
 4/30/2016 5/9

Inner rear side member:

Mark severance cut (1) in accordance with severance cut on vehicle +15 mm extra material and cut.
In area (2) of jacking point, extra material = 5 - 10 mm.
In area (3) extra material = approx. 10 mm.
 4/30/2016 6/9

Adjust new parts to fit and secure.

For severance cuts (1) and (2), prepare reinforcement plates.
Prepare new part for plug welding in areas (3).
 4/30/2016 7/9

Prepare new part for plug welding in areas (1) - (4).

 4/30/2016 8/9

Prepare new part for spot welding in areas (1) - (5).

Remove new parts again and deburr bore holes.

Installation
Install and weld new parts and reinforcement plates.

Note:
The new part must be welded gap-free in area of jacking
point (1).
 4/30/2016 9/9

Perform MAG weld (metal active gas) for new part in areas (1) of jacking points.
For this purpose, set weld seams with a length of 20 mm at a distance of 20 mm in each case.
Additionally weld new part with 20 mm long metal active gas weld seams (2) at distance of 60 mm.
Important!
Risk of damage to adhesive area!
Avoid applying excessive heat to the neighbouring adhesive areas (3)!

Additionally weld new part with 20 mm long metal active gas
weld seams (1) at distance of 60 mm on both sides.
Important!
Risk of damage to adhesive area!
Avoid applying too much heat to adjacent adhesive
area (2) of floor panel!
 4/30/2016 1/2

64 11 832 Replace the actuator drive for the

ventilation flap, right (High A/C system)

Necessary preliminary tasks:

 Remove instrument panel trim

Unlock plug connections (1) and disconnect.

Unlock latch mechanism (3) downward.
Pull out control unit (2).

Note:
For purposes of clarity, illustration shows removed heating and
air conditioning unit.

Release screws (1).
Unfasten plug connection (2) and disconnect.
Remove actuator drive (3).
Installation note:
Make sure actuator drive (3) is correctly seated in the guide (4).

Replacement:
Servomotors must be readdressed in the event of replacement!
Addressing can only be carried out with the BMW diagnosis
 4/30/2016 2/2

system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/5

41 32 031 Replace the A-pillar on the outside left in

the area of the windscreen

Read contents of Body, General.

For stripping and rigging operations, refer to texts on KSD
CD (job number 41 32 031).
Remove or cover those vehicle components in the repair area
which are susceptible to heat or dust.
Use only approved spot-welding apparatus for repairs.

Important!
Operations on pyrotechnical devices may only be carried
out by authorised experts.
Improper, unauthorised operations may result in serious
dangers.
Unauthorised persons are strictly prohibited from
performing any operations on this system.

Warning!
Read and comply with safety instructions for handling
airbag modules and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause injury.
A damaged head airbag must be replaced.
A damaged head airbag exhibits an impaired protective
function and in extreme cases loses its protective function
altogether.

Necessary preliminary tasks:

Disconnect battery earth lead
Remove panel for roof pillar
 4/30/2016 2/5

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) A-pillar, outer

Removing the A-pillar in the area of the windscreen

Unclip wiring harness in these areas (1) and set aside.

Important!
For the exact procedure to perform the next operation, see
repair instructions for removing and installing head airbag!
Loosen airbag at attachment point (2).
 
 4/30/2016 3/5

Important!
Risk of damage!
Airbag must not be kinked or bent!

Note:
Use protective sleeve (1) to protect the airbag.
Check protective sleeve for damage prior to use.
A damaged protective sleeve must not be used!

(2) Velcro fastener

(3) Loop

- Order number, protective sleeve: 81 47 2 159 578

Sourcing reference:
BMW Workshop Equipment Catalogue

Push the protective sleeve (1) onto the airbag up to just below
the roofliner so that the airbag is completely covered.
Fasten protective sleeve with Velcro fastener (2).
Secure protective sleeve with airbag against kinking.
 4/30/2016 4/5

Mark severance cuts in accordance with specified dimensions and cut.

Important!
Cut outer panel only for following severance cuts.
Dimensions a = approx. 150 mm from roof edge.
Dimension b = approx. 380 mm below severance cut a.
Open welded connections in areas (1).
Release and remove partial section of A-pillar from cavity sealing (2).

New part preparation

Mark severance cuts on new parts in accordance with vehicle
and cut.
Prepare reinforcement plates at severance cuts.

Installing the A-pillar in the area of the windscreen

 4/30/2016 5/5

Apply sealing compound to cavity acoustic baffle.

Install and weld new parts and reinforcement plates.
After completing welding work:
Check airbag in area of protective sleeve for damage, replace if
necessary.
 4/30/2016 1/1

51 45 371 Replace the decorative strip on the

dashboard, left.

Note:
When working on trim panel components, make sure that the
sensitive surfaces are not scratched or damaged.

Necessary preliminary work:

 Remove decorative strip on dashboard on left

Unclip fresh air grille, left (1) from decorative trim, left (2) in
direction of arrow.
Installation note:
Clamps labelled with arrows must not be bent or damaged, and
must be renewed if they are.
 4/29/2016 1/2

16 12 440 Replace the fuel filler neck breather pipe

(petrol)

Necessary preliminary tasks:

 Remove right tank cover.
 Remove right wheel arch panel.

Unlock and disconnect snap fastener (1).

Installation note:
Make sure the quick-release fastener snaps in correctly.

Unlock and disconnect snap fastener (1).

Disengage fuel filler neck breather pipe from holder (2).
Installation note:
Make sure the quick-release fastener snaps in correctly.

Detach the fuel filler neck breather pipe (2) from the holders (1)
and feed through body.
4/29/2016 2/2
 4/30/2016 1/1

34 21 131 Replace the retaining ring for the left (or

right) brake pads

Necessary preliminary tasks:

 Remove brake shoe expander
 Remove wheel hub

Release screws (2) and remove brake anchor plate (3).

Release screws (1).
Installation note:
Tightening torque 34 21 3AZ.
 4/30/2016 1/5

51 31 011 Replace windscreen

Special tools required:

 51 0 010

Important!
The following notes form the basis for these repair
instructions and must be adhered to at all times:
 Notes on window bonding
 General procedure for dismantling/installing bonded
window glass

Note:
Removal is performed with Roll Out 2000.

The following new parts / consumables are required (sourcing

reference BMW Parts Department).

Material Quantity

Windscreen 1

Cover, windscreen 1

Spacer buffer 5x5x20 mm 5

Small repair kit 1

Sika Activator 205 (for windscreen cover) 1

Wire from Roll Out 2000 9 m

Expanding foam tape 1

Necessary preliminary tasks:

 Remove cover for cowl panel
 Remove inside mirror
 Remove trim panel for roof pillar (A‐pillar) left/right
 4/30/2016 2/5

Depending on version:
Unplug plug connections (1 to 3).
Remove the rain/light/solar and condensation sensor and
immediately install on a new windscreen.
Remove camera.
Note:
Cables torn from the windscreen must not be soldered back in
place. The windscreen must be replaced

Important!
Tape off body in area of piercing point with fabric adhesive
tape.

Push wire from Roll Out 2000 along line (1) through adhesive

bead (2).
For details on how to proceed, refer to: Window Removal with
"Roll Out 2000".
Lift out windscreen with suction cup.

Fitting spacer buffers (spacers):

Important!
Spacer buffers are installed to avoid windscreen breakage
and wind noises.
Completely remove old spacer buffers (2).
Position the new spacer buffers (2) in the centre of the
 4/30/2016 3/5

embossed marks (1) and bond.

Observe notes on component-bonding with adhesive tape!

Stick expanding foam tape onto the marked area (1) on the
windscreen.

Install the cover / rubber frame (1) for the windscreen.

Pre-treat adhesive area with Sika-Aktivator205.

Overview of windscreen bonding:

 4/30/2016 4/5

Cut A - A / B - B C - C

a [mm] = Position adhesive bead 1 +1 18 +1

b [mm] = Width adhesive bead 8 ±2 8 ±2

h [mm] = Height adhesive bead 12 -2 12 -2

Note:
A tolerance band is printed on the ceramic (two dashed lines) that marks the position of the adhesive bead.
Place the adhesive bead in the outer area of the tolerance band.
x = approx. 300 mm (bead joint distance (1) to windscreen outer edge)
Prepare the body and windscreen.

Perform the following steps carefully on the windscreen (1)

using suction cup (51 3 010):

- feed in on the bottom of the lower front side wall

- Position at top

- Align sides evenly

 4/30/2016 5/5

- press upwards until sealing rests evenly on roof and apply

pressure

- secure in terms of height in this position at top with two

yellow plastic adhesive tapes (2)

Preload on top of windscreen to prevent wind noise:

Windscreen (1) must be lower than roof outer skin (2). This is
the only way to prevent wind noises.
Position special tool 51 0 010 in middle of vehicle depending on
dimension (A) and check underprotrusion of windscreen (1).
Windscreen underprotrusion (A):
A = 2.8 ± 1 mm
X= Measurement stages 1... 4 mm
 4/30/2016 1/2

32 21 231 Replacing (removing and installing) left

or right track rod

Special tools required:

 32 3 160

Important!
The steering box must be replaced if the polished surface
of the rack is damaged (e.g. by corrosion)!

Necessary preliminary tasks:

 Remove cover of steering assemblies front left/right
(only diesel-engine cars with rear-wheel drive)
 Remove track rod end from swivel bearing
 Remove gaiter from steering box and slide back

Important!
To avoid damage to rack and to suspension mounting,
move rack in as far as possible.
 4/30/2016 2/2

Undo the joint (1) using special tools 32 3 160 at the steering
box rack.
Tightening torque 32 21 1AZ.
Installation note:
Clean rack.
Check surface of rack for damage (e.g. corrosion).

On replacement, assemble new part with gaiter:

Determine dimension (A) to simplify following adjustment of
front axle.
Slacken clamping bolt (1) and screw off track rod end.
Slide gaiter with ear clip and band clamp on track rod.
Screw in track rod end to dimension (A).
Tightening torque 32 21 2AZ

After installation:
 Only if replacing/removing track rod end: Perform
chassis / wheel alignment check
 4/30/2016 1/2

33 32 125 Replacing a ball joint in lower steering

stub / wheel carrier

Special tools required:

 33 3 010
 2 240 473
 2 240 469
 2 240 476

The ball joint may not be reused after it has been pressed out!

Necessary preliminary tasks:

 Remove rear wheel.
 Remove camber arm cover.
 Remove coil spring, rear .
 Remove trailing arm.
 Remove camber arm.
 If applicable, remove jointed rod for ride height
sensor from the camber arm bracket.

Pull out ball joint:

Pull out ball joint with special tools 33 3 010, 2 240 473 and
2 240 469.
 4/30/2016 2/2

Pull in new ball joint:

Fit new ball joint (1) with special tools 33 3 010, 2 240 473, and
2 240 476until limit position.

After installation:
 Carry out wheel alignment procedure.
 4/30/2016 1/2

34 35 001 Replacing a brake pad sensor (front)

Important!
The brake pad wear sensor must be replaced once it has
been removed (brake pad wear sensor loses its retention
capability in the brake pad).
If a brake pad wear sensor that has already been ground
has to be replaced even though the minimum brake pad
thickness has not yet been reached, you must observe the
following: The new sliding contact must be filed down with
a file to the same length as the sanded sliding contact.

Necessary preliminary tasks:

 Remove wheel

Fold the connector housing (1) up and disconnect the plug

connection.
Detach the brake pad wear sensor from the brackets (2).
Installation note:
Do not route/fix the brake pad wear sensor cable via the dust
cap of the brake ventilation valve!

Press clamps (1) together and pull brake pad wear sensor (2)
from brake pad (3) in direction of arrow.
Installation note:
Make sure clamps (1) and brake pad wear sensor (2) are
 4/30/2016 2/2

correctly seated in brake pad (3).

 4/30/2016 1/2

34 35 003 Replacing a brake pad sensor (rear)

Important!
The brake pad wear sensor must be replaced once it has
been removed (brake pad wear sensor loses its retention
capability in the brake pad).
If a brake pad wear sensor that has already been ground
has to be replaced even though the minimum brake pad
thickness has not yet been reached, you must observe the
following: The new sliding contact must be filed down with
a file to the same length as the sanded sliding contact.

Necessary preliminary tasks:

 Remove rear right wheel

Slacken nut (1).

Pull wheel arch trim (2) gently to one side.
Disengage cable from holders (3).

Disconnect plug connection (1).

Installation note:
Ensure proper locking of the plug connector and proper seating
of the cable in the brackets.
 4/30/2016 2/2

Disengage cable from holders (1).

Detach brake pad wear sensor (2) in direction of arrow from
brake pad.
Installation note:
Make sure holders (1) and brake pad wear sensor (2) are
correctly seated in brake caliper.
 4/30/2016 1/2

33 32 091 Replacing a control arm

Necessary preliminary tasks:

 Remove rear wheel.
 Remove camber arm cover.

Release screw (1).
Installation note:
Observe installation sequence at the end of document!
Manually lift wheel carrier in region of brake caliper if
necessary.
Replace screw.

Important!
Make sure during installation that in the connection area to
the wheel carrier the tapered end of the bearing bushing
(of the rubber mount) points in the direction of the wheel
carrier.

Slacken nut (1).

Installation note:
Observe installation sequence at the end of document!
 4/30/2016 2/2

Screw head faces away from direction of travel.

Replace self-locking nut.

Important!
You must observe the installation sequence and
installation notes!
Failure to comply with these instructions may result in
serious damage to the threads of the wheel carrier!
Do not use an impact screwdriver!
Installation sequence:
1. Put on screw (1) wishbone to wheel carrier
manually!
2. Fit control arm to rear axle support, insert screw
and screw on nut
Important: Tighten both screw connections in
normal position only
3. Tighten screw connection control arm to wheel
carrier
Tightening torque 33 32 4AZ
4. Tighten screw connection control arm to rear axle
support
Tightening torque 33 32 3AZ.
Put on screw (1) wishbone to wheel carrier manually!
 4/30/2016 1/2

34 52 535 Replacing a rear pulse sensor

Necessary preliminary tasks:

 Remove wheel
 Read and comply with General Information.

Slacken nut (1).

Pull wheel arch trim (2) gently to one side.
Disengage cable from holders (3).

Disconnect plug connection (1).

Installation note:
Ensure proper locking of the plug connector and proper seating
of the cable in the brackets.

Disengage cable from holders (1).

Unfasten socket head cap screw (2).
Withdraw wheel speed sensor (3) from bore hole.
Installation note:
Tightening torque 34 51 4AZ.
Clean bore hole for pulse sensor and lubricate with
Staburags NBU 12/K lubricating grease.

Important!
 4/30/2016 2/2

Check sensor head prior to installation for external

damage, replacing if necessary.
 4/30/2016 1/8

36 12 005 Replacing a run-flat tyre version or UHP

tyres

Note:
UHP tyre = Ultra High Performance tyre
UHP tyres are tyres with an aspect ratio (H:B) ≤ 45 % or tyres
with a speed index ≥"V"

Note:
Follow the tyre fitting machine manufacturer's operating
instructions.
It is absolutely essential to ensure that the equipment is in
proper working condition and that there is no damage to the
disc wheel and tyre.
Balance wheels after completing work.

Important!
For installation and removal work on run-flat tyres and/or
on certified and approved installation equipment, the
following successful training for the "Certified BMW tyre
fitter" is required! (See BMW training programme)
 
Only approved and certified tyre fitting machines may be
used for installing run-flat tyres and/or UHP tyres!
Please refer to the operating instructions of the respective
tyre fitting machine for details of the exact fitting
procedure.
 
Use only BMW-approved plastic-covered mounting levers!
 
Use only BMW-approved tyre-fitting paste.
 4/30/2016 2/8

 
For approved wheel and tyre combinations, tyre makes
and optional equipment, refer to KSD CD.

Note:
Pay attention to different tyre markings:

- Position (1) Identification of BMW-approved tyres. Ensure

that only BMW-approved tyres are fitted.

- Item (2) RSC is the abbreviation for Run-flat System

Component (run-flat tyres).

- Item (3) Outside. The tyre must be fitted so that the

wording Outside is always situated on the outside of the
rim.

Important!
Many tyres are directional!
The arrow on the tyre must point in the ”Forward” direction
of rotation!

Important!
Before removal:

- Observe tyre temperature of min. +15 °C. Refer to

Recommendation for heating.

- Clean wheel/tyre unit

- Remove valve insert (deflate tyre)

- Remove fitted balancing weights

Dismantling of top tyre bead:

Press off tyre bead from rim flange as much as possible with
unseating roller (1).
Note position of sensor - do not unseat in this area!
If using a pressing-off tool (2), unseat 3 to 4 times around
circumference max. 1 cm from rim flange.
 4/30/2016 3/8

Observe pressing-off/unseating limitation.

Start at 90° or 270°.
Do not position at 0° or 180° Refer to following Fig. no. 3601--
81.

Apply sufficient lubricant as deeply as possible between wheel

rim and tyre.

Position mounting head (1) in direction of rotation before valve

(2).
Position hold-down device at 0° to stop tyre in wheel drop
centre.
Position tyre iron (3) on fitting head.

Lever tyre bead (1) over rim flange with mounting lever.
Important!
Avoid damaging the wheel rim by using a suitable
mounting lever with protective coating.
Make sure there is sufficient lubrication between tyre bead
and rim flange, apply lubricant if necessary!
 4/30/2016 4/8

Allow tyre fitting machine to rotate slowly, and relieve tension

on hold-down device and rollers during rotation.

Dismantling of bottom tyre bead:

Important!
Apply sufficient lubricant between wheel rim and tyre.

Position mounting head (1) in direction of rotation before sensor

(2).
Position mounting lever (3) on mounting head (1).
Tyre bead must be positioned entirely in wheel drop centre
opposite mounting head (1).

Lever tyre bead (1) over rim flange with mounting lever.
Important!
Avoid damaging the wheel rim by using a suitable
mounting lever with protective coating.

Allow fitting machine to rotate slowly.

Observe before installation:

- Observe minimum tyre air temperature of +15 °C! Refer to

Recommendation for heating

- Clean wheel/tyre

- Check wheel rim for burrs, wear and other damage

 4/30/2016 5/8

- Clean tyre beads and check for evidence of damage

- Check RDC sensor for damage

- Renew tyre valve

Before installation:
Important!
Apply lubricant to inside of top tyre bead (1) and to outside
of top and bottom tyre sidewall (2) up to top decorative
line!

Apply lubricant over entire well area.

Lever sensor spare.

Installation of bottom tyre bead:

Grip wheel and lay on tyre.
Important!
Apply a light coating of antiseize compound to fitting head.
 4/30/2016 6/8

Position fitting head (1) as pictured.

Important!
Make sure tyre is correctly positioned on fitting head.
Position tyre bead in relation to mounting head (1) in
accordance with equipment manufacturer's specification.
Position sensor (RDC) (3) and valve min. 10--15 cm
before traction point/catching point (2).
Sensor must not be subjected to load.

Allow fitting machine to rotate slowly.

Guide tyre in direction of rotation and press towards wheel drop
centre.

Installation of top tyre bead:

Position sensor (1) in relation to mounting head (2) as pictured.
Important!
Make sure tyre is correctly positioned on fitting head.
Position tyre bead in relation to mounting head (2) in
accordance with equipment manufacturer's specification.
Position sensor (RDC) (1) and valve min. 10--15 cm
before traction point/catching point.
Sensor must not be subjected to load.

Coat bead holding-down element (3) with lubricant and insert.

Allow fitting machine to rotate slowly.

Insert additional bead holding-down elements (1) to hold the
tyre bead in wheel drop centre.
 4/30/2016 7/8

The last part of the tyre bead should jump over the rim flange in
the sensor area.
Important!
Perform fitting in stages, take short breaks and relieve
tension.
Avoid heavy deformations at the traction point.
Do not squash belt edge and side walls through hold-down
devices.
Never use a tyre iron as a holding-down element.

Filling/inflating tyre:
Remove all fitting aids.
Important!
Possibilities for safely mounting the wheel or incorporation
in inflation apparatus should be utilised!
Observe instructions/conditions of trade association.
Observe national regulations!

Inflate with air (without valve insert).

- Increase pressure up to 3.3 bar in stages (fitting

pressure).

- If the tyre bead does not slip fully past the rim edge all
round, do not under any circumstance increase the
pressure.

- If necessary, release air and force off tyre bead again.

- Coat rim flange and tyre again with tyre mounting paste.

- Inflate tyre again up to 3.3 bar.

- When tyre beads are resting perfectly on rim shoulders,

increase tyre pressure to maximum 4.0 bar (settling
pressure) to "settle" the tyre.
Screw in valve insert and correct the tyre pressure.
Observe notes on initialisation of the Run Flat Indicator (RPA)
or RDC (USA=TPM).

Important!
 4/30/2016 8/8

Advise the customer to avoid heavy acceleration and

heavy braking in the initial period.
The assembly paste can cause the tyre to turn on the
wheel rim and give rise to imbalance.
 4/30/2016 1/2

33 32 131 Replacing a wheel carrier

Necessary preliminary tasks:

 Remove rear wheel.
 Remove camber arm cover.
 Remove coil spring.
 Remove brake disc.
 Remove parking brake shoes.
 Remove pulse sensor on wheel carrier.
 Remove drive flange for rear axle shaft.

Secure wheel carrier against falling out.

 
Slacken anti-roll bar link on wheel carrier.
Slacken trailing arm on wheel carrier.
Slacken control arm on wheel carrier.
Slacken toe arm on wheel carrier.
Undo wishbone at the wheel carrier.
Slacken camber arm on wheel carrier.
 
Remove wheel carrier including brake guard plate.

Important!
 Prior to installation, check sensor head and cable of
pulse sensor and renew if necessary.

 Replace wheel bearing.

 Modify or replace  brake guard plate.
 4/30/2016 2/2

After installation:
 Adjust parking brake.
 Carry out wheel alignment procedure.
 4/30/2016 1/1

64 11 835 Replacing actuator drive for left blending

flap

Necessary preliminary tasks:

 Remove instrument panel trim

Note:
For purposes of clarity, illustration shows removed heating and
air conditioning unit.

Unfasten screws (2).

Remove actuator drive (1).
Unlock plug connection (4) and disconnect.
Installation note:
Make sure actuator drive (1) is correctly seated in the guide (3).

Replacement:
Servomotors must be readdressed in the event of replacement!
Addressing can only be carried out with the BMW diagnosis
system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/1

64 11 830 Replacing actuator drive for left

ventilation flap (High A/C system)

Necessary preliminary tasks:

 Remove instrument panel trim

Note:
For purposes of clarity, illustration shows removed heating and
air-conditioning unit.

Unfasten screws (2).

Remove actuator drive (3).
Unfasten plug connection (1) and disconnect.
Installation note:
Make sure actuator drive (3) is correctly seated in the guide (4).

Replacement:
Servomotors must be readdressed in the event of replacement!
Addressing can only be carried out with the BMW diagnosis
system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/2

64 11 850 Replacing actuator drive for rear

compartment flap

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism.

Note:
Lower instrument panel trim partially shown.

Detach left footwell heating duct (1) in area (2) in direction of

arrow.
Detach left footwell heating duct (1) with adapter (3) from
heating and air conditioning and remove in direction of arrow
from left rear compartment heating duct (4).

Installation note:
Make sure clamp (2) is correctly seated on left footwell heating
duct (1).

Insert footwell heating duct (1) with adapter (3) in rear

compartment heating duct (4).
Attach footwell heating duct (1) in area (4) to heating and air-
conditioning unit. Make sure assembly is locked exactly at
point (5).

Note:
For purposes of clarity, illustration shows removed heating and
air-conditioning unit.
Release screws (1).
Unlock plug connection (4) and disconnect.
Remove actuator drive (2).

Installation note:
Make sure actuator drive (2) is correctly seated in guide (3).
 4/30/2016 2/2

Important!
Servomotors must be readdressed in the event of
replacement!
Addressing can only be carried out with the BMW
diagnosis system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/2

64 11 837 Replacing actuator drive for right

stratification flap

Necessary preliminary tasks:

 Remove glove box

Note:
Mark position before removing holder (2).

Release screws (1).

Take off holder (2).

Unclip air duct (1) downward at retaining clasp (2).

Pull off air duct (1) in direction of arrow.
Installation note:
Air duct (3) must be correctly engaged in duct (4).

Release screws (1).
Unfasten plug connection (2) and disconnect.
Remove actuator drive (4).
Installation note:
Make sure actuator drive (4) is correctly seated in the guide (3).
 4/30/2016 2/2

Replacement:
Servomotors must be readdressed in the event of replacement!
Addressing can only be carried out with the BMW diagnosis
system.
Service functions:

- Body

- Heating and air conditioning function

- Flap motors

- Readdress flap motors

 4/30/2016 1/3

64 52 521 Replacing air conditioning system

compressor (N55)

Special tools required:

 00 9 030
 32 1 270

Warning!
Danger of injury!
Refrigerant circuit is under high pressure!
Avoid contact with refrigerant and refrigerant fluid.
Read and comply with safety information:
 Handling R 134a refrigerant
 Handling refrigerant fluid

Important!
Risk of damage!
Restart engine only when air conditioning system has
been correctly filled.
Read and comply with notes on compressor replacement.
Follow notes for opening and replacing parts in refrigerant
circuit.
If air conditioning system is opened for more than 24
hours:
Replace condenser for air conditioning.

Necessary preliminary tasks:

 Drawing off, evacuating and filling the A/C system are not
included in the time value given for this work operation
 4/30/2016 2/3

 Remove drive belt for alternator

 Remove left charge air duct

Important!
Seal openings or lines on compressor with special tool
32 1 270 to prevent escape of media and dirt
contamination.

Release screw (1) from below.

Tightening torque 64 52 3AZ.

Release screws (4) and remove refrigerant lines (3).

Tightening torque 64 52 1AZ.
Unfasten plug connection (2) and disconnect.
Note:
Secure compressor (1) against falling out.

Release screws (5).

Tightening torque 64 52 3AZ.
Feed out compressor (1) in upward direction.
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to mount sealing rings without
damaging them.

Replacement:
 Change oil of compressor
 4/30/2016 3/3

After installation:
 Evacuate and fill air conditioning system
 4/29/2016 1/2

13 72 001 Replacing air filter element (N55)

Necessary preliminary tasks:

 F33 only:
Remove front end strut.

Release clamps (2) from upper section of intake filter

housing (1).

Pull upper section of intake filter housing (1) slightly towards top

until air filter element (2) is accessible.
Remove air filter element (2).
Installation note:
Clean upper part and lower section of intake silencer
housing from inside.
Install new air filter element.

Assemble engine.
4/29/2016 2/2
 4/30/2016 1/2

34 32 861 Replacing all brake pipes

Special tools required:

 34 5 100

Note:
The brake lines are only supplied in the straight version and
correct length with connecting nipple.
Read and comply with General Information.
After completing work, bleed brake system.
Observe safety instructions on raising the vehicle.

The new brake lines are bent into shape with bending tool
 34 5 100.
Removed brake lines can be used as templates for bending.
Important!
- Protective coating of brake line must not be
damaged during bending.

- Do not kink or bend back brake lines.

- Watch distances to rigid and movable vehicle parts.

 Minimum of 5 mm to vehicle components fixed
rigidly to body.
 Minimum of 10 mm to moving vehicle
components.
 Minimum of 10 mm to vehicle components
 4/30/2016 2/2

fixed rigidly to body, if brake line is fastened to

moving vehicle components (e.g. axle
support).

- Brake lines may not make contact or rub.

- Tighten down brake line couplings with torque

wrench.

Installation note:
Tightening torque 34 32 1AZ.
 4/29/2016 1/4

11 24 571 Replacing all connecting rod bearing

shells (N55)

Special tools required:

 00 2 590
 00 9 120

Important!
Modified procedure:
All crank pins are connected with the crankshaft.
The Blue/Red connecting rod bearing shell colours are no
longer fitted in combination.

Necessary preliminary tasks:

 Removing oil sump.

Important!
All crankshaft crank pins are classified.
The identification (2) is located on the first crank web.
 4/29/2016 2/4

Optional classifications (2) per connecting rod

On the connecting rod and connecting rod bearing cap:
r. Connecting rod = Yellow.
Connecting rod bearing cap = Red.
b. Connecting rod = Violet.
Connecting rod bearing cap = Blue

Example:
Possible classification: b r r r r r

Cylinder Classification b
1: Violet (connecting rod) / \Blue (connecting rod
bearing cap)
Cylinder Classification r
2: Yellow (connecting rod) / Red (connecting rod
bearing cap)
Cylinder Classification r
3: Yellow (connecting rod) / Red (connecting rod
bearing cap)
Cylinder Classification r
4: Yellow (connecting rod) / Red (connecting rod
bearing cap)
Cylinder Classification r
5: Yellow (connecting rod) / Red (connecting rod
bearing cap)
Cylinder Classification r
6: Yellow (connecting rod) / Red (connecting rod
bearing cap)

Release connecting rod bolts (1).

Remove connecting rod bearing cap (2).
 4/29/2016 3/4

Important!
Risk of damage to cylinder wall and to crankshaft.

Gently release connecting rod from crankshaft.

Remove connecting rod bearing shells (1 and 2).
Use new connecting rod bearing shells according to code letter.
Installation note:
Pay attention to guide lugs during installation.

Important!
All crankshaft crank pins are classified.

In each case insert only one colour of connecting rod bearing

shell (1 and 2) for each connecting rod.

Check connecting-rod bearing play.

Piston in BDC position.
To determine the connecting rod bearing play, make sure that
the bearing positions are clean and free from oil and grease.
Fit special tool  00 2 590 (Plastigage type PG 1) to oil-free
crankshaft.
Fit connecting rod bearing cap so that pairing letters match up.

Important!
Do not distort connecting rods or crankshaft.
 4/29/2016 4/4

Use the old connecting rod bolts to check connecting-rod

bearing play.
Tighten down connecting rod bolts with special tool  00 9 120.
Tightening torque 11 24 1AZ.

Unscrew connecting rod bearing cap. Read off connecting rod

bearing play at width of flattened Plastigage on measurement
scale.
Connecting rod bearing play.
 Remove Plastigage
 Coat crankshaft and connecting rod bearing shells with oil
 Install new connecting rod bolts and tighten down with
special tool  00 9 120.
Tightening torque 11 24 1AZ.

Assemble engine.
 4/29/2016 1/6

11 21 531 Replacing all crankshaft main bearing

(N55)

Special tools required:

 00 2 590
 11 4 470
 11 8 510

Necessary preliminary tasks:

 Remove crankshaft.

Checking position of oil spray nozzles:

Check position of oil spray nozzle according to position on
special tool 11 8 510 .
Insert special tool 11 8 510 into main bearing screw connection
and secure from turning with screw (1).

If necessary, adjust oil spray nozzles and secure.

Tighten banjo bolt (1).
Tightening torque: 11 11 5AZ.
 4/29/2016 2/6

Installation note:
Bearing shell (1) with lubricating groove must be fitted in upper
section of crankcase.
Bearing shell (2) without lubricating groove must be installed in
lower section of crankcase.

Important!
Allocation of bearing positions:
Bearing position 1 is at the front on the timing chain drive
in the direction of travel.

Main bearing classification (1) in crankcase.

Installation note:
When all the letters and number code have been determined,
the bearing shell colour must be allocated, see table.

Main bearing classification:

Code letters A / B or C) are used for the crankcase upper
section.
For bearing seat assignment from 1 to 7, the first bearing
position is indicated by a star (1) on timing drive.
 4/29/2016 3/6

Main bearing classification:

ID codes 1 / 2 or 3) are used for crankcase lower section.
For bearing seat assignment (1) from 1 to 7, the first bearing
position is located on timing drive.
Note:
Code letters (2) are required exclusively for classifying
connecting rod bearing.

Observe bearing classification.

Installation note:
The letter / number combination produces a bearing shell
pairing.
Identification by different colours.

Important!
First bearing position is on the timing drive.
Engine damage will result if an insufficiently small radial
clearance is determined.
If a large radial clearance is determined, this can lead to
noises in crankshaft drive.

Code letters on crankcase:

Code letter A = bearing shell (1) colour Yellow with lubricating
groove.
Code letter B = bearing shell (1) colour Green with lubricating
 4/29/2016 4/6

groove.
Code letter C = bearing shell (1) colour Red with lubricating
groove.
Code numbers on crankshaft:
Code number 1 = bearing shell (2) Yellow without lubricating
groove.
Code number 2 = bearing shell (2) Green without lubricating
groove.
Code number 3 = bearing shell (2) Red without lubricating
groove.
Important!
The colour set Yellow and Red must not be fitted; the
bearing colours Green / Green must be selected for this
colour set.

Installation note:
Possible colour combinations for mounting the crankshaft in the
crankcase.

Installation example:
For bearing 1 with code letter B on crankcase and code letter 1
on crankshaft, the bearing shell (1) with the colour Green is
required for the crankcase upper section and bearing shell (2)
with the colour Yellow for the crankcase lower section
(bedplate).
Bearing 2: B and 2 colours Green and Green.
Bearing 3: A and 2 colours Yellow and Green.
Bearing 4: B and 2 colours Green and Green.
Bearing 5: A and 1 colours Yellow and Yellow.
Bearing 6: B and 3 colours Green and Red.
Bearing 7: B and 1 colours Green and Yellow.
Important!
The colour set Yellow and Red must not be fitted; the
bearing colours Green / Green must be selected for this
colour set.

(A 1) Crankcase / Yellow (B 1) Crankcase / Green (C 1) Crankcase / Green

 4/29/2016 5/6

(A 1) Crankcase lower (B 1) Crankcase lower section / (C 1) Crankcase lower section /
section /Yellow Yellow Green

     

(A 2) Crankcase / Yellow (B 2) Crankcase / Green (C 2) Crankcase / Red

(A 2) Crankcase lower section / (B 2) Crankcase lower section / (C 2) Crankcase lower section /
Green Green Green

     

(A 3) Crankcase / Green (B 3) Crankcase / Green (C 3) Crankcase / Red

(A 3) Crankcase lower sections / (B 3) Crankcase lower section / (C 3) Crankcase lower section /
Green Red Red

Note:
Guide bearing shell (1) at bearing seat 4 is a thrust bearing.
Observe bearing classification.

Important!
Do not use any metal-cutting tools.
Only use special tool 11 4 470 to clean sealing surfaces.

Installation note:
Clean all sealing surfaces.

Install bearing shells (2) and guide bearing shell (3).

Installation note:
If a radial clearance needs to be redetermined, use special tool
00 2 590 to do this.
 4/29/2016 6/6

Installation note:
All measuring points must be clean and free from oil and
grease. If necessary, clean all measuring points.

The old bearing screws can be used to determine the radial

clearance.
Set up crankcase lower section with bearing shells.

Remove crankcase lower section.

Read off radial clearance at width of flattened Plastigage and
measuring scale.
Installation note:
Remove Plastigage.
Apply a light coat of oil to bearing shells and crankshaft.

Fit crankcase lower section.

Assemble engine.
 4/30/2016 1/2

33 17 004 Replacing all rubber mounts for rear

axle final drive mounting at front

Special tools required:

  33 5 166
  33 5 163
  33 5 162
  33 5 161
  33 4 465
  33 4 466
  33 5 105
  33 5 165

Important!
Do not press in and out rubber mount several times.

Necessary preliminary tasks:

 Remove rear axle final drive.

Withdrawing rubber mount:

Pull out rubber mount with special tools 33 5 166,  33 5 163,
 33 5 162,  33 5 161,  33 4 465 and  33 4 466.
 4/30/2016 2/2

Note:
The milled recess of special tool  33 5 162 must point towards
rear axle support.
Use ratchet ring spanner  33 5 105.

Installing rubber mount:

Important!
Align rubber mount horizontally by way of notches (1).
Slot (2) on rubber mount points towards centre of vehicle.

Pull on rubber mount (1) with special tools  33 5 165,  33 5 163,

 33 4 465 and  33 4 466 as far as it will go.
Note:
Use ratchet ring spanner  33 5 105.
 4/29/2016 1/4

11 34 715 Replacing all valve springs (N55)

Special tools required:

 11 4 481
 11 4 482
 11 8 841
 11 8 842
 11 9 000
 11 9 007

Necessary preliminary tasks:

 Remove cylinder head.
 Remove exhaust camshaft.
 Remove intermediate lever.
 Remove intake camshaft.
 Remove rocker arm.

Place cylinder head on special tool  11 9 000.

Align special tool 11 9 007 on particular combustion chamber.

Position special tool 11 9 007 on cylinder head.

Push locks (1 and 2) toward inside and preload via eccentric
shaft.
 4/29/2016 2/4

Press down intake valve with special tool 11 8 841.

Remove valve key (1) with a magnet.

Remove valve spring with spring cups.
If individual components are to be reused, they must be placed
in neat order in special tool 11 4 481.

Press down discharge valve with special tool 11 8 842.

 4/29/2016 3/4

Remove valve key (1) with a magnet.

Remove valve spring with spring cups.
If individual components are to be reused, they must be placed
in neat order in special tool 11 4 482.

Important!
Incorrect assembly possible.
Incorrect installation will result in valve spring breakage.
Risk of mixing up the valve springs for the inlet and
exhaust valves.

Valve springs are marked in colour (1).

Colours for intake valves:
 Green/blue
 Yellow/Blue
Colours for discharge valves:
 Green/white
 Yellow/white
Install the valve spring so that the larger diameter points to the
lower spring cup.
 4/29/2016 4/4

Arrangement:
1) Valve
2) Valve stem seal with lower spring cup
3) Valve spring
4) Upper spring cup
5) Valve keys

Assemble engine.
Check function of Digital Engine Electronics; if necessary,
readjust uniform mixture distribution.
 4/29/2016 1/3

11 34 560 Replacing all valve stem seals (N55)

Special tools required:

 11 1 480
 11 6 380

Necessary preliminary tasks:

 Remove cylinder head.
 Remove intermediate lever.
 Remove eccentric shaft.
 Remove intake camshaft.
 Remove exhaust camshaft.
 Remove rocker arm.

Press special tool 11 1 480 forcefully onto valve stem seals.

Detach valve stem seal from valve stem by turning and
simultaneously pulling special tool 11 1 480.
Installation note:
Insert all valves.

Note:
For use on the N55 engine, special tool 11 6 380 must be
remachined according to the graphic with a 10 mm dia. drill bit
to a depth of B = approx. 23 mm.
 4/29/2016 2/3

This modification has already been taken into account for

reordering.

Important!
Different diameters at valve stem.
All valve stem seals are colour-coded.

For 5 mm dia. valves, the valve stem seal is marked red or
brown.
For 6 mm dia. valves, the valve stem seal is marked green.

Installation note:
Fit the mounting sleeves (plastic sleeves) contained in the
delivery specification on the valve stem end.
Lubricate assembly sleeve.

Press on valve stem seal by hand with special tool 11 6 380 as

far as it will go.
Note:
Graphic N42.

Assemble engine.
4/29/2016 3/3
 4/29/2016 1/1

12 31 ... Replacing alternator belt pulley (with

overrunning clutch)

Special tools required:

 12 7 120

Remove and install alternator drive belt.

Grip alternator shaft with:

- internal serration
 
Release nut with special tools 12 7 120.
Installation:
Tightening torque 12 31 3AZ.
 4/30/2016 1/2

61 35 179 Replacing and installing (replacing) the

solar rain/light sensor and condensation
sensor

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove inside mirror

Disconnect plug connection (2).

Unlock the metal spring (3) on both sides outward.
Remove solar rain-light-condensation sensor (1) from
windscreen.
Risk of damage:
The silicone-coated surface below it must not be touched or
damaged!
Installation note:
Connect plug connection (2) only after fitting solar rain/light and
condensation sensor on windscreen!
Press centre of metal spring (3) to ensure latch mechanism is
correct in both hooks (5) on each side of retaining element (4).

Initialise sensor
Note:
 For F2x; (not F25); F3x and F8x (M3; M4) the coding is
automatically carried out by JBBFE.
 On F25, encoding is performed automatically via a
terminal change (terminal 15) by Junctionbox.

Replacement:
Carefully clean windscreen at contact area with rain/light/solar
and condensation sensor! Remove all silicone residues.
 4/30/2016 2/2

Remove protective cover from the new solar rain/light and

condensation sensor.
Risk of damage:
The silicone-coated surface below the protective cover must not
be touched or damaged!
 4/30/2016 1/1

33 55 041 Replacing anti-roll bar link for anti-roll

bar bar on left or right

Necessary preliminary tasks:

 Remove rear wheel.

Release nuts (1); if necessary, grip at inner Torx socket.

Tightening torque 33 55 2AZ.
Remove anti-roll bar link (2).
Installation note:
Replace self-locking nuts.
 4/30/2016 1/5

41 21 003 Replacing A-pillar with reinforcement on

left

Procedure Observe repair stage 3!

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD CD
(job number: 41 21 003).
Spot-weld bonding is used on this vehicle. Observe specific
procedure.
Use only approved spot-welding apparatus for repairs.
Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Middle side frame

- (2) Outer front side frame

- (3)Outer side sill

Removal:
 4/30/2016 2/5

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2).
Release and remove A-pillar outer section from cavity sealing (3).
 4/30/2016 3/5

Roughly mark areas (1) as pictured and cut.

Important!
Cut outer panel only.
Do not damage bulkhead in area (2)!
Open welded connections in areas (3).
Open spot-welded adhesive joints in area (4).
Remove A-pillar reinforcement.
If necessary, additionally replace side member attachment. .............................HTSP.........
........................addition top ..instructions for outer A-pillar in area of windscreen..................................
.......................and bottom side member attachment, first left side sill 41 1 420 ...................
.......................side member attachment: Clarification first concerning severance cut (material)......

Preparation of new part:

Open welded connections for components (1) which are not

required. Remove components (1) which are not required.
 4/30/2016 4/5

Adjust new parts to fit with alignment bracket or universal

mounting.
Note:
When adjusting, due to the absence of an outer skin, it is
necessary to place a panel of equal thickness in the area of the
door hinges.

Installation:

Install A-pillar with alignment bracket or universal fixture and weld in areas (1) and (2).
Note:
When installing, due to the absence of an outer skin, it is necessary to place a panel of equal thickness in the
area of the door hinges.
Note double number of welding spots in areas (2).
Apply repair welding spot (3) to existing welding spot on vehicle. This is necessary because the adhesive
 4/30/2016 5/5

between the spot flanges acts as an insulator.

Apply sealing compound to cavity sealing (3).

Install new parts and weld in areas (1) and (2).
Note:
Note double number of welding spots in area (2).
Vehicles with slide/tilt sunroof: Make sure water drain hose is installed correctly! (watertightness).
In vehicles with a normal roof, a grommet is installed instead of the water drain hose.
 4/30/2016 1/5

41 21 003 Replacing A-pillar with reinforcement on

left

Procedure Observe repair stage 3!

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD CD
(job number: 41 21 003).
Spot-weld bonding is used on this vehicle. Observe specific
procedure.
Use only approved spot-welding apparatus for repairs.
Place vehicle on straightening bench.

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) A-pillar, outer

- (2) Middle side frame

- (3) Shaped part, A-pillar, top (not shown)

- (4) Shaped part, A-pillar, top inside (not shown)

 
Following consumables are required:

Material Quantity

Blind rivet N1 1

Blind rivet N2 1

Removing the A-pillar with reinforcement

 4/30/2016 3/5

View of passenger compartment A-pillar.

Loosen welded connections (1) and remove A-pillar
reinforcement.

New part preparation

Mark severance cuts on new parts according to severance cuts
on vehicle and sever.
Prepare reinforcement plates at severance cuts.

Adjust A-pillar to fit with alignment bracket or universal mount

and secure.
Note:
When adjusting, due to the absence of an outer skin, it is
necessary to place a panel of equal thickness in the area of the
door hinges.
 4/30/2016 4/5

In areas (1), set 2 bore holes Ø 6.8 mm for blind rivets.

Remove new parts and deburr bore holes.

Installing the A-pillar with reinforcement

Apply sealant to cavity sealing.
Install new A-pillar and reinforcement plates with alignment
bracket or universal mount and fix.
When adjusting, the lack of outer skin means that a plate with
the same thickness must be used as a shim in the area of the
door hinges.

Rivet new part in areas (1) and (2).

Area (1): Blind rivet N1.
Area (2): Blind rivet N2.
Weld new part in further joint areas.

Install and weld outer A-pillar and reinforcement plates.

 4/30/2016 5/5

Note:
 Vehicles with slide/tilt sunroof: Make sure water drain
hose (1) is correctly installed (watertightness).
 In vehicle with a normal roof, a grommet is installed
instead of the water drain hose.
Please ensure correct installation of the grommet!
 4/30/2016 1/1

51 16 156 Replacing ashtray insert

Open ashtray cover (1) and pull ashtray insert (2) out of

mounting.
Installation note:
Press ashtray insert (2) until it engages in mounting.
 4/30/2016 1/1

61 31 823 Replacing audio unit

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove radio and IHKA controls

Disconnect plug connection (1).

Unclip audio operating unit (2) at the marked points using a
suitable tool (such as a screwdriver - 3 mm blade).
Remove the audio operating unit (2) from the cover (3) toward
the rear.
Installation note:
Audio control unit (2) must noticeably and audibly snap into
cover (3).
 4/30/2016 1/1

61 31 823 Replacing audio unit

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove radio and IHKA controls

Disconnect plug connection (1).

Unclip audio operating unit (2) at the marked points using a
suitable tool (such as a screwdriver - 3 mm blade).
Remove the audio operating unit (2) from the cover (3) toward
the rear.
Installation note:
Audio control unit (2) must noticeably and audibly snap into
cover (3).
 4/30/2016 1/3

52 15 405 Replacing backrest cover for front seat

(sport/manual)

Special tools required:

 52 0 050

Necessary preliminary tasks:

 Remove front seat
 Remove rear panel on front seat backrest
 Remove guide sleeves

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Version with seat heating only:

Unlock plug connection (1) for seat heating and disconnect.
Detach cable strap.
Release seat heater cable (2) from cable clips on seat
mechanism.
Installation note:
Plug connection is encoded to prevent incorrect connection.
Replace cable strap.

Important!
Feed the wiring harness carefully through the seat and
 4/30/2016 2/3

backrest mechanism as the edges of the frame can be

sharp.

Lift welt out of backrest frame.

Detach backrest cover at bottom from the metal tabs in the
marked area.
Carefully slide bracing cloth with foam through backrest gap
and seat structure.
If applicable, route cable carefully through seat and backrest
mechanics as the edges of the frame may be sharp.
Installation note:
Slide foam completely through backrest gap and seat structure.
Make sure foam and bracing cloth are correctly fitted.

Pull off backrest cover (1) with upholstery sideways and

towards top from backrest frame.

Release all clamps in marked area.

Remove backrest cover from padding.
Note:
Remove all remnants of clamps from backrest cover and
upholstery.

Installation note:
 4/30/2016 3/3

Bend new clamp (2) with special tool 52 0 050.

1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in backrest cover
5. Backrest cover

Replacement only:
Pull trim wires out of backrest cover.
Cut new backrest cover to size and insert trim wires.
 4/30/2016 1/3

52 14 405 Replacing backrest cover for left or right

front seat (normal/electrical)

Special tools required:

 52 0 050

Necessary preliminary work:

 Remove front seat
 Remove rear panel
 Remove guide sleeves for head restraint

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Version with seat heating only:

Unlock plug connection (1) for seat heating and disconnect.
Detach cable strap.
Detach seat heater cable (2) from cable clips on seat
mechanism.
Installation note:
Plug connection is encoded to prevent incorrect connection.
Replace cable strap.
 4/30/2016 2/3

Lift welt out of backrest frame.

Detach backrest cover at bottom from the metal tabs in the
marked area.
Carefully slide bracing cloth with foam through backrest gap
and seat structure.
If applicable, route cable carefully through seat and backrest
mechanics as the edges of the frame may be sharp.
Installation note:
Slide foam completely through backrest gap and seat structure.
Make sure foam and bracing cloth are correctly fitted.

Pull off backrest cover (1) with upholstery sideways and

towards top from backrest frame.

Release all clamps in marked area.

Remove backrest cover from padding.
Note:
Remove all remnants of clamps from backrest cover and
upholstery.

Installation note:
Bend new clamp (2) with special tool 52 0 050.

1. Upholstery
2. Clamp
 4/30/2016 3/3

3. Trim wire in upholstery

4. Trim wire in backrest cover
5. Backrest cover

Replacement only:
Pull trim wires out of backrest cover.
Cut new backrest cover to size and insert trim wires.
 4/30/2016 1/3

52 13 405 Replacing backrest cover for left or right

front seat (normal / manual)

Special tools required:

 52 0 050

Necessary preliminary work:

 Remove front seat
 Remove rear panel
 Remove guide sleeves for head restraint

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Version with seat heating only:

Unlock plug connection (1) for seat heating and disconnect.
Detach cable strap.
Detach seat heater cable (2) from cable clips on seat
mechanism.
Installation note:
Plug connection is encoded to prevent incorrect connection.
Replace cable strap.
 4/30/2016 2/3

Lift welt out of backrest frame.

Detach backrest cover at bottom from the metal tabs in the
marked area.
Carefully slide bracing cloth with foam through backrest gap
and seat structure.
If applicable, route cable carefully through seat and backrest
mechanics as the edges of the frame may be sharp.
Installation note:
Slide foam completely through backrest gap and seat structure.
Make sure foam and bracing cloth are correctly fitted.

Pull off backrest cover (1) with upholstery sideways and

towards top from backrest frame.

Release all clamps in marked area.

Remove backrest cover from padding.
Note:
Remove all remnants of clamps from backrest cover and
upholstery.

Installation note:
Bend new clamp (2) with special tool 52 0 050.

1. Upholstery
2. Clamp
 4/30/2016 3/3

3. Trim wire in upholstery

4. Trim wire in backrest cover
5. Backrest cover

Replacement only:
Pull trim wires out of backrest cover.
Cut new backrest cover to size and insert trim wires.
 4/30/2016 1/4

52 26 411 Replacing backrest cover for left rear

seat (basic seat)

Special tools required:

 52 0 050

Necessary preliminary tasks:

 Remove left backrest
 Remove guide sleeves left

Release screw.
Tightening torque 52 26 07AZ.
Lift out trim.

Feed seat belt strap out of cover.

 4/30/2016 2/4

Unclip lock finisher (1) in direction of arrow (2) starting with

backrest side section.
Remove lock finisher (1) in direction of arrow (3).

Installation note:
Retaining lugs (1) and (2) of cover must not be damaged.
Replace faulty cover.

Important!
Risk of damage!

Insert plastic wedge from outside between cover (1) and lock.
Carefully raise outer side of cover (1) with plastic wedge
upwards out of catch.
Raise inner side of cover (1) with plastic wedge out of catch.
Remove cover upwards.

Release screw (1).
Tightening torque 52 26 03AZ.
Remove outer mount (2).
Installation note:
Replace screw.
 4/30/2016 3/4

Lever out welt in marked area from backrest frame.

Remove backrest cover with padding from backrest frame.

Detaching cover and upholstery:

 Separate all clamps on trim wires
 Remove cover from upholstery
 Remove remaining clamps from cover and upholstery
Replacing cover:
 Remove all trim wires from cover
 If necessary, cut pockets in new cover for trim wires
 Push trim wires into cover pockets

Installation note:
Insert new clamp (2) with special tool 52 0 050.
In so doing, enclose wire in padding and trim wire of cover and
bend closed.

1. Upholstery
 4/30/2016 4/4

2. Clamp
3. Trim wire in upholstery
4. Trim wire in seat cover
5. Backrest cover
 4/30/2016 1/5

52 26 420 Replacing backrest cover for left rear

seat (through-loading facility)

Special tools required:

 52 0 050

Necessary preliminary tasks:

 Remove rear seat backrest, left
 Remove guide sleeves

Remove sleeve (1) from shaft.

Remove backrest for centre rear seat (1) from support of left
backrest in direction of arrow.

Installation note:
Plastic bush (1) may slide when removing the centre backrest.
Make sure plastic bush (1) is fitted correctly in the backrest
frame.
 4/30/2016 2/5

Remove sleeve (1).

Unclip lock finisher (1) in direction of arrow (2) starting with

backrest side section.
Remove lock finisher (1) in direction of arrow (3).

Installation note:
Retaining lugs (1) and (2) of cover must not be damaged.
Replace faulty cover.
 4/30/2016 3/5

Important!
Risk of damage!

Insert plastic wedge from outside between trim (1) and lock.

Carefully raise outer side of cover (1) with plastic wedge
upwards out of catch.
Raise inner side of cover (1) with plastic wedge out of catch.
Remove trim upwards.

Release screw.
Tightening torque 52 26 07AZ.
Lift out trim.

Feed seat belt strap out of cover.

 4/30/2016 4/5

Release screw (1).
Tightening torque 52 26 03AZ.
Remove outer mount (2).
Installation note:
Replace screw (1).

Lever out welt in marked area from backrest frame.

Remove backrest cover with padding from backrest frame.

Detaching cover and upholstery:

 Release all clamps on trim wires.
 Remove cover from upholstery
 Remove remaining clamps from cover and upholstery
 4/30/2016 5/5

Installation note:
Insert new clamp (2) with special tool 52 0 050 and bend
closed.

1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in backrest cover
5. Backrest cover

Replacing cover:
 Remove all trim wires from cover
 If necessary, cut pockets in new cover for trim wires
 Push trim wires into cover pockets
 4/30/2016 1/6

52 26 414 Replacing backrest cover for rear seat,

centre

Special tools required:

 52 0 070

Necessary preliminary tasks:

 Remove left backrest for rear seat
 Remove centre armrest
 Removing rear middle head restraint

Remove backrest for centre rear seat (1) from support of left
backrest in direction of arrow.

Installation note:
Plastic bush (1) may slide when removing the centre backrest.
Make sure plastic bush (1) is fitted correctly in the backrest
frame.
The plastic bush (1) must be retained in the backrest frame.
If applicable, clip the plastic bush (1) in from the inside out.

Unclip trim cover for lock with a plastic wedge.

Move trim cover for lock a little towards the middle.
Detach trim cover for lock by pulling towards rear.
 4/30/2016 2/6

Installation note:
Retaining lugs on the trim cover for the lock must not be
damaged.
Replace defective trim cover for lock.

Carefully lift the centre armrest in the marked area (1) out of the
backrest frame.

Unlock the back of the centre armrest cover (1).

Remove centre armrest cover (1) in direction of arrow from
backrest frame.
Installation note:
Make sure guide pin is correctly seated in backrest frame.
 4/30/2016 3/6

Guide pins (2) and latch mechanism (1) must not be damaged.

Replace defective centre armrest cover.

Detach bottom trim wire from claw studs.

Lever out welt in lower marked area.

Remove lower seat cover.
 4/30/2016 4/6

Lever out welt in top marked area.

Important!
Risk of damage!

Insert plastic wedge from outside between trim (1) and lock.

Carefully lever out cover (1) from latch mechanism with plastic
wedge in upward direction.
Remove trim upwards.

Insert special tool 52 0 070 into guide hole of sleeve (2) up to

upper area of retaining lug.
Feed release tongue of special tool into rear gap on retaining
lug (1).
Turn tool to release sleeve (2) and pull out by lifting upwards.
Installation note:
 4/30/2016 5/6

Replace guide sleeves and install as follows:

1. Short guide sleeves centre right

2. Short guide sleeve with centre left lock

Detach trim wire from claw studs.

Detach cover from plastic tabs.

Pull cover forward to remove from operating unit.

Detach cover from plastic tabs.
4/30/2016 6/6
 4/30/2016 1/3

52 26 412 Replacing backrest cover for right rear

seat

Special tools required:

 52 0 050

Necessary preliminary tasks:

 Remove right backrest
 Remove guide sleeves right

Unclip lock finisher (1) in direction of arrow (2) starting with

backrest side section.
Remove lock finisher (1) in direction of arrow (3).

Installation note:
Retaining lugs (1) and (2) of cover must not be damaged.
Replace faulty cover.

Important!
Risk of damage!

Insert plastic wedge from outside between trim (1) and lock.

Carefully raise outer side of cover (1) with plastic wedge
upwards out of catch.
 4/30/2016 2/3

Raise inner side of cover (1) with plastic wedge out of catch.
Remove trim upwards.

Release screw (1).
Tightening torque 52 26 03AZ.
Remove outer mount (2).
Installation note:
Replace screw (1).

Lever out welt in marked area from backrest frame.

Remove backrest cover with padding from backrest frame.

Detaching cover and upholstery:

 Release all clamps on trim wires.
 Remove cover from upholstery
 Remove remaining clamps from cover and upholstery
 4/30/2016 3/3

Installation note:
Insert new clamp (2) with special tool 52 0 050 and bend
closed.

1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in backrest cover
5. Backrest cover

Replacing cover:
 Remove all trim wires from cover
 If necessary, cut pockets in new cover for trim wires
 Push trim wires into cover pockets
 4/30/2016 1/2

52 15 062 Replacing backrest width adjustment

with valve on left or right

Necessary preliminary tasks:

 Remove the rear panel from the front seat
 Fully drain air cushion

Unfasten plug connection (1) and disconnect.

Unlock quick connector (2) and pull off air hose from adapter.
Installation note:
Connections are coded against incorrect assembly.
Air hoses must not be kinked.

Unclip valve (1) towards top from spring wire.

Note:
Removal operation is shown on left side, right analogous to
that.
Air cushion (2) must be fully drained.
 4/30/2016 2/2

Detach spring (1) top and bottom.

Lever out clips.
Feed out air cushion (2) between spring wire and backrest
frame.
Installation note:
Replace faulty clips.
Insert the air cushion without kinks.
Check air cushion for damage.

Note:
Run a function check.
 4/30/2016 1/1

25 11 041 Replacing ball socket for gearshift lever

Necessary preliminary tasks:

 Remove gearshift lever.

Pull ball socket (1) off the gearshift lever.

Installation note:
Grease ball joint.
 4/30/2016 1/2

51 11 158 Replacing base plate for number/license

plate

Only use the vehicle-specific license plate baseplate.

The installation of other license plate baseplates is not permissible.
Refer to Service Information License plate attachment at front.
If a number plate baseplate is not offered for the corresponding national-market version, the
number plate must be mounted directly on the bumper using a drilling template

Note:
Schematic diagram is example of F30 Europe national-market
version.

Release screws (1).
Tightening torque 51 11 8AZ.
Remove holder (2) towards front.

If replacing bumper:
Drill out marks (1) on bumper to 10 mm.

Attach support (2) to bumper and insert screws (1).

Tightening torque 51 11 8AZ.
4/30/2016 2/2
 4/30/2016 1/1

25 11 235 Replacing bearing bushes for gearshift

arm

Necessary preliminary tasks:

 Remove the gearshift arm.

- Push the bearing bushes (1) out.

- Coat new bearing bushes with Circolight (sourcing

reference: BMW Parts Department).

- Press the bearing bushes (1) into the gearshift arm until
the side face protrudes evenly.
 4/30/2016 1/3

31 21 180 Replacing bearing for front wheel

Special tools required:

 31 2 230
 11 8 580

Necessary preliminary tasks:

 Remove brake disc.

Slacken nut (1).

Tightening torque 31 31 3AZ.
Pull out screw.
Installation note:
Replace nut (1).
Bolt head points in direction of travel.

To release wheel bearing screw connection:

 Expand swivel bearing with special tool 31 2 230.
 Pull swivel bearing approx. 5 cm towards the bottom.
 4/30/2016 2/3

Installation note:
Keep press fit of swivel bearing and spring strut in lower area
clean and free from oil and grease.
Align swivel bearing (1) to positioning pin (2) on the rear side of
the spring strut along the gap and slide all the way in.

Release screws (1) with special tool 11 8 580.

Tightening torque 31 21 1AZ.
Press off wheel bearing from swivel bearing using a suitable
tool.
Installation note:
Replace microencapsulated screws.

Installation note:
Keep contact surface (1) of swivel bearing and wheel bearing
clean and free from oil and grease.
When reusing, all the threads on the wheel bearing must be
recut.
4/30/2016 3/3
 4/30/2016 1/4

41 00 ... Replacing blind rivets

Special tools required:

 2 348 128
 72 1 210

Important!
Lay out protective mats to protect the interior against swarf
from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:

- Dashboard

- Entrance area

- Passenger compartment

Schematic diagram of folding pack holder for head airbag:

Drill off rivet plate down to rivet shank with a 10 mm twist drill
bit.

Described for grab handle holder:

Drill off rivet plate down to rivet shank with a 10 mm twist drill
bit.
 4/30/2016 2/4

Cut off blind rivet shanks down to sheet metal as level as

possible.

Deburr remaining rivets with nipper pliers.

Installation note:
Apply primer to paintwork damages on side frame.

Note:
Depending on accessibility, the rivet heads will have to be
removed using special tool 2 348 128 or 72 1 210.

Press off rivet heads (1) using special tool 2 348 128 and

remove.
 4/30/2016 3/4

Special tool 72 1 210 for collecting rivet heads.

Shank (1) of special tool is flexible and can be adapted to the
relevant body contours.
Note:
Insert butyl in the collecting tray (2) to secure rivet heads and
prevent them from falling out.

Insert special tool 72 1 210 through bore hole in body next to

attachment points.
Position special tool from rear on rivet head in cavity.
Note:
A second person will be needed to help hold the special tool on
the rivet head during the driving-out operation.
Make sure collecting tray is correctly fitted on rivet head.

Drive out stem with hammer and 6 mm punch.

Carefully feed special tool out of body so that rivet head does
not fall out of collecting tray.

Note:
If the rivet falls out of the collecting tray into the side frame
when the special tool is fed out, this area must be generously
filled with foam.
For details of procedure for filling cavities with foam, see further
 4/30/2016 4/4

operations.
Use cavity preservation (refer to BMW Parts Department) for
foam filling.
Cavity foam (refer to BMW Parts Department) can also be used
if necessary.

Fit tube to foam can.

Push the hose in through the pillar holes.
Fill cavity with a filling material.
Warning!
Empty foam can completely onto cardboard and after
hardening dispose of foam and can in residual waste.
Can may burst if not completely emptied.

Overview of rivet gun:

Riveting of gas generator housing and holders for folding pack
with rivet gun (refer to BMW Workshop Catalogue).
The interchangeable head is changed for the different work
operations.
Riveting of gas generator housing with:
1.) 17/36 nosepiece and short shank
Riveting of holders for folding pack:
2.) 17/40 nosepiece and long shank
 4/30/2016 1/5

REP-REP-RAGRP41-4105_NIETKÖPFE   Replacing blind rivets

VIN: XXXXXXX Vehicle: 1'/F20/5-DOOR/M135I/N55/MANUAL/EUR/RL/2014/02

System Version: 3.42.40.11060 Data Version: R3.42.40.11060

41 00 ... Replacing blind rivets

Special tools required:

 2 348 128
 72 1 210

Important!
Lay out protective mats to protect the interior against swarf
from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:

- Dashboard

- Entrance area

- Passenger compartment

Schematic diagram of folding pack holder for head airbag:

Drill off rivet plate down to rivet shank with a 10 mm twist drill
bit.

Described for grab handle holder:

Drill off rivet plate down to rivet shank with a 10 mm twist drill
bit.
 4/30/2016 2/5

Cut off blind rivet shanks down to sheet metal as level as

possible.

Deburr remaining rivets with nipper pliers.

Installation note:
Apply primer to paintwork damages on side frame.

Note:
Depending on accessibility, the rivet heads will have to be
removed using special tool 2 348 128 or 72 1 210.
 4/30/2016 3/5

Press off rivet heads (1) using special tool 2 348 128 and

remove.

Special tool 72 1 210 for collecting rivet heads.

Shank (1) of special tool is flexible and can be adapted to the
relevant body contours.
Note:
Insert butyl in the collecting tray (2) to secure rivet heads and
prevent them from falling out.

Insert special tool 72 1 210 through bore hole in body next to

attachment points.
Position special tool from rear on rivet head in cavity.
Note:
A second person will be needed to help hold the special tool on
the rivet head during the driving-out operation.
 4/30/2016 4/5

Make sure collecting tray is correctly fitted on rivet head.

Drive out stem with hammer and 6 mm punch.

Carefully feed special tool out of body so that rivet head does
not fall out of collecting tray.

Note:
If the rivet falls out of the collecting tray into the side frame
when the special tool is fed out, this area must be generously
filled with foam.
For details of procedure for filling cavities with foam, see further
operations.
Use cavity preservation (refer to BMW Parts Department) for
foam filling.
Cavity foam (refer to BMW Parts Department) can also be used
if necessary.

Fit tube to foam can.

Push the hose in through the pillar holes.
Fill cavity with a filling material.
Warning!
Empty foam can completely onto cardboard and after
hardening dispose of foam and can in residual waste.
Can may burst if not completely emptied.

Overview of rivet gun:

Riveting of gas generator housing and holders for folding pack
with rivet gun (refer to BMW Workshop Catalogue).
The interchangeable head is changed for the different work
operations.
 4/30/2016 5/5

Riveting of gas generator housing with:

1.) 17/36 nosepiece and short shank
Riveting of holders for folding pack:
2.) 17/40 nosepiece and long shank
 4/30/2016 1/3

84 50 565 Replacing Bluetooth cable aerial

Note:
If a Combox is installed, the Bluetooth aerial is in the wiring
harness to the Combox.
If the vehicle is equipped with a high equipment headunit, the
Bluetooth aerial is located in the wiring harness to the high
equipment headunit.

Bluetooth cable aerial installation location

(E61) when Combox is installed.
 
Remove backrest side section
Remove rear left door sill cover strip.
Reposition underbody panelling on the left
side.
 

Unlock and disconnect plug connection of Bluetooth cable

aerial (2) at Combox (1).
Secure Bluetooth cable aerial  (2) repair kit at wiring harness for
entrance, and close plug connection (1).
After successful completion of functional check, disconnect start
and end of faulty Bluetooth cable aerial at first mounting point.
 4/30/2016 2/3

Installation location of the Bluetooth cable

aerial (E61) on vehicles with NBT/HU.
Remove Headunit High or Headunit.
Partially remove centre console.

Unlock and disconnect plug connection of Bluetooth cable

aerial (1).
 4/30/2016 3/3

Secure Bluetooth cable aerial  (1) repair kit at wiring harness

below centre console (2), and close plug connection.
After successful completion of functional check, disconnect start
and end of faulty Bluetooth cable aerial at first mounting point.
 4/30/2016 1/2

52 16 056 Replacing both cushions for backrest

width adjustment on left or right front
seat

Necessary preliminary work:

 Remove the rear panel from the front seat
 Completely drain air cushion for backrest width
adjustment

Unclip valve body (1) from seat mechanism and feed out from
backrest frame.
Installation note:
Check the valve body (1) for correct fit in the backrest frame
and spring wire.
Air hoses must not be kinked.

Unlock quick connectors and detach air hoses (1).

Valve body for backrest width adjustment:
1. Lumbar support left/right = hose clear, quick-connector
white
Installation note:
Connections are coded against incorrect assembly.

Note:
Removal operation is shown on left side, right analogous to
that.
 4/30/2016 2/2

The air cushion must be deflated completely.

Detach spring (1) top and bottom.

Lever out clips.
Feed out air cushion (2) between spring wire and backrest
frame.
Installation note:
Replace faulty clips.
Check air cushion for damage.
Insert air cushion without kinks.

Note:
Carry out function check
 4/30/2016 1/1

33 55 021 Replacing both rubber mounts for anti-

roll bar mounting

Necessary preliminary tasks:

 Lower rear axle support.

Release screws (1).
Tightening torque, 33 55 1AZ.
Remove retaining brackets (2).
Slide rubber mount (3) towards vehicle exterior and remove.
Installation note:
Keep retaining bracket (2), rubber mount (3) and anti-roll bar
clean and free from oil and grease.
Clean anti-roll bar on both sides.
Slide rubber mount with retaining bracket on anti-roll bar to
installation position.
 4/30/2016 1/1

61 61 041 Replacing both windscreen wiper blades

Important!
Make sure the wiper arm does not contact the windscreen
without its wiper blade.

Note:
In the event of a customer complaint regarding the cleaning or
wiping performance or noise build-up (scratching, squeaking)
by the wiper blades, proceed as follows: First check whether
the complaint is caused by dirt (preservation wax on new
vehicles, resins or other environmental influences) on the
windscreen; if necessary, clean the windscreen thoroughly!
Replace the wiper blades only if cleaning the windscreen fails to
remedy the situation.

Fold wiper arm (1) away from windscreen.

Press lock (2) and remove wiper blade (3) in direction of arrow.
Installation note:
Make sure guide (4) is correctly seated in wiper blade (3).
 4/30/2016 1/1

61 31 310 Replacing brake light switch

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism.

Disconnect plug connection (1).

Pull brake light switch (2) in direction of arrow out of brake light
switch holder (4).
Installation note:
 Press brake pedal (3) to floor.
 Push brake light switch (2) as far as it will go into brake
light switch holder (4).
 Counter hold brake light switch (4) holder, slowly return
brake pedal (3) to initial position and tighten to stop.

Note:
Removing brake light switch holder (1):

Press brake pedal.

Unclip brake light switch holder (1) at shanks (2) and remove
towards rear.
 4/30/2016 1/2

63 99 110 Replacing bulb for daytime driving lights,

left

Warning!
Follow instructions for handling light bulbs (exterior lights).

Turn protective cap (1) counterclockwise and remove.

Important!
Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must lock correctly!
Turn protective cap (1) clockwise to limit position.

Unlock bulb holder (1) in direction of arrow and pull out of

headlight (2) toward rear.
 
Installation note:
Make sure bulb holder (1) is exactly seated in headlight (2).

Pull bulb for daytime driving lights (1) out of bulb socket (2).

 
Installation note:
 4/30/2016 2/2

Note bulb type.

 4/30/2016 1/1

63 99 431 Replacing bulb for front interior roof light

Warning!
Follow notes for handling light bulbs (interior lights).

Necessary preliminary tasks:

Version with roof switch cluster:
 Partially remove roof switch cluster
Version with interior roof light only:
 Partially remove interior roof light

Note:
Interior roof light shown removed for purposes of clarity.

 
Turn bulb holder (1) in direction of arrow and pull out of interior
roof light (2).

Pull bulb (1) in direction of arrow out of bulb holder (2).

Installation note:
Note bulb type.
 4/30/2016 1/2

63 99 274 Replacing bulb for front left turn indicator

(with xenon headlight)

Important!
Follow instructions for handling light bulbs (exterior lights).

Turn protective cap (1) counterclockwise and remove.

Important!
Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must lock correctly!
Turn the protective cap (1) clockwise to end stop (A)!

Turn bulb holder (1) in direction of arrow and remove from

headlight.

Turn bulb (1) in direction of arrow and remove from bulb holder.
 
Installation note:
 4/30/2016 2/2

Note bulb type.

 4/30/2016 1/1

63 99 461 Replacing bulb for glove box light

Warning!
Follow instructions for handling light bulbs (interior lights).

Necessary preliminary tasks:

 Remove glovebox light

Turn bulb holder (1) in direction of arrow and pull out of light (2).

Installation note:
Make sure bulb holder (1) is correctly seated and engaged in
light (2).

Remove bulb (1) from bulb holder (2) in direction of arrow.

Installation note:
Note bulb type.

Note:
LED technology lights can only be replaced completely!
 4/30/2016 1/1

63 99 432 Replacing bulb for interior roof light

(rear)

Warning!
Follow instructions for handling light bulbs (interior lights).

Necessary preliminary tasks:

 Remove rear interior roof light

Turn bulb holder (1) in direction of arrow and pull out of interior

roof light (2).

Remove bulb (1) from bulb holder (2) in direction of arrow.

Installation note:
Note bulb type.
 4/30/2016 1/2

63 99 132 Replacing bulb for side lights, front left

Warning!
Follow instructions for handling light bulbs (exterior lights).

Turn protective cap (1) counterclockwise and remove.

Important!
Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must lock correctly!
Turn protective cap (1) clockwise to limit position.

Pull bulb holder (1) in direction of arrow out of headlight (2).

 
Installation note:
Make sure bulb holder (1) is exactly seated in headlight (2).

Note:
Similar to graphic.

Firstly turn bulb for side lights (1) in direction of arrow and then
 4/30/2016 2/2

pull out of bulb holder.

 
Installation note:
Note bulb type.
 4/30/2016 1/2

63 99 273 Replacing bulb for turn indicator, front

left

Warning!
Follow instructions for handling light bulbs (exterior lights).

Unlock and remove cover (1).

Turn protective cap (1) counterclockwise and remove.

Important!
Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must lock correctly!
Turn the protective cap (1) clockwise to end stop (A)!

Turn bulb holder (1) in direction of arrow and remove towards

rear from headlight (2).
 4/30/2016 2/2

Pull bulb (1) in direction of arrow out of bulb holder (2).

 
Installation note:
Note bulb type.
 4/30/2016 1/1

41 21 ... Replacing bulkhead new part

preparation

Additionally weld new part in this area (1).

 4/30/2016 1/3

41 33 050 Replacing centre front panel

Necessary preliminary tasks:

 Remove intake silencer housing
 F33 only: Remove front strut

 
Most of operation is described on the left side. Right side
identical.

Release screws (1).
Tightening torque 51 11 13AZ.
Unfasten screws (2).
Tightening torque 51 11 7AZ.

Release screws (1) and remove headlight mount.

Tightening torque 63 12 1AZ.
Release screws (2) and place hinge directly under front panel.
Tightening torque 51 23 1AZ.
Release screws (3).
Tightening torque 51 11 14AZ.

Release screws (1).
Tightening torque 41 33 1AZ.
Remove cover (2).
 4/30/2016 2/3

Press locks (1) together and pull the bearing pin (2) out toward
the top.
Remove centre front panel (3).

Remount holder (1) for radiator.

Remove rubber mount (1).

Unlock latch mechanisms for rubber buffers (2) and remove
rubber buffers.
 4/30/2016 3/3

Slide lock (1) upwards in direction of arrow.

Turn the holder (2) for the rubber mount clockwise and take off.
 4/30/2016 1/2

26 11 020 Replacing centre mount gaiter

Necessary preliminary tasks:

 Remove propeller shaft.

Note:
The propeller shaft is balanced.
The front and rear propeller shafts must be reassembled
in the same position.
Detach gaiter (1) from groove (2).

Mark front propeller shaft (3) and rear propeller shaft (4) in one

plane.

Pull apart propeller shaft.

Installation note:
If necessary, insert new clamping ring (1) into front propeller
shaft (2).
 4/30/2016 2/2

Release gaiter (1) with screwdriver from groove (2) and pull off

over longitudinal splines.
Installation note:
Apply an even coating of grease to longitudinal splines on shaft.
Grease, refer to BMW Service Operating Fluids.
Observe markings and force front propeller shaft onto
longitudinal splines (markings must be flush).
Push gaiter (1) during installation into groove (2) and make sure
it is firmly fitted.
 4/30/2016 1/2

REP-REP-RAF3026-2611020_TEST   Replacing centre mount gaiter

VIN: XXXXXXX Vehicle: 1'/F20/5-

DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System 3.42.40.11060 Data R3.42.40.11060

Version: Version:

26 11 020 Replacing centre mount gaiter

Necessary preliminary tasks:

- Remove propeller shaft.

Note:
The propeller shaft is balanced.
The front and rear propeller shafts must be
reassembled in the same position.
Detach gaiter (1) from groove (2).

Mark front propeller shaft (3) and rear propeller shaft (4)

in one plane.

Pull apart propeller shaft.

 4/30/2016 2/2

Installation note:
If necessary, insert new clamping ring (1) into front
propeller shaft (2).

Release gaiter (1) with screwdriver from groove (2) and

pull off over longitudinal splines.
Installation note:
Apply an even coating of grease to longitudinal splines
on shaft.
Grease, refer to BMW Service Operating Fluids.
Observe markings and force front propeller shaft onto
longitudinal splines (markings must be flush).
Push gaiter (1) during installation into groove (2) and
make sure it is firmly fitted.
 4/30/2016 1/2

25 11 001 Replacing complete gearshift lever

Necessary preliminary tasks:

 Remove gearshift lever.

Unlock vibration absorber (1) by turning counterclockwise.

Remove vibration absorber (1) upwards.
Installation note:
Ensure the locking pin (2) is correctly locked in the gate of the
vibration absorber (1).

Pull ball socket (1) off the gearshift lever.

Installation note:
Grease ball joint.

- Grease, refer to BMW Service Operating Fluids.

Detach rubber boot (2) from gearshift lever (1).

 4/30/2016 2/2

Installation note:
Degrease gearshift lever (1).
Coat rubber boot on inside of shaped element (2) with
Circo Light.

- Circolight, refer to BMW Parts Service.

Pull rubber boot from above over gearshift lever (1) and
align. Arrow (4) on rubber boot must point in direction of
travel.
 4/30/2016 1/3

26 12 001 Replacing complete propeller shaft

centre bearing

Special tools required:

 00 7 500
 33 1 020

Necessary preliminary tasks:

 Remove propeller shaft.

Note:
The propeller shaft is balanced.
The front and rear propeller shafts must be reassembled
in the same position.

Detach gaiter (1) from groove (2).

Mark front propeller shaft (3) and rear propeller shaft (4) in one
plane.
Installation note:
Make sure gaiter (1) is securely fitted in groove (2).

Pull apart propeller shaft.

 4/30/2016 2/3

Installation note:
If necessary, insert new clamping ring (1) into front propeller
shaft (2).

Release gaiter (1) with screwdriver from groove (2) and pull off

over longitudinal splines.
 
Installation note:
Apply a coating of grease to longitudinal splines on shaft.
Grease, refer to BMW Service Operating Fluids.
Push gaiter (1) during installation into groove (2) and make sure
it is firmly fitted.
Observe markings and force front propeller shaft onto
longitudinal splines (markings must be flush).

Install special tool  00 7 500 between centre mount (1) and

universal joint (2).
 4/30/2016 3/3

Using a hydraulic press, force centre mount (1) off propeller

shaft (2).

Force new centre mount (1) onto propeller shaft. Collar (2) must

point in direction of travel towards front propeller shaft. Drive
centre mount to limit position with special tool  33 1 020.
 4/30/2016 1/4

64 11 ... Replacing condensation water drain

hose of heating and air conditioning
system

Special tools required:

 23 4 050
 00 2 030

Necessary preliminary tasks:

 Remove intake filter housing
 Release left charge air duct at throttle valve
 Partially release propeller shaft

- Disconnect propeller shaft at transmission.

- Release centre mount.

- Tie up the propeller shaft to the vehicle

underbody.
Note:
A too high deflection angle on the propeller
shaft can cause preliminary damage to the
joint/propeller shaft!

Note:
Picture for example purposes.

Remove acoustic cover (1).

 4/30/2016 2/4

Slacken nut (1).

Take off holder (2).

Supporting transmission:
Support transmission with special tools 23 4 050, 00 2 030.
Secure transmission to mounting with tensioning strap (1).

Release screws (1).
Tightening torque 22 32 3AZ.
Slightly lower the transmission.
 4/30/2016 3/4

Release condensation water drain hose (1) in marked area and

remove in direction of arrow.
Installation note:
Firstly secure condensation water drain hose (1) in marked area
then lock it by turning slightly to left and right top.

Installation note:
Guides (1) on
condensation water
drain hose (2) must
be inserted exactly
at marked points in
retaining ring (3).
Make sure
condensation water
drain hose (2) is
correctly fitted.
4/30/2016 4/4
 4/29/2016 1/3

12 14 550 Replacing control unit (DME) (N55)

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Switch off ignition.
 Disconnect battery negative lead.
 Remove intake plenum.

Important!
Follow instructions for removing and installing control units

Replacement:
 Carry out programming/encoding
 If no data can be read out from the previous control unit,
carry out injection quantity compensation (description at
end of instructions).

Important!
It is absolutely essential to read out the fault memory with
the BMW diagnosis system and to create a fault memory
printout.
 4/29/2016 2/3

Switch off ignition.

Release screws (1).
Tightening torque 12 14 2AZ.

Release screws (1).
Tightening torque 12 14 1AZ.
Remove control unit from intake plenum.
Installation note:
Renew gasket between intake plenum and control unit.

Injection quantity compensation:

If the DME control unit has been replaced, it will also be
necessary to carry out adjustment of the injectors!
Injection quantity compensation is carried out with the aid of so-
called adjustment values.
The adjustment value is printed with three digits - depending on
 4/29/2016 3/3

the version - on the injector body.

The adjustment values must be stored in the new control unit!

If injector quantity compensation is not carried out, the engine

may run roughly or fail to start.
Read off the adjustment values and enter according to the
installation location (cylinder) of the injectors:

- Connect BMW diagnosis system

- Identify vehicle

- Select ”Function selection”

- Select ”Service functions”

- Select ”Engine electronics”

- Select ”Adjustment function”

- Select ”Adjust injectors”

- Select ”Test plan”

- The adjustment value must be entered for each cylinder.

Note:
Check stored fault message.
Delete fault memory.
 4/30/2016 1/2

63 12 860 Replacing control unit for left xenon

headlight

Warning!
Version with xenon lighting system: Danger to life due to
high voltage! Therefore disconnect all components from
voltage supply before removal.
Work on the entire xenon lighting system (ignition device,
control unit and bulb) may only be carried out by qualified
personnel.
Comply with notes and notes on handling exterior lights.

Necessary preliminary work:

 Remove left headlight

Release screws (1).
Tightening torque 63 12 3AZ.
Remove control unit for xenon headlight (2) upwards from
headlight (3).

Installation note:
When installing control unit for xenon headlight (1), make sure
sealing cup (2) is correctly seated.
4/30/2016 2/2
 4/30/2016 1/1

64 11 225 Replacing controller for heating and air

conditioning system blower

Necessary preliminary tasks:

 Remove bottom right dashboard trim panel

Release screws (1).
Unlock plug connections (2) and disconnect.
Remove controller (3) downwards.
 4/29/2016 1/2

13 62 531 Replacing coolant temperature sensor

(N55)

Warning!
Risk of scalding!
Only perform this repair work on an engine that has cooled
down.

Recycling
Catch and dispose of escaping coolant.
Observe country-specific waste disposal regulations.

Necessary preliminary work:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Remove ignition coil cover.

Note:
Coolant temperature sensor is mounted on cylinder head at
front.

Unlock connector (1) and remove.

Unfasten coolant temperature sensor (2).
Installation note:
Tightening torque 13 62 5AZ.
 4/29/2016 2/2

If necessary, top up coolant.

Note:
Check stored fault messages.
Clear diagnostic fault entries from fault memory.
 4/29/2016 1/10

11 21 500 Replacing crankshaft (N55)

Special tools required:

 00 2 010
 00 9 120
 11 4 370
 11 4 440
 11 4 470
 11 6 251
 11 6 252
 11 9 360

Important!
Aluminium screws/bolts are permitted with and without
colour coding (blue).
Aluminium screws/bolts must be replaced each time they
are released.
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Remove engine
 Mount engine on assembly stand
 Remove vibration damper
 Remove oil sump
 Remove oil pump
 Remove timing chain module
 Remove oil pump/vacuum pump chain module
 Remove cylinder head.
 Remove flywheel
 Removing all pistons
 4/29/2016 2/10

Release screws (1).
Tightening torque 11 13 5AZ.
Installation note:
Replace aluminium screws.

Remove oil deflector with integrated intake snorkel.

Release aluminium screws (1).

Release aluminium screws (2).
Installation note:
Replace aluminium screws.

Release aluminium screws (1).

Installation note:
Replace aluminium screws.

Note:
Graphic shows N52.

Release screws (1).
Unfasten screws (2).
Installation note:
Replace aluminium screws.

Release steel screws (14 to 1) from outside inwards.

 4/29/2016 3/10

Remove crankcase lower section upwards.

Important!
Remove crankshaft with aid of a second person.
Weight of crankshaft approx. 25 kilograms.

Remove crankshaft (1) upward in direction of arrow.

Remove bearing shells (2) and guide bearing shell (3), replace
if necessary.

Clean all sealing surfaces (1) with special tool 11 4 470.

Check fitting sleeves for damage and secure seating; replace if

necessary.
Install all bearing shells.
Installation note:
Oil all bearing points adequately with engine oil.
 4/29/2016 4/10

Important!
Insert crankshaft with aid of a second person.
Weight of crankshaft approx. 25 kilograms.

Insert crankshaft (1).
Fit crankcase lower section (watch fitting bushes).
 4/29/2016 5/10

Follow tightening/torque sequence for the steel bolts (1 to 14).

Join steel bolts (1).

Mark across all steel bolts (1) with a coloured mark.

 4/29/2016 6/10

Tighten all steel bolts with a special tool 00 9 120.

Tightening torque 11 11 1AZ.
Installation note:
All steel bolts must be positioned the same with respect to the
coloured mark after being fastened (see illustration R 11 8151).

Installation note:
Aluminium bolts (1) and (2) can have a blue coloured mark.
Aluminium screws/bolts are not magnetic.

Important!
In the case of aluminium screws, jointing torque and angle
of rotation must be observed without fail.

Join all aluminium bolts (1) from inside toward the outside.

Tightening torque 11 11 2AZ.
 4/29/2016 7/10

Mark across all aluminium bolts (1) with a coloured mark.

Tighten all aluminium bolts (1) only with special tool 00 9 120.
Tightening torque 11 11 3AZ.
Tightening torque 11 11 4AZ.
Installation note:
All aluminium bolts must be equally positioned with respect to
the coloured mark after being fastened.

Fit special tool 11 6 252 with magnetic foot on special tool

11 4 440.
Clamp special tool 11 6 251 on special tool 11 6 252.
Position special tool 11 6 251 with button on the flat side of the
crankshaft.
Press crankshaft (1) in direction of arrow up to stop.
 4/29/2016 8/10

Set dial gauge with knurled screw (2) on zero.

Press crankshaft (1) in direction of arrow from right to left up to

stop.
Determine crankshaft axial clearance.

Turn crankshaft (1) via the central bolt with special tool

00 2 010 to determine the coefficient of friction.

Drive both injector nozzles (1) on left and right on crankcase

into the bore hole (see arrow) with special tool 11 9 360.
Installation note:
Replace injector nozzles (1).
 4/29/2016 9/10

Drive in both injector nozzles (1) on left and right with special

tool 11 9 360 into crankcase.

Drive injector nozzle (1) all the way in.

Installation note:
Use primer 1.3 and liquid sealing compound 1.4.
Prepare liquid sealing compound (2) in special tool 11 4 370.
Screw on nozzle (1) for injecting sealing compound.
 4/29/2016 10/10

Slowly and evenly insert liquid sealing compound (1) via the

injector nozzle with special tool 11 4 370 in direction of arrow.
Graphic N42.

Replace front crankshaft seal.

Replace crankshaft seal (transmission side).
Assemble engine.
 4/29/2016 1/2

12 14 521 Replacing crankshaft pulse sensor

(N55)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Remove starter motor.

Unlock connector (1) and remove.

Release screw (2).
Tightening torque 13 62 2AZ.
Remove connector housing from crankcase.
Release screw (3).
Tightening torque 13 62 8AZ.
Pull pulse sensor from crankcase and remove.

Installation note:
During installation of pulse sensor make sure that guide pin (1)
of pulse sensor is inserted in guiding groove (2) of crankcase.
 4/29/2016 2/2

Note:
Assemble engine.
Check stored fault message.
Delete fault memory.
 4/29/2016 1/3

11 12 101 Replacing cylinder head gasket (N55)

Special tools required:

 11 4 430
 11 4 470

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Necessary preliminary tasks:

 Remove cylinder head.
 Check cylinder head for deviation from flatness.
 Check cylinder head for watertightness.

Remove the cylinder head gasket.

Insert special tool 11 4 430 into feed pipe of oil pump.
 4/29/2016 2/3

Remove remnants of oil and dirt from blind holes (1).

Important!
Work on sealing surface on engine block and on cylinder
head with special tool 11 4 470 only.
Do not use any metal-cutting tools.

Check adapter sleeves (1) for damage and firm seating.

The cylinder head gasket on the N55 is a beaded metal gasket.

 4/29/2016 3/3

Place cylinder head gasket (2) in direction of arrow on engine

block.
Fix new cylinder head gasket with fitting sleeves (1).

Assemble engine.
 4/30/2016 1/1

32 33 016 Replacing design cover for M sports

steering wheel

Necessary preliminary tasks:

 Remove airbag unit

Release screws (1) on steering wheel.

Release screw (2) on rear side of steering wheel.
Remove design cover.
 4/30/2016 1/1

51 21 003 Replacing door detent (lock striker),

front left or right

Release screws (1) and remove door detent (2).

Installation note:
If necessary, carry out basic adjustment by way of notches (3)
on door detent (2) and B-pillar.
Tightening torque 51 21 2AZ.

After installation:
Adjust door detent.
 4/30/2016 1/1

51 22 001 Replacing door detent (lock striker), rear

left or right

Release screws (1).
Remove lock striker.
Tightening torque 51 22 2AZ.
 
After installation:
Adjust door detent.
 4/29/2016 1/2

11 28 010 Replacing drive belt for alternator (N55)

Special tools required:

 11 0 390

Necessary preliminary tasks:

 Remove fan cowl.

Routing of drive belt without Dynamic Drive

Note:
Mark the direction of travel of the drive belt if it is to be reused.

Turn belt tensioner (2) in direction of arrow until belt tensioner

bore hole is flush on crankcase.
Hold belt tensioner (2) under tension.
Secure special tool 11 0 390.
Remove drive belt (3).

Routing of drive belt with Dynamic Drive

Note:
Mark the direction of travel of the drive belt if it is to be reused.
 4/29/2016 2/2

Turn belt tensioner (2) in direction of arrow until belt tensioner

bore hole is flush on crankcase.
Hold belt tensioner (2) under tension.
Secure special tool 11 0 390.
Remove drive belt (3).

Assemble engine.
Installation note:
Check drive belt for correct installation position and, if reusing,
observe direction of travel. Risk of damage.
 4/30/2016 1/7

33 41 000 Replacing drive flange on left/right rear

axle shaft

Necessary preliminary tasks:

 Remove rear wheel.
 Remove parking brake shoes.

Important!
Check sensor head and cable of pulse sensor and renew
if necessary.

If necessary, remove visual protection cap (1).

Important!
Expand anti-twist lock sufficiently to avoid damaging
thread when releasing collar nut (1).
 4/30/2016 2/7

Activate parking brake and release collar nut (1).

Tightening torque 33 41 1AZ.
Installation note:
Slightly grease the gearing at the shaft journal.
No oil permitted on thread of shaft journal or collar nut.
Replace collar nut (1) by positive peening at flat areas of output
shaft.

Use special tool, see BMW Workshop Catalogue.

 

- Hydraulic unit - 81 64 2 155 744

- Adapter kit 1 -  81 64 2 155 745

- Adapter kit 2 -  81 64 2 155 746

- Adapter - 81 64 2 318 661

The following work steps describe the removal of the drive flange:
 4/30/2016 3/7

The following tools are required to pull out the drive flange hub from the wheel bearing; see graphic for
arrangement:
Vehicle components:

I Drive flange hub

II Wheel carrier

Required components for all models and types:

E3 Washer

B1 Adapter

E1 Holding sleeveM24

F1 Spindle M24 / M20 (length 425 mm)

1 Hydraulic unit

A1 Device

* Components specific to model and type:

Note:
 4/30/2016 4/7

Two variants of the wheel carrier are installed.

M5 Adapter diameter 90 mm

K1 Screws M12 x 1.5

or

M3 Adapter Ø 102 mm

K1 Screws M12 x 1.5

Important!
The wheel bearing is destroyed when the drive flange is
removed and cannot be reused!

Replace wheel bearing.

The following work steps pulling in the drive flange:

 4/30/2016 5/7

The following tools are required to insert the drive flange hub; see graphic for arrangement:
Vehicle components:

I Drive flange hub

II Wheel carrier

III Output shaft

Required components for all models and types:

1 Hydraulic unit

E1 Holding sleeveM24

D1 Washer

F2 Spindle M24 / M20 (length 335 mm)

* Components specific to model and type (thread diameter, output shaft):

G2 Adapter M24 x 1.5 to M20

 4/30/2016 6/7

Installation note:
Oil drive flange lightly and attach to gearing of output shaft.
The output shaft and drive flange may be inserted in the same procedure.

Important! Risk of damage!

Due to the technical requirements, the special
tool used, sleeve G,* is relatively thin-walled.
To ensure that the load limit of the tensioning
sleeve is not exceeded when drawing in the
output shaft, it is essential to use adapter 81
64 2 318 661 in combination with a torque
wrench.
 
Fit adapter with torque wrench to hydraulic
unit (see graphic).
Set torque wrench to 20 Nm.
Draw in output shaft with hydraulic tool until
the torque wrench is activated.

Tighten collar nut (1), activate parking brake for this purpose.
 4/30/2016 7/7

Tightening torque 33 41 1AZ.

Installation note:
No oil permitted on thread of shaft journal or collar nut.
Replace collar nut (1) by positive peening at flat areas of output
shaft.

After installation:
 Adjust parking brake.
 4/30/2016 1/2

64 12 670 Replacing electric auxiliary heater -front-

Necessary preliminary tasks:

 Remove glove box
Version with A/C system:
 Remove front storage compartment
Version with automatic air conditioning:
 Remove centre console.

Version with automatic climate control:

Remove air duct (1) and sound insulation (2) in direction of
arrow.

Fold up the carpet in the marked area.

Slacken nut (1).
Remove ground cable (2).

Note:
Mark position before removing holder (2).

Release screws (1).

Take off holder (2).
 4/30/2016 2/2

Unclip air duct (1) downward at retaining clasp (2).

Pull off air duct (1) in direction of arrow.
Installation note:
Air duct (3) must be correctly engaged in duct (4).

Disconnect plug connections (1) and (2).

Release screws (3).
Auxiliary heater (4) in direction of arrow.
 4/30/2016 1/1

67 61 515 Replacing electric motor with gearbox

(front) for operation of slide/tilt sunroof

Necessary preliminary tasks:

 Remove roof switch cluster

Note:
Secure drive with gearbox for actuating slide/tilt sunroof (3)
against falling out.

Unfasten plug connection (1) and disconnect.

Release screws (2), tightening torque 54 13 1AZ.
Remove drive with gearbox for actuating slide/tilt sunroof (3).

Installation note:
Insert gear (1) of electric motor with gearbox for operation of
slide/tilt sunroof (2) exactly in gearing (3).

Installation note:
 Initialise slide/tilt sunroof.
 4/30/2016 1/1

84 10 ... Replacing emergency battery for

Telematic Communication Box (TCB)

Important!
Read and comply with notes on protection against
electrical damage (ESD protection).

Necessary preliminary tasks:

 Remove the Telematic Communication Box (TCB)

Open lid (1)·on TCB (2) in direction of arrow.

Unfasten plug connection (1) and disconnect.

Remove emergency battery (2) from TCB (3).
 4/30/2016 1/3

41 14 531 Replacing engine support/front left side

frame connection (front left wheel arch
removed).

Observe procedure for repair stage 3.

 
Read contents of Body, General.
Spot-weld bonding is used on this vehicle. Observe specific
procedure.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 14 531).

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Connection, wheel arch/entrance

Removing the engine support side frame connection:

Open welded connections in areas (1).

Loosen spot-welded adhesive joints in areas (2).
 4/30/2016 2/3

Open welded connections in area (1)

Open spot-welded adhesive joints in area (2) and remove
engine support / side frame connection (3).

New part preparation

Open welded connections in area (1) and remove part

section not required.
 4/30/2016 3/3

Installing the engine support side frame connection

Install and weld new parts.

Important!
Risk of damage to adhesive area.
Avoid applying too much heat to adjacent adhesive
area (1).
 4/30/2016 1/5

41 11 091 Replacing engine support in front of

bulkhead, left

Observe procedure of repair stage 3.

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 11 091).
Use only approved spot-welding apparatus for repairs.
Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Engine support, outer left

- (2) Engine support, inner left

 
Following consumables are required:

Material Quantity

Blind rivets N1 4

Removing the engine support

Open welded connections in areas (1).

 4/30/2016 2/5

Open welded connections in areas (1).

Roughly mark severance cut (1) as pictured and cut.

Open welded connections in area (2) and remove engine
support (3).

Open welded connections in areas (1) by grinding and remove

residual section of engine support (2).
 4/30/2016 3/5

New part preparation

Open welded connections (1) and remove component (2) which

is not required.

Release welded connections (1) and remove adapter plate (2).

 4/30/2016 4/5

Set bore holes for welding the reinforcements (2) in areas (1).
Refer to series part for number and position and transfer to new
part.

Adjust new parts to fit with alignment bracket or universal

mounting.
In areas (1), create 4 dia. 6.8 mm bore holes for blind rivets N1.
Note:
Three-sheet joint in area (2)!
All three panels must be welded in area (2)!
Prepare new parts and vehicle accordingly.
 

Remove new parts and deburr bore holes.

Installing engine support

Install new parts using an alignment bracket or universal mount.
 4/30/2016 5/5

Rivet and weld new parts.

Note:
Weld the outer section of the engine support to the body in the
areas (1) and (2)!
 4/30/2016 1/9

41 11 095 Replacing engine support in front of

wheel arch, left

Follow procedure for repair stage 3.

Read contents of Body, General.
Strip down vehicle.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 11 095).
Use only approved spot-welding apparatus for repairs.
Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Engine support, outer

- (2) Engine support, inner

Removal

Mark severance cut in accordance with Dimension a and cut.

Important!
Offset severance cuts!
Cut outer metal panel only.
 4/30/2016 2/9

Dimension a = approx. 63 mm before centre point of 9 x 9 mm

dia. hole.
Severance cut path is carried out through 7 mm diameter hole.
Open welded connections in areas (1).

View of inside:
Mark severance cut in accordance with Dimension a and cut.
Important!
Cut outer metal panel only.

Dimension a = approx. 5 mm from component edge of

reinforcement plate.
Remove section of engine support.

New part preparation

Open welded connections (1) and remove component (2) which

is not required.
Mark severance cuts on new parts according to severance cuts
on vehicle and sever.
Adjust new parts to fit with alignment bracket or universal
mounting.
 4/30/2016 3/9

Adjust engine support outer section (1) to alignment bracket or universal fixture and fix in position.
Adjust reinforcement plate (2) for engine support outer section (1) according to schematic diagram.
Remove engine support outer section.
Important!
Reinforcement plate must be adjusted in area of axle support (3).
Different procedure: Reinforcement plate is welded from inside during installation.
Bore hole for welding the reinforcement plate from outside are therefore not required.
Alignment bracket not shown for purposes of clarity.
 4/30/2016 4/9

Adjust engine support inner section (1) to alignment bracket or universal fixture and fix in position.
Adjust reinforcement plate (2) for engine support inner section (1) according to schematic diagram.
Important!
Reinforcement plate (2) must be adjusted in area of axle support (3).
Reinforcement plate is welded from inside to outside during installation.
Bore hole for welding the reinforcement plate from outside are therefore only required in the front area.
See graphic below.
Alignment bracket and carrier support not shown for purposes of clarity.
 4/30/2016 5/9

In areas (2), set bore holes for plug welding.

Remove engine support inner section (1).

Installation
 4/30/2016 6/9

Install the reinforcement plate (1) for the engine support inner section and weld to the axle support.
For this purpose, in areas (2) set MAG weld seams with a length of 10 - 15 mm.
Note:
Alignment bracket and engine support inner section not shown for purposes of clarity.
 4/30/2016 7/9

Install engine support outer section (1) and reinforcement plate (2) with alignment bracket or universal fixture
and weld.
For this purpose, in areas (3) set MAG weld seams with a length of 10 - 15 mm.
Note:
Alignment bracket not shown for purposes of clarity.
 4/30/2016 8/9

Install engine support inner section with alignment bracket or universal fixture and weld in areas (1) and (2).
Note:
Alignment bracket not shown for purposes of clarity.

In areas (1) weld new part.

Weld new part in area (1).

4/30/2016 9/9
 4/30/2016 1/11

41 11 071 Replacing engine support with front left

wheel arch in front of bulkhead

Note the special vehicle identification number procedure when

replacing the front right wheel arch (order the new body part
with the vehicle identification number, if necessary)!

Observe procedure of repair stage 3.

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD
CD (job number 41 11 071).
Spot-weld bonding is used on this vehicle. Observe specific
procedure.
Use only approved spot-welding apparatus for repairs.
Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Wheel arch, front

- (2) Extension, wheel arch carrier support

- (3) Shaped part, wheel arch carrier support (not shown)

 
Following consumables are required:

Material Quantity

Adhesive K1 1

Blind rivets N7 9
 4/30/2016 2/11

Blind rivets N3 5

Punch rivets N5 12

Sealant D1  

Cleaning agent R1 1

Removal of engine support with wheel arch

Mark severance cut (1) at component edge and cut.

Mark severance cut (2) as pictured and cut.
Loosen spot-welded adhesive joints in area (3).
Open welded connections in area (4).
Release metal section from cavity sealing (5) and remove.
Remove cavity sealing (5).

Open welded connections in area (1).

 4/30/2016 3/11

Open welded connections in area (1).

 4/30/2016 4/11

Open welded connections in areas (1) and (2).

Open welded connections in area (1).

Open welded connections in area (1).

 4/30/2016 5/11

Mark severance cut (1) roughly as pictured and cut engine

support.
Open welded connections in area (2) and remove engine
support (3) with wheel arch.

Open welded connections in areas (1) by grinding and remove

residual section of engine support (2).

New part preparation

 4/30/2016 6/11

Mark and disconnect severance cut on the new part according

to the severance cut on the vehicle + 20 mm added material
(1).

Release welded connections and remove non-required

components (1) from new part.

Mark severance cut in accordance with dimension and cut.

Measurement a = approx. 145 mm from component edge.
Cut outer metal panel only.
Open welded connections in area (1).
Remove metal section (2).
Note:
 4/30/2016 7/11

The metal section (2) is needed to close the engine support.

Prepare reinforcement plate at severance cut.

Adjust new parts to fit with alignment bracket or universal

mounting.

Adjust extension, wheel arch carrier support new part to fit and
secure.
In areas (1) and (2), set dia. 6.8 mm bore holes for blind rivets.

Area Number

1 3

2 5

In area (3), set 4 dia. 4.2 mm bore holes for blind rivets N3 .
Remove new parts and deburr bore holes.

Important!
Structure bonding!
Observe preparation of bonding surfaces.
 4/30/2016 8/11

Installation of engine support with wheel arch

Install new front wheel arch and reinforcement plate with
alignment bracket or universal mount.

Weld new part in area (1).

Weld new part in the areas (1) and (2).

 4/30/2016 9/11

Weld new part in area (1).

Weld severance cut (2) and reinforcement plate.

Weld new part in area (1).

Weld new part in the areas (1) and (2).

 4/30/2016 10/11

Weld new part in area (1).

Installation of extension, wheel arch carrier support

Clean bonding surfaces with cleaning agent R1.
Apply adhesive  to bonding surfaces.
Apply sealant to cavity sealing.
Install extension, wheel arch carrier support.

In areas (1) and (2), rivet new part with blind rivets N7.
In area (3) rivet new part with blind rivets N3.
In areas (4) and (5), rivet new part with punch rivets N5.

Area Number
 4/30/2016 11/11

4 6

5 5
 4/30/2016 1/1

64 11 943 Replacing evaporator temperature

sensor

Special tools required:

 00 9 327

Necessary preliminary tasks:

 Remove trim for instrument panel, bottom left

Disconnect plug connection (2).

Unclip the evaporator temperature sensor (1) with special
tool 00 9 327 from the heating and air-conditioning unit (3) and
remove.
Installation note:
Ensure evaporator temperature sensor (2) is correctly seated.
 4/30/2016 1/2

26 11 051 Replacing flexible disc for front propeller

shaft

Necessary preliminary tasks:

 Remove propeller shaft at transmission and centre
bearing.
 Remove complete propeller shaft (F06, F10, F12,
F13 - S63).

Note:
To protect universal joints, tie back propeller shaft in area
of centre mount.

Release screws and remove flexible disc (1) from propeller

shaft.
Tightening torque and angle of rotation 26 11 2AZ.
Important!
Replace ZNS bolts and self-locking nuts.

Note:
On the F06, F10, F12, F13 - S63 a silicone flexible disc is
installed instead of the conventional rubber part flexible disc.

Installation note:
- During installation arrows (2) on circumference of
flexible disc must point to flange arms (3).

Note:
Instead of conventional rubber flexible disks, F series also use
aluminium flexible discs, which are also called EGG (constant
velocity joints).
 4/30/2016 2/2

Installation note:
Check centring mount.
Replace damaged centring mount.
Grease centring mount.
 4/30/2016 1/3

34 00 027 Replacing fluid in brake system (M sport

brake)

Note:
Read and comply with General Information.
The capacities are oil change quantities. See Electronics Parts
Catalogue/Commercial Service Data (ETK/KSD) (capacities)

Necessary preliminary tasks:

 Remove the left engine compartment cover.

Important!
When carrying out repairs to the brake system, follow the
procedure set out in Bleeding brake system with DSC.
Use only BMW-approved brake fluids, see BMW operating
fluids.

Connect bleeder unit to expansion tank (1) and switch on.

Note:
Follow the applicable machine manufacturer's operating
instructions.
 4/30/2016 2/3

Charging pressure should not exceed 2 bar.

Completely flush brake system, rear.

Connect tank ventilation line (1) with collecting vessel to vent
valve on rear right brake caliper.
Open bleeder valve and purge until clear, bubble-free brake
fluid emerges.
Close vent valve.
Carry out the same procedure on the rear left wheel brake.

Completely flush brake system, front right outer.

Connect tank ventilation line (1) with collecting vessel to vent
valve on front right outer brake caliper.
Open bleeder valve and purge until clear, bubble-free brake
fluid emerges.
Close vent valve.

Completely flush brake system, front right inner.

Connect tank ventilation line (1) with collecting vessel to vent
valve on front right inner brake caliper.
Open bleeder valve and purge until clear, bubble-free brake
fluid emerges.
Close vent valve.
 4/30/2016 3/3

Carry out the same procedure on the front left wheel brake.

Switch off bleeder unit and remove from expansion tank.

Check brake fluid level. If necessary, top up/draw off to ”MAX”
level.
Close expansion tank.
Note:
Pay attention to seal (1) in sealing cap.
 4/29/2016 1/2

34 00 027 Replacing fluid in brake system

Note:
Read and comply with General Information.
The capacities are oil change quantities. See Electronics Parts
Catalogue/Commercial Service Data (ETK/KSD) (capacities)

Necessary preliminary tasks:

 Remove the left engine compartment cover.

Important!
When carrying out repairs to the brake system, follow the
procedure set out in Bleeding brake system with DSC.
Use only BMW-approved brake fluids, see BMW operating
fluids.

Connect bleeder unit to expansion tank (1) and switch on.

Note:
Follow the applicable machine manufacturer's operating
instructions.
 4/29/2016 2/2

Charging pressure should not exceed 2 bar.

Completely bleed the brake system.

Connect vent hose (1) with collecting vessel to vent valve on
rear right brake caliper.
Open bleeder valve and purge until clear, bubble-free brake
fluid emerges.
Close vent valve.
Follow same procedure on rear left, front right and front left
wheel brake.

Switch off bleeder unit and remove from expansion tank.

Check brake fluid level. If necessary, top up/draw off to ”MAX”
level.
Close expansion tank.
Note:
Pay attention to seal (1) in sealing cap.
 4/30/2016 1/3

31 11 001 Replacing front axle support

Warning!
Danger of injury!
Failure to comply with the following instructions may result
in the vehicle slipping off the vehicle hoist and critically
injuring other persons.
When supporting components, make sure that:
 the vehicle can no longer be raised or lowered
 the vehicle does not lift off the locating plates on the
vehicle hoist.

Important!
Before lowering/removing front axle support:
 
Observe safety information on raising the vehicle.
 
In order to avoid damage to vehicle hoist, perform weight
compensation on vehicle.
 Load spring strut domes with sand bags.

Note:
From 01/2013 vibration absorbers (1) are installed on the front
axle support on vehicles with rear-wheel drive and run-flat tyres!
Tightening torque 31 10 5AZ.

Warning!
Danger to life!
Secure engine in installation position with special tool to
 4/30/2016 2/3

prevent it from falling down.

Necessary preliminary tasks:

 Secure engine in installation position.
 Disconnect battery earth lead.
 Remove front wheels.
 Remove steering shaft from steering gear.
 Remove anti-roll bar links from anti-roll bar.
 Remove both track rods from swivel bearing.
 Remove wishbone from front axle support.
 Remove trailing links from front axle support.

The subsequent procedure is described under

"Lowering/raising front axle support".

Remove heat shield(s) from front axle support.

Remove jacking point from front axle support.
Remove engine mount.
Remove steering box.
Remove anti-roll bar.
 4/30/2016 3/3

Installation note:
Use previous front axle support as a template for modifying or
replacing small parts.

After installation:
 Carry out wheel alignment procedure.
 4/29/2016 1/6

11 14 005 Replacing front crankshaft seal (N55)

Special tools required:

 11 0 371
 11 0 372
 11 4 370
 11 9 221
 11 9 222
 11 9 224
 11 9 231
 11 9 233
 11 9 234
 11 9 235

Necessary preliminary work:

 Remove vibration damper

Important!
Do not release central bolt.
If the central bolt is released, the sprockets of the timing
chain and the oil pump will no longer be non-positively
connected to the crankshaft. Intake and exhaust
camshafts can turn in relation to crankshaft.
Risk of damage!

Screw special tool 11 0 371 with 80 Newton metres into the

 4/29/2016 3/6

Push radial shaft seal (1) 11 9 235carefully in direction of arrow

on the special tool .

Important!
11 9 235Special tool can only be fastened with
2 opposite bolts.
Determine hole pattern on special tool.

Screw special tool 11 9 235 with special tool 11 9 234 on

crankshaft.

Align groove (2) of radial shaft seal (1) centred to the housing

partition (3.
Important!
After installation, the grooves must be filled with sealing
compound.
 4/29/2016 4/6

Draw in radial shaft seal with special tool 11 9 231 in

conjunction with special tool 11 9 233 until flush.

Installation note:
Use primer 1.3 and liquid seal 1.4.

Prepare liquid sealing compound (1) in special tool 11 4 370.

Remove sealing caps (1) from injector (2).
Screw on metering needle.
Insert piston for pressing out.
Syringe (2) contains the sealing compound Loctite,
manufacturer's number 128357.
Bottle (3) contains the primer Loctite, manufacturer's
number 171000.

Before filling with sealing compound:

Moisten brush with Loctite primer, manufacturer's
number 171000. Insert brush as far as possible into grooves (1)
on crankshaft seal in order to coat housing partition on engine
block.
 4/29/2016 5/6

Graphic N42.

Using syringe (2), fill both grooves (3) flush with Loctite sealing

compound, manufacturer's number 128357.
Graphic N42.

Note:
Loctite primer, manufacturer's number 171000, binds the
Loctite sealing compound, manufacturer's number 128357, and
prevents leakage.

Coat surface of sealing compound in both grooves (1) with

Loctite primer, manufacturer's number 171000.
Graphic N42.

Assemble engine.
4/29/2016 6/6
 4/30/2016 1/2

34 32 881 Replacing front left or right brake hose

Note:
 Read and comply with General Information.
After completing repair work: Bleed brake system.

Press brake pedal down to floor and secure with pedal support.
Note:
The pedal support may only be released when the brake lines
are reconnected.
This prevents brake fluid from emerging from the expansion
tank and air from entering the system when the brake lines are
opened.

Pull out retaining clip (1) upwards.

Important!
Grip brake hose at square head (3) to prevent connector
from turning in retaining bracket.

Detach brake hose from brake line (2).

Installation note:
Tightening torque 34 32 1AZ.

Detach brake hose (1) from brake caliper.

Installation note:
Tightening torque 34 32 2AZ.

Important!
Make sure that the brake hose is routed correctly!
Brake hose must run between body and anti-roll bar link
(see graphic)!
 4/30/2016 2/2

Important!
First tighten brake hose on brake caliper.
Move wheels into straight-ahead position.
Insert brake hose into holder on spring strut side and
attach with retaining clip.
Insert brake hose into holder on body side and screw onto
brake line.
Never twist brake hose when installing it and avoid all
contact with parts attached rigidly to the body.
 4/30/2016 1/4

31 33 100 Replacing front left or right coil spring

Special tools required:

 31 3 340
 2 240 487
 2 240 490

Important!
Both coil springs on the relevant axle must be replaced
only in the event of corrosion breakage!

The coil spring is allocated in the Electronic Parts

Catalogue (EPC) under the "Spring table" menu item after the
vehicle identification number has been entered and the optional
equipment of the particular car has been selected.

Warning!
Before using the special tool 31 3 340 take care to read
through the Owner's Handbook!
All the safety information and instructions contained in the
Owner's Handbook must be strictly observed!
Failure to observe these safety precautions and
instructions increases the risk of serious physical injury,
damage to your health and damage to property and
equipment!

Important!
1. Prior to each use, check the special tools for
defects, modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the
special tools!
4. These special tools are intended solely for the
purpose of tightening and relieving cylindrical and
tapered suspension springs.
 4/30/2016 2/4

5. Keep special tools dry, clean and (down to the

spindle) free from grease.
6. Impact screwdrivers are prohibited!
7. Do not compress coil spring to full extent.

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Necessary preliminary tasks:

 Remove front spring strut.

Relieve tension on coil spring.

Release special tool 2 240 487.
Take out the coil spring with protective tube and support
bearing.
Installation note:
Check support bearing and protective tube for damage, replace
if necessary.
 4/30/2016 3/4

Installation note:
The flattened end (1) of the spring is placed onto the support
bearing.

Important!
Do not compress coil spring to full extent.
The gummed side of the pressure plate 2 240 487 is fitted
against the top spring coil!

Position the coil spring:

1. Insert the coil spring with protective tube and support
bearing.
2. Assemble the pressure plate 2 240 487 with
screws 2 240 490.
3. Position the spring so that the end of the spring (1)
protrudes by 40 mm beyond the pressure
plate 2 240 487.
4. Tighten the screws 2 240 490 evenly at 7 Nm.

Important!
The pressure plate 2 240 487 must be aligned parallel with
the top spring coil (1)!

Tension coil spring.

Further assembly:
See Replacing the front left or right spring strut
 4/30/2016 4/4

After installation:
 Check headlight adjustment, correct if necessary.
 4/30/2016 1/2

51 32 211 Replacing front left or right rubber guide

for left or right door window

Necessary preliminary tasks:

 Open side window completely.
 Remove cover on door window frame
 Remove exterior mirror on front door

Important!
Instructions for installation of rubber window seal are
fundamental to this repair instructions and must absolutely
be complied with.

Pull rubber window seal (1) out of rear window guide.

Unfasten screws (2).
Push cover (3) downwards slightly and feed out rubber window
seal (1) towards the top.
Installation note:
if necessary, replace faulty plastic nuts for screws (2).
Moisten rubber guide (1) prior to fitting with approved lubricant.
Make sure rubber window seal (1) is correctly seated on
cover (3).

Detach rubber window seal (1) in direction of arrow from front

door (2).
Installation note:
Moisten rubber guide (1) prior to fitting with approved lubricant.
Make sure rubber guide (1) is correctly seated on door window
glass.

Installation note:
Rubber guide (1) must not be damaged in corners (2).
 4/30/2016 2/2

Installation note:
Ensure that the rubber window seal (2) is correctly mounted on
the window frame (3) and the cover is correctly mounted on the
window frame (1).

Installation note:
In the area of the inside mirror, ensure that the rubber window
seal (1) is correctly mounted on the door (2).
 4/30/2016 1/4

41 33 040 Replacing front left or right side wall

holder

Note:
Read contents of Body, General.
Side wall removed.
Transfer the systematic diagram onto the respective holder version.

General information:
Procedure Observe repair stage 2!

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Holder, side wall, front (variant 1)

- (2) Holder, side wall, front (variant 2)

 
Following consumables are required:

Material Quantity

Adhesive K5a 1

Blind rivets N3 2

Cleaning agent R1 1

Removal of side wall holder (variant 1):

Release welded connections in areas (1) and remove

holder (2).
 4/30/2016 2/4

Preparation of new part:

Adjust new part in conjunction with side panel in front to fit.

In area of bonding surfaces (1), set 2 4.2 mm dia. bore holes (2)
for blind rivetsN3.
Remove new part and deburr holes.

Important!
Do not grind bonding surfaces down or off.

Installation of side wall holder:

Clean all bonding surfaces with cleaning agent R1.
Apply adhesive  to bonding surfaces.
Install new part and rivet with blind rivets.

Removal of side wall holder (variant 2):

 4/30/2016 3/4

Release welded connection in area (1) and remove holder (2).

Preparation of new part:

Fit in new part.

In area of adhesive surface (1), drill a 4.2 mm dia. bore hole (2)
for blind rivet N3.
Remove new part and deburr holes.

Important!
Do not grind bonding surfaces down or off.

Installation of side wall holder:

Clean all bonding surfaces with cleaning agent R1.
 4/30/2016 4/4

Apply adhesive to bonding surface.

Install new part and rivet with blind rivet.
 4/30/2016 1/6

37 11 032 Replacing front left or right spring strut

(adaptive M suspension)

Special tools required:

 31 3 340
 31 2 230
 31 3 341
 2 240 516
 2 240 482
 2 240 523
 2 240 487
  2 240 290
 2 240 490
 33 0 040

Important!
- When replacing the spring strut, replace the auxiliary
damper as well!

Warning!
Before using the special tool 31 3 340 take care to read
through the Owner's Handbook!
All the safety information and instructions contained in the
Owner's Handbook must be strictly observed!
Failure to observe these safety precautions and
instructions increases the risk of serious physical injury,
damage to your health and damage to property and
equipment!

Important!
 4/30/2016 2/6

1. Prior to each use, check the special tools for

defects, modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the
special tools!
4. These special tools are intended solely for the
purpose of tightening and relieving cylindrical and
tapered suspension springs.
5. Keep special tools dry, clean and (down to the
spindle) free from grease.
6. Impact screwdrivers are prohibited!
Risk of damage inside the shock absorber!
7. Do not compress coil spring to full extent.

Necessary preliminary tasks:

 Remove front spring strut

Release nut (1), remove holder (2) and remove screw (3).

Tightening torque 31 31 3AZ.
Expand swivel bearing with special tool 31 2 230 and pull off
spring strut.
Installation note:
Keep press fit of swivel bearing and spring strut in lower area
clean and free from oil and grease.
Screw head must point in direction of travel.
Replace self-locking nut.

Installation note:
 4/30/2016 3/6

Expand swivel bearing (1) with special tool 31 2 230. Align

swivel bearing (1) to positioning pin (2) on the rear side of the
spring strut along the gap and slide all the way in.

Clamp special tool 31 3 341 in vice.

Fit special tool 2 240 516 and 2 240 482 onto special tool
31 3 341 until retaining bolt (1) can be felt and heard to snap
into place.
Insert the centring insert 2 240 523 in the round tensioning
plate 2 240 482.
Check seating of special tools 2 240 516 and 2 240 482 with
centring insert2 240 523, correct if necessary.

Installation of "spring brake" onto round tensioning plate:

Move counter support 2 240 486 into the correct position/bore
hole (see Figure A or B)

- Standard suspension: Screw connection using bore holes

1 and 17

- Sport suspension: Screw connection using bore holes 7

and 15
Turn centring insert 2 240 253 until counter support 2 240 486
can be screwed into place at the specified position.
Screw together counter support with round tension plate and
centring insert with screws (1) so they are hand-tight.

Clean coil spring to remove contamination.

Spring must be free of grease, clean and dry.
 
Insert spring strut into spring tensioner.
 4/30/2016 4/6

Warning!
Insert the guide pins (1) of the support bearing must fit into
the recesses on the centring insert 2 240 523.
The support bearing must be completely fitted against the
centring ring 2 240 523.
The lower spring coil must be placed completely into the
recess of special tool 2 240 516!

Attach pressure plate 2 240 487 with the screws 2 240 290!

The gummed side of the pressure plate 2 240 487 must be
fitted against the top spring coil.
Position the spring strut so that the end of the spring (1)
protrudes by 40 mm beyond the pressure plate 2 240 487.
Tighten the screws 2 240 490 evenly at 7 Nm.

Important!
The pressure plate 2 240 487 must be aligned parallel with
the top spring coil (1)!
When the end of the spring begins turning relative to the
pressure plate, stop tensioning immediately.
Check that the pressure plate is correctly seated and
check the rubber mount and pressure plate for wear.

Tension coil spring with spring tensioner 31 3 341 until stress

on piston rod is relieved.

Release nut with special tool 33 0 040.

Remove the spring strut with auxiliary damper.

Impact
screwdrivers
are prohibited!
 4/30/2016 5/6

Risk of
damage inside
the shock
absorber!

Installation note:
Remove the spring pad (1) and mount onto the new spring
strut, replace if necessary.
Replace the auxiliary damper (2).

Insert spring strut into tensioned coil spring.

Important!
Align the lower end of the spring (1) flush with the spring
pad (2).
Check installation position of the protective tube and
correct fold if necessary.

Replace nut and tighten down with special tool 33 0 040.

Tightening torque 31 31 2AZ.
Relieve tension on coil spring and remove spring strut.

Impact
 4/30/2016 6/6

screwdrivers
are prohibited!
Risk of
damage inside
the shock
absorber!

After installation:
 Carry out wheel alignment procedure.
 Use the diagnosis system to perform the wheel speed
accelerator sensor adjustment.
-> see service functions/start-up VDM
 4/30/2016 1/6

31 31 031 Replacing front left or right spring strut

shock absorber

Special tools required:

 31 3 340
 31 2 230
 31 3 341
 2 240 516
 2 240 482
 2 240 523
 2 240 486
 2 240 487
 2 240 490
 33 0 040

Important!
- When replacing the spring strut, replace the auxiliary
damper as well!

Warning!
Before using the special tool 31 3 340 take care to read
through the Owner's Handbook!
All the safety information and instructions contained in the
Owner's Handbook must be strictly observed!
Failure to observe these safety precautions and
instructions increases the risk of serious physical injury,
damage to your health and damage to property and
equipment!

Important!
 4/30/2016 2/6

1. Prior to each use, check the special tools for

defects, modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the
special tools!
4. These special tools are intended solely for the
purpose of tightening and relieving cylindrical and
tapered suspension springs.
5. Keep special tools dry, clean and (down to the
spindle) free from grease.
6. Impact screwdrivers are prohibited!
Risk of damage inside the shock absorber!
7. Do not compress coil spring to full extent.

Necessary preliminary tasks:

 Remove front spring strut.

Slacken nut (1).

Tightening torque 31 31 3AZ.
Take off holder (2).
Pull out screw (3).
Expand swivel bearing with special tool 31 2 230 and pull off
spring strut.
Installation note:
Keep press fit of swivel bearing and spring strut in lower area
clean and free from oil and grease.
Screw head must point in direction of travel.
Replace self-locking nut (1).
 4/30/2016 3/6

Installation note:
Expand swivel bearing (1) with special tool 31 2 230.
Align swivel bearing (1) to positioning pin (2) on the rear side of
the spring strut along the gap and slide all the way in.

Clamp special tool 31 3 341 in vice.

Fit special tool 2 240 516 and 2 240 482 onto special tool
31 3 341 until retaining bolt (1) can be felt and heard to snap
into place.
Insert the centring insert 2 240 523 in the round tensioning
plate 2 240 482.
Check seating of special tools 2 240 516 and 2 240 482 with
centring insert2 240 523, correct if necessary.

Installation of brake onto round tensioning plate:

Move counter support 2 240 486 into the correct position/bore
hole (see Figure A or B)

- Standard suspension: Screw connection using bore holes

1 and 17

- Sport suspension: Screw connection using bore holes 7

and 15
Turn centring insert 2 240 523 until counter support 2 240 486
can be screwed into place at the specified position.
Screw together counter support with round tension plate and
centring insert with screws (1) so they are hand-tight.

Clean coil spring to remove contamination.

Spring must be free of grease, clean and dry.
 
Insert spring strut into spring tensioner.
 4/30/2016 4/6

Warning!
Insert the guide pins (1) of the support bearing must fit into
the recesses on the centring insert 2 240 523.
The support bearing must be completely fitted against the
centring ring 2 240 523.
The lower spring coil must be placed completely into the
recess of special tool 2 240 516!

Attach pressure plate 2 240 487 with the screws2 240 490!
The gummed side of the pressure plate 2 240 487 must be
fitted against the top spring coil.
Position the spring strut so that the end of the spring (1)
protrudes by 40 mm beyond the pressure plate 2 240 487.
Tighten the screws 2 240 490 evenly at 7 Nm.

Important!
The pressure plate 2 240 487 must be aligned parallel with
the top spring coil (1)!
When the end of the spring begins turning relative to the
pressure plate, stop tensioning immediately.
Check that the pressure plate is correctly seated and
check the rubber mount and pressure plate for wear.

Tension coil spring with spring tensioner 31 3 341 until stress

on piston rod is relieved.

Release nut with special tool 33 0 040.

Remove the spring strut with auxiliary damper.
Installation note:
Replace nut.
 4/30/2016 5/6

Impact
screwdrivers
are prohibited!
Risk of
damage inside
the shock
absorber!

Installation note:
Remove the spring pad (1) and mount onto the new spring
strut, replace if necessary.
Replace the auxiliary damper (2).

Insert spring strut into tensioned coil spring.

Important!
Align the lower end of the spring (1) flush with the spring
pad (2).
Check installation position of the protective tube and
correct fold if necessary.

Tighten new nut with special tool 33 0 040.

Tightening torque 31 31 2AZ.
Relieve tension on coil spring.

Impact
 4/30/2016 6/6

screwdrivers
are prohibited!
Risk of
damage inside
the shock
absorber!

After installation:
 Carry out wheel alignment procedure.
 4/30/2016 1/1

31 33 001 Replacing front left or right spring strut

support bearing

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Note:
Procedure is described in the document ”Replacing front left or
right coil spring”.
 4/30/2016 1/13

41 14 020 Replacing front left wheel arch

When replacing front right wheel arch: observe specific

procedure regarding the vehicle identification number. (order
new body part with vehicle identification number if necessary)

Observe procedure of repair stage 3.

Read contents of Body, General.
Strip down vehicle.
Use only approved spot-welding apparatus for repairs.
Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Wheel arch, front

- (2) Extension, wheel arch carrier support

- (3) Shaped part, wheel arch carrier support (not shown)

 
Following consumables are required:

Material Quantity

Adhesive K1 1

Blind rivet N1 8
 4/30/2016 2/13

Blind rivet N7 29

Blind rivet N3 5

Punch rivets N5 12

Sealant D1  

Cleaning agent R1 1

New part preparation

Open welded connections in areas (1).

Centre punch the welded connections in area (2) in the middle
and drill out with a drill diameter of 6.8 mm.
Note:
The new part is joined in areas (2) by adhesive riveting.
The bore holes in areas (2) are required for fitting the blind
rivets.
The new part is joined the areas (1) by plug-welding.

Open welded connections in areas (1).

Centre punch the welded connections in area (2) in the middle
and drill out with a drill diameter of 6.8 mm.
Remove components (3) which are not required.
Note:
New part is attached in area (2) using adhesive riveting
technology.
The bore holes in areas (2) are required for fitting the blind
 4/30/2016 3/13

rivets.
The new part is joined the areas (1) by plug-welding.

Open welded connections in area (1).

Remove component (2) which is not required.
 4/30/2016 4/13

Views of the wheel arch (new part) to be fitted:

- (1) View from outside

- (2) View, engine compartment

Removing the wheel arch

Mark severance cut (1) at component edge and cut.

Mark severance cut (2) as pictured and cut.
Loosen spot-welded adhesive joints in area (3).
Open welded connections in area (4).
 4/30/2016 5/13

Release metal section from cavity sealing (5) and remove.

Remove cavity sealing (5).

Open welded connections in area (1).

 4/30/2016 6/13

Open welded connections in areas (1) and (2).

Open welded connections in areas (1).

Note:
Do not drill into or through the engine support when releasing
the welded connections!

Open welded connections in areas (1).

Remove the wheel arch.
Note:
Do not drill into or through the engine support when releasing
the welded connections!
 4/30/2016 7/13

Fit in new part

Adjust wheel arch new part to fit with alignment bracket or

universal mount and secure.
Areas (1) and (2): Transfer existing 6.8 mm diameter bore
holes for blind rivets to engine support.
In areas (3), prepare new part and vehicle for plug-welding.
 4/30/2016 8/13

In areas (1) and (2), prepare new part and vehicle for plug-welding.

Areas (1): Transfer existing 6.8 mm diameter bore holes for

blind rivets to engine support.
In areas (2), prepare new part and vehicle for plug-welding.

In area (1), prepare new part and vehicle for plug welding.

 4/30/2016 9/13

In area (1), prepare new part and vehicle for plug welding.

Mark and disconnect severance cut on the new part according

to the severance cut on the vehicle + 20 mm added material
(1).

Adjust extension, wheel arch carrier support new part to fit and
secure.
In areas (1) and (2), set 6.8 mm diameter bore holes for blind
rivets.

Area Number
 4/30/2016 10/13

1 3

2 5

In area (3), set 4 4.2 mm diameter bore holes for blind rivets
N3.
Remove new parts and deburr bore holes.

Important!
Structure bonding!
Observe preparation of bonding surfaces.

Installing new part, front wheel arch

Clean bonding surfaces with cleaning agent R1.
Apply adhesive  to bonding surfaces.
Install wheel arch with alignment bracket or universal mount.

In areas (1), rivet new part with blind rivets N1.

In areas (2), rivet new part with blind rivets N7.
In areas (3) weld new part.
 4/30/2016 11/13

In areas (1) and (2), weld new part.

In areas (1), rivet new part with blind rivets N7.

In areas (2) weld new part.

Weld new part in area (1).

 4/30/2016 12/13

Weld new part in area (1).

Installation of extension, wheel arch carrier support

Clean bonding surfaces with cleaning agent R1.
Apply adhesive  to bonding surfaces.
Apply sealant to cavity sealing. Install cavity sealing.
Install extension, wheel arch carrier support.

In areas (1) and (2), rivet new part with blind rivets N7.
In area (3) rivet new part with blind rivets N3.
In areas (4) and (5), rivet new part with punch rivets N5.

Area Number
 4/30/2016 13/13

4 6

5 5
 4/30/2016 1/1

37 14 511 Replacing front ride height sensor

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Slacken nut (1).

Tightening torque 37 14 4AZ.
Detach jointed rod (2).
Disconnect plug connection (3).
Release screws (4).
Tightening torque 37 14 2AZ.
Remove ride height sensor to front.
Installation note:
Replace nut (1).
Sensor lever points in direction of travel starting from ride height
sensor.

After installation:
 Check headlight adjustment, correct if necessary.
 4/29/2016 1/3

18 12 046 Replacing front silencer (N55)

Warning!
Risk of burning!
Only perform this repair work after engine has cooled
down.
Danger of injury!
Removal of the exhaust system must be carried out with
the assistance of a second person.

Necessary preliminary tasks:

 Support front pipe with a suitable jack and secure
against falling down.
 F21 only:
Remove rear trailing link.

Note:
If the separation point is not marked by a punch mark in the
pipe, determine the separation point by means of the pipe
length on the new front pipe.
Carry over separation point to defective front pipe and mark.
Secure front silencer against falling out.
Cut through exhaust pipes at marked point with a suitable tool
and deburr.

Release clamp (1).

Tightening torque 18 31 1AZ.
 4/29/2016 2/3

If fitted:
Release screws (1).
Tightening torque 18 31 3AZ.
Remove reinforcement plate (2).

If fitted:
Release screws (1).
Tightening torque 18 20 4AZ.
Unfasten screws (2).
Tightening torque 18 20 5AZ.

Release screws (1).
Tightening torque 18 20 2AZ.
 4/29/2016 3/3

Installation note:
Adjust new front silencer and connect with clamps.
Align clamping sleeves so that:
 Nuts point downwards.
 Cutting line is in middle of clamping sleeve.
 There is sufficient spacing to adjoining components.
Centre clamp and tighten down.
Tightening torque 18 31 3AZ.

Installation note:
Check rubber mount for damage, replace if necessary.
Check exhaust system for leak tightness.
 4/30/2016 1/1

25 11 081 Replacing gaiter (shift lever cover) for

shift lever

Necessary preliminary tasks:

 Remove shift lever knob.

Release retaining tabs and lift out gaiter.

Installation note:
Retaining lugs must not be damaged.
 4/30/2016 1/2

32 11 100 Replacing gaiter for steering box on left

or right

Important!
The hydraulic steering gear must be replaced if the
polished surface of the rack is damaged (e.g. by
corrosion)!

Necessary preliminary tasks:

 Remove underbody protection
 Remove cover of front steering assemblies (diesel-
engine cars with rear-wheel drive only)
 Remove track rod end

Clean track rod.

Release band clamp (1), ear clamp (1) and band clamp (2).
Detach gaiter from track rod.
Installation note:
Clean rack and check surface for damage (e.g. by corrosion).
Clean track rod and apply grease to taper.

Note:
This ensures that the gaiter is not rotated when the track rod is
rotated.

After installation:
 Perform chassis / wheel alignment check
4/30/2016 2/2
 4/30/2016 1/1

25 11 211 Replacing gearshift arm for gearshift

lever mount

Necessary preliminary tasks:

 Remove gearshift lever.

Detach support bearing (1) from gearshift arm.

Installation note:
Grease bearing journal of gearshift arm.
Grease, refer to BMW Service Operating Fluids.

Push the bearing bushes (1) out.

Coat new bearing bushes with Circolight (sourcing reference:
BMW Parts Department).
Press the bearing bushes (1) into the gearshift arm until the
side faces protrude evenly.
Installation note:
If the bearing bushes are damaged, replace them.
Grease bearing bushes.

Grease, refer to BMW Service Operating Fluids.

 4/30/2016 1/1

25 11 071 Replacing gearshift lever knob

Note:
Do not twist gearshift lever knob during removal as this
would cause the anti-twist lock in the knob to shear off.

Tug firmly to remove gearshift lever knob (1).

Installation note:
Fit gearshift lever knob (1) on shift lever, align and press
on until it snaps noticeably into place.
 4/30/2016 1/2

25 11 101 Replacing gearshift rod

Detach retaining clip.

Important!
Retaining clip must interlock captively with retaining
web (1) behind gearshift rod pin.

Pull gearshift rod (1) out of gearshift rod joint (2).

Installation note:
Grease gearshift rod pin (3).
Grease, refer to BMW Service Operating Fluids.

Detach retaining clip (1).

Remove gearshift rod (2).
Installation note:
 4/30/2016 2/2

Grease gearshift rod pin.

Grease, refer to BMW Service Operating Fluids.
 4/30/2016 1/2

26 12 011 Replacing grooved ball bearing in

propeller shaft centre bearing

Special tools required:

 23 1 160
 33 3 202
 33 3 203

Necessary preliminary tasks:

 Replace propeller shaft centre bearing

Press grooved ball bearing using special tool  23 1 160 out of

centre mount (1).
Note:
Illustration shows E46.

Coat rubber-coated bearing seat of centre mount (2) with

Circolight.
Circolight, refer to BMW Parts Department.
Use special tools  33 3 202/ 33 3 203 to press grooved ball
 4/30/2016 2/2

bearing (1) into centre mount (2).

Note:
Illustration shows E46.
 4/30/2016 1/1

23 11 617 Replacing guide sleeve for clutch

operator (GS6-45BZ/DZ)

Necessary preliminary tasks:

 Remove transmission.
 Remove clutch operator and release lever from
guide tube.

Release screws (1).
Tightening torque: 23 11 2AZ.
Remove guide tube (2).
Installation note:
Replace screws (1).

Installation note:
Remove all traces of label (1) and adhesive from guide
tube using suitable solvent.
 4/30/2016 1/1

52 13 ... Replacing guide sleeves for front left or

right head restraint

Necessary preliminary tasks:

 Remove front head restraint

Note:
Shown here without backrest cover for a better overview.

Push the backrest cover with upholstery down next to the guide
sleeve.
Carefully insert screwdriver between the backrest cover and
guide sleeve.
Unlock the retaining lug with a screwdriver and remove the
guide sleeves through the top.

Installation note:
Install guide sleeves as follows:
1. Guide sleeve with pushbutton (3) in direction of travel left
2. Guide sleeve without pushbutton in direction of travel
right
 4/30/2016 1/2

63 99 072 Replacing halogen bulb for headlight on

left

Warning!
Follow instructions for handling light bulbs (exterior lights).

Unlock and remove cover (1).

Turn protective cap (1) in anti-clockwise direction and remove

from headlight (2).
Important!
Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must lock correctly!
Twist protective cap (1) clockwise up to limit position!

Turn bulb holder (1) counterclockwise and pull out of headlight.

 
Installation note:
Make sure retaining tabs (2) in headlight are correctly seated.
 4/30/2016 2/2

Detach bulb (1) from bulb holder (2).

Installation note:
Note bulb type.
 
Recommendation:
Check headlight adjustment, correct if necessary.
 4/30/2016 1/2

63 99 002 Replacing halogen bulb for high beam

headlight on left

Warning!
Follow instructions for handling light bulbs (exterior lights).

Turn protective cap (1) in direction of arrow and remove in

upward direction.
Important!
Risk of damage due to moisture penetration!

Installation note:
Seal in protective cap (1) must not be missing or damaged.
Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must be correctly engaged.

Turn bulb holder (1) in direction of arrow and pull towards rear

out of headlight.
Installation note:
Make sure retaining tabs (2) in headlight are correctly seated.

Detach bulb (1) from bulb holder (2).

Installation note:
 4/30/2016 2/2

Note bulb type.

 4/30/2016 1/1

63 99 210 Replacing halogen bulb for left fog light

Warning!
Follow instructions for handling light bulbs (exterior lights).

Necessary preliminary tasks:

 Remove ornamental grille in bumper trim (lateral)

Note:
Wheel arch panel is shown removed for purposes of clarity.

Unfasten plug connection (1) and disconnect.

Turn bulb holder (2) in direction of arrow and remove from fog
light (3).
Installation note:
Note bulb type.
 4/30/2016 1/1

63 99 211 Replacing halogen bulb for right fog light

Warning!
Follow notes for handling light bulbs (exterior lights).

Necessary preliminary tasks:

For version with additional wheel arch radiator:
 Partially remove front wheel arch cover
All other versions:
 Remove ornamental grille in bumper panel towards
the side

Note:
Wheel arch panel is shown removed for purposes of clarity.

Unfasten plug connection (1) and disconnect.

Turn bulb holder (2) in direction of arrow and remove from fog
light (3).
Installation note:
Note bulb type.
 4/30/2016 1/1

34 41 071 Replacing handle for handbrake lever

Necessary preliminary tasks:

 Remove gaiter for handbrake lever

Pull off handle for handbrake lever (1) in direction of arrow.

Installation note:
Handbrake lever grip (1) must snap audibly into place.
 4/30/2016 1/2

64 11 208 Replacing heat exchanger

Special tools required:

 00 9 030

Necessary preliminary tasks:

 Remove heater

Slide rubber grommet (3) with foam seal forward slightly.

Release screw (4).
Carefully open holder (2) and feed out pipes(1) past rubber
grommet (3).
Installation note:
If necessary, replace rubber grommet (3) and/or foam seal.
Make sure rubber grommet (3) is fitted correctly on line clip (2).

Release screws (1).
Unlock plug connection (4) and disconnect.
Remove actuator drive (2).
Installation note:
Make sure actuator drive (2) is correctly seated in guide (3).

Release screws (1).
Remove housing (2).
 4/30/2016 2/2

Loosen clasp (1).

Remove pipes (2).
Installation note:
Replace clasps (1) and sealing rings.
Use special tool 00 9 030 to install sealing rings without
damaging them.

Release screw (1).
Unlock heater (2) at marked points and pull out toward the front.
Installation note:
Make sure the heater (2) is correctly latched at the marked
points.
 4/29/2016 1/3

12 13 511 Replacing ignition coils (N55)

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Check stored fault messages and process procedure.
 Switch off ignition
 Remove ignition coil cover.
 Remove sound insulation bulkhead upper part, centre.
 Remove rear ignition coil cover.

Important!
Ignition coils must not be contaminated by fuel.
The resistance of the silicone material is reduced
significantly by contact with fuel, which may cause the
ignition coil to fail!
The silicone tube of the spark plug connector is coated
with talc to reduce the pulling forces. The silicone tube
must NOT be oiled or greased. This would greatly reduce
the durability of the silicone material, which can lead to a
malfunction of the ignition coil.

Release oxygen sensor connector (1) from bracket.

Release screw (2).
Put cable clip aside.

Unlock plug catch (1) of ignition coil (2) and disconnect plug.

Pull out the ignition coil (2) slowly in a smooth upwards
movement.
 4/29/2016 2/3

Note: There is a possibility that the silicone tube will tear and
therefore be destroyed.
This procedure is applicable to all ignition coils.

Installation note:
Position the ignition coil and gently push it to the limit position, if
necessary by twisting it back and forth slightly. Then check anti-
twist lock.
The rubber cap must completely surround the sealing collar of
the cylinder head cover.
Note: If rubber parts are squashed, the ignition coil can slip out
again during engine operation.
Push connector (1) with connector catch (2) open onto ignition
coil.
Carefully close connector catch (2) in direction of arrow.
The connector catch must snap into place without great effort.
The connector must be positioned on the counter piece with
hardly any gaps when the locking lever is being closed. In the
process, the cheeks of the lever are positioned inside the
counter piece.
Note: The locking lever can become deformed if it is not
installed correctly. This means that there is no longer a safety
lock on the plug connection. As a result, the connector can slip
out during engine operation (loose contact, misfiring).

Note:
Delete fault memory.
Assemble engine.
4/29/2016 3/3
 4/30/2016 1/2

63 12 870 Replacing ignition unit for left xenon

headlight

Warning!
Version with xenon headlights: Danger to life due to high
voltage! Therefore disconnect all components from voltage
supply before removal.
Work on the entire xenon lighting system (ignition device,
control unit and bulb) may only be carried out by qualified
personnel.
Follow instructions for handling light bulbs (exterior lights).

Unlock and remove cover (1).

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.
 

Turn protective cap (1) to the left and remove.

Important!
Risk of damage due to moisture penetration!
Installation note:
Check seal. Replace protective cap (1) if necessary.
Comply with Instructions for replacing the protective cap.
Protective cap (1) must lock correctly!
Turn the protective cap (1) to the right to end stop (A)!
 4/30/2016 2/2

Disconnect plug connection (1) on ignition device with bulb (2).

Remove ignition device with bulb (2) in direction of arrow.

Recommendation:
Check headlight adjustment, correct if necessary.
 4/30/2016 1/1

51 45 031 Replacing instrument panel trim

Necessary preliminary tasks:

 Remove Central Information Display
 Remove instrument panel trim
 Modify light operating facility.
 Modify fresh air grille

Press gap cover (2) of steering column at left and right slightly
inward in direction of arrow and lever out at top, then remove
completely.

Modify passenger's side airbag module (1).

Modify air ducts (2).
If necessary, replace and modify faulty retaining elements (3).
If necessary, modify other retaining elements that are not
included with the new part.
 4/30/2016 1/1

63 31 182 Replacing LED for front inside door

opener (left or right)

Necessary preliminary tasks:

 Remove front door trim panel

Note:
Work shown on the F20 by way of example,deviations in detail
are possible in other models.

Release catches (1).
Remove fibre-optic conductor (2) in direction of arrow out from
door opener (3).
Installation note:
Make sure that the fibre-optic conductor (2) latches correctly in
door opener (3).
Latch mechanisms (1) must not be damaged or missing.
 4/30/2016 1/1

63 31 193 Replacing LED for rear inside door

opener (left or right)

Necessary preliminary tasks:

 Remove rear door trim panel

Note:
Work shown on the F20 by way of example,deviations in detail
are possible in other models.

Release catches (1).
Remove optical fibre (2) in direction of arrow from door opener
(3).
Installation note:
Make sure that the fibre-optic conductor (2) latches correctly in
door opener (3).
Latch mechanisms (1) must not be damaged or missing.
 4/30/2016 1/4

31 21 090 Replacing left / right swivel bearing

Special tools required:

 31 2 230

Note:
When replacing swivel bearing pay attention to camber
correction swivel bearings.
Camber correction swivel bearing are used to correct the
camber values by ±30 minutes. To be used only if the camber
tolerance values are exceeded and undershot.
Important!
On the M135i and M235i the camber correction of -30 min for
the swivel bearing is standard status for production vehicles.
Identification is made at the part number on swivel bearing.

Necessary preliminary tasks:

 Remove brake disc.
 Remove pulse sensor from swivel bearing.

Important!
Prior to installation, check sensor head and cable from
pulse sensor and renew if necessary.

Only on ride-height sensor at left:

Release link at wishbone.
 4/30/2016 2/4

Slacken wishbone bolt connection on front axle support in order

to prevent wishbone rubber mount from being damaged.
Remove wishbone from swivel bearing.
Remove track rod end from swivel bearing.
Remove tension strut from swivel bearing

Support swivel bearing with workshop jack and suitable fixture.

Slacken nut (1).
Tightening torque 31 31 3AZ.
Take off holder (2).
Pull out screw.
Installation note:
Replace nut (1).
Bolt head points in direction of travel.

Expand swivel bearing with special tool 31 2 230.

Lower workshop jack and remove swivel bearing.
Installation note:
Keep press fit of swivel bearing and spring strut in lower area
clean and free from oil and grease.
 4/30/2016 3/4

Installation note:
Expand swivel bearing with special tool 31 2 230.
Alight gap on swivel bearing (1) to positioning pin (2) on spring
strut.
Slide on swivel bearing to limit position.

 Remount wheel bearing or replace if necessary.

 Remount brake guard plate or replace if necessary.

After installation:
 Carry out wheel alignment procedure.
4/30/2016 4/4
 4/30/2016 1/1

22 11 011 Replacing left engine mount (N55)

Necessary preliminary tasks:

 Remove engine support arm.

Release screws (1).
Tightening torque 22 11 1AZ.
Remove engine mount.

Installation note:
Rubber part (1) of engine mount must point to centre of vehicle.
 4/30/2016 1/1

22 11 011 Replacing left engine mount (N55)

Necessary preliminary work:

 Remove engine support arm.

Installation note:
Rubber part (1) of engine mount must point to centre of vehicle.
 4/30/2016 1/1

22 11 110 Replacing left engine support arm (N55)

Necessary preliminary work:

- Remove left charge air duct.

- Remove alternator drive belt.

- Secure engine in installation position.

Note:
In order to remove the alternator, it is necessary to remove the
air-conditioning compressor for the air conditioning system.
In so doing:

- Do not draw off air conditioning refrigerant.

- Do not detach refrigerant lines from A/C compressor.

- Do not remove A/C compressor; instead, remove from

bracket only and place to one side.
Remove A/C compressor from bracket.

Slacken nut (4).

Tightening torque 22 11 2AZ.
Unfasten screws (2).
Release screw (3).
Tightening torque 22 11 6AZ.
Release screw (1).
Remove engine support arm.
Tightening torque 22 11 3AZ.
 4/30/2016 1/1

22 11 110 Replacing left engine support arm (N55)

Necessary preliminary tasks:

- Remove left charge air duct.

- Secure engine in installation position.

Slacken nut (4).

Tightening torque 22 11 2AZ.
Unfasten screws (2).
Release screw (3).
Tightening torque 22 11 6AZ.
Release screw (1).
Remove engine support arm.
Tightening torque 22 11 3AZ.
 4/30/2016 1/5

51 34 191 Replacing left or right fixed door window

in rear window frame

Special tools required:

 51 3 220

Important!
The following notes form the basis for these repair
instructions and must be adhered to at all times:
 Notes on window bonding
 General procedure to dismantle / install bonded
window glass

Note:
Removal is carried out with wire pull handles.

The following new parts / consumables are required (sourcing

reference BMW Parts Department).

Material Quantity

Side window 1

Small repair kit 1

Cutting wire 1

Necessary preliminary tasks:

 Remove cover for window guide
 Remove rubber window seal for door window in area
of fixed door window.

To avoid damage, the door must be taped off with yellow plastic
adhesive tape in area (1 and 2).
(1) Outer
(2) Inside and outside
 4/30/2016 2/5

Slide cutting wire (1) through adhesive bead above latch

mechanism (2).
Sever adhesive bead in direction of arrow up to area (A), pulling
outward.
Note:
Dashed line (1) represents the cutting wire on the inside of the
door.

Lay the cutting wire (1) at the top behind the PVC coating (2)
and feed it in behind the spacer (3) if possible.
Sever the adhesive bead up to area (A), pulling from the inside
only.
Note:
Dashed line (1) represents the cutting wire on the inside of the
door.

Lay cutting wire (1) at the bottom behind PVC coating (2) and
press underneath spacer (3).
Sever remaining adhesive bead and remove door window.
 4/30/2016 3/5

Replace faulty clamps (1).

Remove remnants frame in the areas (2).

Overview for taping of door window ()

 4/30/2016 4/5

Position (1) corresponds to bead joint.

Cut A - A

a [mm] = Position adhesive bead 1 +1 / along frame contour

b [mm] = Width adhesive bead 8 ±1

h [mm] = Height adhesive bead 15 ±2

Important!
In the marked area, the adhesive bead does not follow the contour of the frame.

F20 F30/F35/F80

a1 6 +1 mm 2 +1 mm

a2 8 +1 mm 4 +1 mm

Carefully insert door window (1) with special tool 51 3 220 at

bottom first, align sideways and insert latch mechanisms (2) in
mountings (3).
 4/30/2016 5/5

Assemble the door immediately after installation of the door

window.
 4/30/2016 1/1

54 12 015 Replacing left or right gaiter for glass

slide/tilt sunroof

Important!
Handle the gaiter with extreme care throughout the entire
procedure.
Soft component is highly susceptible to tearing and
kinking.
Grip the gaiter by its attachment strip and do not pull on
the rubber (risk of damage!).

Move glass slide/tilt sunroof into vent position.

I. Carefully detach gaiter (1) at top from guide.
II. Twist gaiter (1) out of lower guide.
Installation note:
Check that attachment strips are firmly seated on guides.
 4/30/2016 1/1

33 33 001 Replacing left or right rear axle support

compression strut

Important!
Observe safety instructions for raising the vehicle
Driving without compression struts is not permitted!
 
Risk of damage!
The rear axle support must be supported at the front if
both compression struts need to be replaced.

Necessary preliminary work:

 Remove tank cover.

Release screws (1).
Tightening torque 33 33 2AZ.
Installation note:
Replace screws.
 

Release screw (2) and remove compression strut.

Tightening torque 33 33 1AZ.
Installation note:
Check threads for damage; if necessary, repair with Helicoil
thread inserts.
 4/30/2016 1/2

32 21 151 Replacing left or right track rod end

Note:
If the track rod end to track rod screw connection is released, it
is necessary after reinstallation to carry out a wheel alignment
check.

Necessary preliminary tasks:

 Remove front wheel

Important!
Do not release track rod end from swivel bearing with
impact tool.
Rubber boot of track rod end must not be damaged!

Release nut (1), if necessary, grip at inner Torx socket.

Remove track rod end (2) from swivel bearing.
Installation note:
Keep track rod end to swivel bearing connection clean and free
 4/30/2016 2/2

from oil and grease.

Replace self-locking nut.
Tightening torque 32 21 3AZ.

Determine dimension (A) to simplify following adjustment of

front axle.
Slacken bolt (1).
Screw off track rod end; if necessary, grip track rod with open-
end spanner.
Installation note:
Check gaiter for damage, replace if necessary.
Screw track rod end onto track rod to dimension (A).
Tightening torque 32 21 2AZ.

After installation:
 Perform chassis / wheel alignment check
 4/30/2016 1/1

33 32 021 Replacing left or right trailing arm

Important!
- The trailing arm must be installed with the opening
(U-section) facing downward!

Unscrew nuts (1).

Tightening torque 33 32 1AZ.
Move screw toward the rear.
Installation note:
Note direction of insertion of bolts.
Replace nut.
Tighten down screw connection in normal position.
 
Slacken nut (2).

Tightening torque 33 32 2AZ.

Move screws toward the rear.
Remove trailing arm (3) downward.
Installation note:
The trailing arm must be installed with the opening (U-section)
facing downward!
Note direction of insertion of screw.
Replace nut.
Tighten down screw connection in normal position.
 4/30/2016 1/6

33 41 151 Replacing left or right wheel bearing on

rear axle shaft

Necessary preliminary tasks:

 Remove output shaft.
 Remove drive flange for rear axle shaft.
 Detach wheel bearing inner ring from drive flange.

Press circlip (1) together using pliers (2) and remove.

Installation note:
Install retaining ring (1).
Check circlip (1) fit and correct if necessary.

Use special tool, see BMW Workshop Catalogue.

 

- Hydraulic unit - 81 64 2 155 744

- Adapter kit 1 -  81 64 2 155 745

- Adapter kit 2 -  81 64 2 155 746

- Adapter - 81 64 2 318 661

The following work steps describe the removal of the wheel bearing:
 4/30/2016 2/6

The following tools are required to pull the wheel bearing out of the wheel carrier; see graphic for arrangement:
Vehicle components:

I Drive flange hub

II Wheel carrier

Required components for all models and types:

E1 Holding sleeveM24

1 Hydraulic unit

F1 Spindle M24 (length 425 mm)

A1 Device

E2 AdapterM24

* Components specific to model and type:

Note:
Two variants of the wheel bearing are installed.
 4/30/2016 3/6

Wheel bearing with inner diameter 42 mm

N3 Adapter diameter 42 mm

M5 Adapter diameter 90 mm

or

Wheel bearing with inner diameter 45 mm

N2 Adapter diameter 45 mm

M3 Adapter diameter 102 mm

Important!
Do not reuse previously installed wheel bearing!
The black multi-pole gasket (1) must point towards the
centre of the vehicle!

The following work steps describe the insertion of the wheel bearing:
 4/30/2016 4/6

The following tools are required to insert the wheel bearing into the wheel carrier; see graphic for arrangement:
Vehicle components:

I Wheel bearing

II Wheel carrier

Required components for all models and types:

E1 Holding sleeveM24

1 Hydraulic unit

F1 Spindle M24 (length 425 mm)

* Components specific to model and type:

Note:
Two variants of the wheel bearing are installed.

Wheel bearing with inner diameter 42 mm

P4 Adapter diameter 42 / 75 mm

 4/30/2016 5/6

R4 Adapter M24 Ø 64/75 mm

or

Wheel bearing with inner diameter 45 mm

P5 Adapter ∅ 45/84 mm

R6 Adapter M24 ∅ 63/75 mm

Mount adapter 81 64 2 318 661 to hydraulic unit using torque wrench (see graphic).
Set torque wrench to 20 Nm.
Move wheel bearing in using hydraulic tool until the torque wrench activates.

After installation:
 Adjust parking brake.
4/30/2016 6/6
 4/30/2016 1/2

37 14 605 Replacing left or right wheel speed

accelerator sensor

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Disconnect plug connection (1) from acceleration sensor on the

spring strut.
Release screw (1).
Tightening torque 37 14 8AZ.
Remove sensor.

Installation note:
Check installation position.
Fit wheel speed acceleration sensor with retaining pin (1) into
bore hole on the spring strut holder!

After installation:
 Use the diagnosis system to perform the wheel speed
accelerator sensor adjustment.
 4/30/2016 2/2

-> see service functions/start-up VDM

 4/30/2016 1/1

63 99 437 Replacing light bulb for footwell light

Warning!
Follow instructions for handling light bulbs (interior lights).

Necessary preliminary tasks:

 Remove footwell light

Turn bulb holder (1) in direction of arrow and pull out of footwell

light (2).
 
Installation note:
Make sure bulb holder (1) is correctly seated and latched on
footwell light (2).

Pull bulb (1) in direction of arrow out of bulb holder (2).

Installation note:
Note bulb type.
Note:
LED technology lights can only be replaced completely!
 4/30/2016 1/3

63 99 451 Replacing light bulb for luggage

compartment lighting

Warning!
Follow instructions for handling light bulbs (interior lights).

Necessary preliminary tasks:

 Remove luggage compartment light

Version A:
Move headlight lens cover (1) in direction of arrow and remove.
Remove festoon (2) underneath.
Installation note:
Note bulb type.

Version B:
Turn bulb holder (1) in direction of arrow and pull out of light (2).
Installation note:
Make sure bulb holder (1) is correctly seated and engaged in
light (2).

Remove bulb (1) from bulb holder (2) in direction of arrow.

Installation note:
Note bulb type.
 4/30/2016 2/3

Version C:
Release headlight lens cover (1) at latch mechanisms (2) on
both sides.
Remove headlight lens cover (1) from luggage compartment
light (3) in direction of arrow.

Push bulb (1) out of socket with a suitable tool (e.g. screwdriver

3 mm blade) in direction of arrow and remove.
Installation note:
Note bulb type.

Check headlight lens cover (1) before fitting.

If necessary, carefully press together both side tabs a little in
direction of arrow.
4/30/2016 3/3
 4/30/2016 1/8

41 12 700 Replacing luggage compartment floor

and side member on left (left side wall
and tail panel removed)

Read contents of Body, General.

Strip down vehicle
Place vehicle on straightening bench.

Observe procedure of repair stage 3.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Luggage compartment well

- (2) Luggage compartment floor, rear

- (3) Luggage compartment well, left

- (4) Frame side member, top left

- (5) Side member, bottom left

- (6) Luggage compartment floor, left section

Following consumables are required:
 4/30/2016 2/8

Material Quantity

Adhesive K5a 2

Blind rivet N3 17

Blind rivet N6 6

EMC screws 7

Cleaning agent R1 1

Sealant D1  

Removal of side member and luggage compartment floor:

Open welded connections in area (1).

Open welded connections in area (1).

 4/30/2016 3/8

Mark severance cut (1) next to reinforcement (2) and

disconnect.
Open welded connections in area (3).

Open welded connections in area (1).

Open welded connections in area (1).

Remove the luggage compartment floor.
 4/30/2016 4/8

Mark and cut severance cut (1) through Ø 20 mm hole.

Cut side member.
 
Mark severance cut (2) through elongated hole for MAG weld seam and cut.
Important!
Cut outer panel only.
Open welded connections in areas (3).
Remove side member.

New part preparation

 4/30/2016 5/8

Mark severance cuts on side members in accordance with

severance cuts on vehicle and cut.
Loosen component not required (cross member) from luggage
compartment well.
For all severance cuts on side members, prepare reinforcement
plates.

Mark severance cut at luggage compartment floor in

accordance with severance cut on vehicle + 15 mm extra
material and cut (1).
Create three 4.2 mm dia. bore holes in area (2).
Adjust new parts with alignment bracket or universal mount and
in conjunction with side wall and tail panel and secure.

In areas (1) to (3), set ∅ 4.2 mm bore holes for blind rivets N3.

Area Number

1 2

2 2

3 3

If necessary, mark bore holes in area (3) on body and create

after removal of new part.
Note:
Side wall and tail panel have been hidden for clarity.

In areas (1) and (2), set ∅ 4.2 mm bore holes for blind rivets.

 4/30/2016 6/8

Area Number Rivet type

1 3 each Blind rivet N6

2 7 Blind rivet N3

Remove new parts and deburr bore holes.

Important!
Do not grind new parts and body in area of bonding
surfaces.

Installation of side member and luggage compartment well:

Install new parts and reinforcement plates with alignment
bracket or universal mount and weld analogue to series
standard:
(1) Extension, bottom side member
(2) Extension, top side member
(3) Luggage compartment well, left
(4) Luggage compartment well

Installation of rear luggage compartment floor and left luggage

compartment floor:
Clean all bonding surfaces with cleaning agent R1.
Apply adhesive to bonding surfaces.
Install new part and rivet with blind rivets .
When installing the new part, make sure that all bonding
 4/30/2016 7/8

surfaces have sufficient adhesive.

After hardening of the adhesive install 4 EMC screws in the

areas shown (1).

In area (1) install one EMC screw.

In area (1) install two EMC screws.

4/30/2016 8/8
 4/30/2016 1/5

41 12 653 Replacing luggage compartment floor,

left section (rear side panel and tail
panel removed)

Read contents of Body, General.

Procedure Observe repair stage 2!
Strip down vehicle

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Luggage compartment floor, left section

 
Following consumables are required:

Material Quantity

Adhesive K5a 1

Blind rivet N3 7

EMC screws 3

Cleaning agent R1 1

Sealant D1  

Removal of luggage compartment floor

 4/30/2016 2/5

Mark severance cut (1) next to reinforcement (2) and

disconnect.
Open welded connections in area (3).

Open welded connections in area (1).

Open welded connections in area (1).

Remove the luggage compartment floor.
 4/30/2016 3/5

New part preparation

Mark severance cut at luggage compartment floor in

accordance with severance cut on vehicle + 15 mm extra
material and cut (1).
Create three 4.2 mm dia. bore holes in area (2).

Adjust luggage compartment floor in combination with side

panel and tail panel to fit and secure.
In areas (1) to (3), create 4.2 mm dia. bore holes.

Area Number
 4/30/2016 4/5

1 2

2 2

3 3

If necessary, mark bore holes in area (3) on body and create

after removal of new part.
Remove new parts and deburr bore holes.
Note:
Side wall and tail panel have been hidden for clarity.

Important!
Do not grind new part and body in area of bonding
surfaces.

Installation of luggage compartment floor

Clean all bonding surfaces on new part and on vehicle with
cleaning agent R1.
Apply adhesive on all bonding and riveting surfaces.
Install new part and rivet with blind rivets .
When installing the new part, make sure that all bonding
surfaces have sufficient adhesive.

Fit an EMC screw after adhesive has hardened in area (1).

 4/30/2016 5/5

In areas (2), use two EMC screws.

 4/30/2016 1/2

64 31 011 Replacing microfilter for interior

ventilation

Important!
Risk of damage!
A/C system must not be operated without the prescribed
filter element.

Note on cleaning:
Spray microfilter housing from inside with BMW pollen filter
housing cleaner* (observe instructions for use).
Comply with notes and instructions on handling cleaning
agents !
Wipe away excess fluid.
This kills off germs, bacteria and fungi that cause smells.
The smell that results on the plastic parts of the microfilter
housing is eliminated.
* Sourcing reference: BMW Parts Department

Necessary preliminary tasks:

 Remove bottom right dashboard trim panel

Release screws (1).
Release latch mechanisms at marked points.
Partially remove the cover (2).

Remove the microfilter (1) from the filter housing (2) in direction

of arrow.
Installation note:
 4/30/2016 2/2

Make sure microfilter (1) is correctly fitted.

 4/29/2016 1/2

64 31 011 Replacing microfilter for interior

ventilation

Important!
Risk of damage!
A/C system must not be operated without the prescribed
filter element.

Note on cleaning:
Spray microfilter housing from inside with BMW pollen filter
housing cleaner* (observe instructions for use).
Comply with notes and instructions on handling cleaning
agents !
Wipe away excess fluid.
This kills off germs, bacteria and fungi that cause smells.
The smell that results on the plastic parts of the microfilter
housing is eliminated.
* Sourcing reference: BMW Parts Department

Necessary preliminary tasks:

 Remove bottom right dashboard trim panel

Release screws (1).
Release latch mechanisms at marked points.
Partially remove the cover (2).

Remove the microfilter (1) from the filter housing (2) in direction

of arrow.
Installation note:
 4/29/2016 2/2

Make sure microfilter (1) is correctly fitted.

 4/30/2016 1/4

41 12 557 Replacing middle luggage compartment

floor (tail panel has been removed)

Read contents of Body, General.

Observe procedure of repair stage 3.
Strip down vehicle

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Luggage compartment floor, rear

- (2) Luggage compartment well

- (3) Luggage compartment well, left

- (4) Luggage compartment well, right

 
Following consumables are required:

Material Quantity

Adhesive K5a 1

Blind rivets N3 7

Blind rivets N6 6

EMC screws 4

Cleaning agent R1 1

Sealant D1  

Removal of luggage compartment floor, middle

 4/30/2016 2/4

Operation is described on the left side. Right side identical.

Open welded connections in area (1) and remove luggage
compartment floor.

New part preparation luggage compartment well

Loosen component not required (cross member) from luggage
compartment well.
Adjust new part in conjunction with luggage compartment floor
and secure.

Installation of luggage compartment well

Install new parts and weld the same as series
(1) Luggage compartment well, left
(2) Luggage compartment well
(3) Luggage compartment well, right
 4/30/2016 3/4

New part preparation luggage compartment floor, rear

Adjust new part in conjunction with tail panel and secure

In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets.

Area Number Rivet type

1 3 each Blind rivet N6

2 7 Blind rivet N3

Remove new parts and deburr bore holes.

Important!
Do not grind new part and body in area of bonding
surfaces.
 4/30/2016 4/4

Installation of luggage compartment floor, rear

Clean all bonding surfaces with cleaning agent R1.
Apply adhesive to bonding surfaces.
Install new part and rivet with blind rivets.

After hardening of the adhesive install 4 EMC screws in areas

(1).
 4/30/2016 1/2

51 16 026 Replacing mirror glass

Special tools required:

 00 9 327

Warning!
Danger of injury!
Move mirror glass with hand carefully and slowly.
If mirror glass is damaged:
Wear protective goggles and cut-proof gloves.
Danger of injury by flaking-off glass splinters.

Important!
Risk of damage!
Bring exterior mirror to room temperature to prevent latch
mechanisms from breaking off.

Important!
Risk of damage!
Secure mirror glass (1) against falling out.

Press mirror glass (1) on side vehicle by hand to full extent.

Starting on the outside, unclip mirror glass (1) around all sides
with special tool 00 9 327.
 4/30/2016 2/2

Unlock and disconnect associated plug connections (2).

Remove the mirror glass (1).

Installation note:
Retaining lugs (1) must not be damaged.
Fit mirror glass (2) with retaining lugs (1) flush on mirror
adjusting drive and clip into place.
Ensure correct locking.
Make sure mirror adjusting drive functions correctly.
 4/30/2016 1/2

51 14 111 Replacing model name plate, rear

Note:
This document describes a general procedure for replacement
and new bonding of model designations/lettering using the 335i
(F30) as an example.
The procedure can be used for all models, positions and
installation locations.
The model designation is attached with adhesive and can not
be reused.
 
Refer to instructions for securing components with adhesive
tape!

Consumables:

Cutting cord

Masking tape 19 mm or 30 mm

Yellow plastic adhesive tape

Eraser disk

Cleaning agent R2

Replacing model designation:

Mark position of model designation (1) with yellow plastic
adhesive tape (2).
Coat separating string or strong yarn with tensides (e.g.
washing-up liquid).
Cut through adhesive layer and remove model designation (1).
Refer to "Installation" operation for further procedure.

Replacing model designation (new or newly painted tailgate):

 4/30/2016 2/2

Note:
Transfer position of model designation (1) from old tailgate by
making an adhesive tape template.
For paintwork, keep adhesive tape template up to installation.

Stick masking tape (2) to nearby reference edges of tailgate

and therefore determine position of model designation (1).
Pull off masking tape (2) completely and stick to same
reference edges of new/painted tailgate.
Check position, realign if required.
Refer to "Installation" operation for further procedure.

Assembly:
If required, remove adhesive layer residues with grinding wheel
and/or cleaning agent R2.
Clean the adhesive area.
Number and letter combinations (1) of the model designation
are not connected to each other and are supplied on a backing
film (2).
Remove liner (3) (protective film for bonding surface).
Place model designation at marked position and press down
firmly.
Remove backing film (2) and template.
 
 4/29/2016 1/3

11 78 610 Replacing monitoring sensor (N55)

Special tools required:

 11 7 030
 11 9 150

Warning!
Risk of burning!
Work should only be carried out on an exhaust system
that has cooled down.

Necessary preliminary tasks:

 Remove rear ignition coil cover.
 Remove the catalytic converter.

Installation note:
The threads of new monitoring sensors are already coated with
NEVER-SEEZ compound (refer to BMW Parts Service).
If a monitoring sensor is to be reused, apply a thin and even
 4/29/2016 2/3

coating of NEVER-SEEZ compound to the thread only.

The part of the monitoring sensor which projects into the
exhaust branch (sensor ceramics) must not be cleaned and not
coated with lubricant.

Disconnect plug connection of monitoring sensor (1).

Installation note:
Cable colour of control sensor = black.
Cable colour of monitoring sensor = grey.

Remove monitoring sensor.

Tightening torque 11 78 2AZ.

Reassemble the vehicle.

Check function of DME.
4/29/2016 3/3
 4/30/2016 1/1

61 12 013 Replacing negative battery lead

Warning!
Observe safety informations for handling vehicle battery.
Read and comply with notes and notes on intelligent
battery sensor.

Necessary preliminary tasks:

 Remove luggage compartment storage
compartment

Slacken nut (1) on negative battery terminal.

Tightening torque 61 21 1AZ.
 
Important!
Do not under any circumstances use force to pull off
negative terminal.

Detach battery earth lead with intelligent battery sensor (IBS) in

upward direction, lay to one side and secure.
Disconnect plug connection (2).
Release nut (3) and battery earth lead (4).
Tightening torque 61 21 6AZ.
 4/30/2016 1/1

34 52 525 Replacing one front pulse sensor

Necessary preliminary tasks:

 Remove front wheel.
 Read and comply with General Information.

Open connector housing (1), pull plug connection out of holder

and disconnect.
Disengage cable with rubber grommets from holders (2).
Installation note:
Ensure proper locking of plug connection and proper seating of
rubber grommets.

Release hexagon socket screw (1) and pull wheel speed

sensor (2) out of bore hole.
Installation note:
Tightening torque 34 51 3AZ.
Clean bore for pulse sensor and lubricate with Staburags NBU
12/K grease.

Important!
Check sensor head prior to installation for external
damage, replacing if necessary.
 4/30/2016 1/3

33 32 071 Replacing one upper wishbone

Note:
If the wishbone is detached from the rear axle support, it is
necessary after reinstallation to carry out a chassis / wheel
alignment check.

Necessary preliminary tasks:

 Remove rear wheel.

Open clamps and remove cable clip (1).

Installation note:
Replace faulty cable clips.

Release screw (1).
Installation note:
Replace screw.
Observe installation sequence at the end of document!
 4/30/2016 2/3

Release nut (1) and remove screw towards front.

Installation note:
Observe installation sequence at the end of document!
Bolt head points in direction of travel.
Replace self-locking nut.

Important!
Make sure during installation that in the connection area to
the wheel carrier the tapered end of the bearing bushing
(of the rubber mount) points in the direction of the wheel
carrier.

Important!
You must observe the installation sequence and
installation notes!
Failure to comply with these instructions may result in
serious damage to the threads of the wheel carrier!
Do not use an impact screwdriver!
 4/30/2016 3/3

Installation sequence:
1. Put on screw (1) wishbone to wheel carrier
manually!
2. Fit wishbone to rear axle support, insert screw and
screw on nut
Important: Tighten both screw connections in
normal position only!
3. Tighten wishbone to wheel carrier screw connection
Tightening torque 33 32 6AZ
4. Tighten wishbone to rear axle support screw
connection
Tightening torque 33 32 5AZ

After installation:
 Carry out wheel alignment procedure.
 4/30/2016 1/1

61 31 204 Replacing operating unit for seat

adjustment

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove cover from front seat

Unlock catch (2).
Unscrew the operating unit (3) in the direction of arrow from
front seat cover (1).
Installation note:
Operating unit (3) must be fitted correctly under the latch
mechanism (4).
 4/29/2016 1/3

11 78 510 Replacing oxygen control sensor (N55)

Special tools required:

 11 7 030
 11 9 150
  11 4 260

Warning!
Risk of burning!
Work should only be carried out on an exhaust system
that has cooled down.

Installation note:
The threads of new oxygen control sensors are already coated
with Never Seez Compound (refer to BMW Parts Department).
If a oxygen control sensor is to be reused, apply a thin and
even coating of Never Seez compound to the thread only.
The part of the lambda control sensor which projects into the
exhaust system branch (sensor ceramics) must not be cleaned
and not coated with lubricant.

Necessary preliminary tasks:

 Remove rear ignition coil cover.
 4/29/2016 2/3

Disconnect plug connection on oxygen control sensor (1).

Installation note:
Cable colour of oxygen control sensor = black.
Cable colour of oxygen monitoring sensor = grey.

Unclip cable (1) of control sensor out of holder.

Release oxygen sensor (1) from above with special

tool 11 4 260.
Tightening torque 11 78 1AZ.
 4/29/2016 3/3

Reassemble the vehicle.

Check function of DME.
 4/29/2016 1/3

11 25 671 Replacing piston rings on all pistons

(N55)

Necessary preliminary tasks:

 Remove all pistons.

Measuring side clearance of piston rings in piston ring groove.

Technical Data.
Note:
It is not possible to measure the axial clearance of the M-flex
rings.

Remove plain rectangular compression ring and stepped ring

upwards with piston ring pliers.
The M-flex ring comprises two steel band rings and a bearing
spring.
Note:
The M-flex ring cannot be removed with piston ring pliers.
Put aside all piston rings in correct sequence and installation
position.
It might not be possible to find the identification on used piston
rings.

Installation note:
New pistons may only be installed together with new piston
rings.
 4/29/2016 2/3

Insert removed piston ring into cylinder bore hole.

With aid of piston (piston crown), position piston ring in its
measuring position.
Determine end clearance with a feeler gauge.

Note:
Schematic diagram of piston rings.

Installation note:
1. Plain rectangular compression ring "top"
2. Piston ring "top"
3. Steel band with M-flex ring

Installation note:
Piston rings with "TOP" identification (1) must point to piston
crown.

Note:
The M-flex ring comprises two steel band rings (1) and a
bearing spring (2).

Installation note:
Insert bearing spring (2) into piston ring groove and then fit
steel band rings (1) so that contact points are offset by approx.
 4/29/2016 3/3

120°.

The contact points (1) of the piston rings must be arranged

offset by approx. 120°. However, the contact points (1) must not
be arranged over the gudgeon pin boss.
Note:
Graphic of N52.

Assemble engine.
 4/30/2016 1/2

61 12 002 Replacing positive battery cable (from

battery to luggage compartment cable
connector)

Warning!
Observe safety informations for handling vehicle battery.

Necessary preliminary tasks:

 Clamp off battery lead from negative connection
point

Open cover (1) and slacken nut (2) on safety battery

terminal (3).
Tightening torque 61 21 1AZ.
Important!
Do not under any circumstances pull or lever off safety
battery terminal (3) by force.

Remove safety battery terminal (3) towards top, lay to one side

and fix in position.

Release lock of plug connection (1) in direction of arrow with a

suitable tool.
Remove plug connection (1) from safety battery terminal (2) in
direction of arrow.
Pull off plug connection (3) from safety battery terminal (2).

Unscrew nuts (1).

Tightening torque 61 21 5AZ.
Remove retaining bracket (2) from battery (3).
 4/30/2016 2/2

Remove battery crash pad (4) towards top.

Remove cover (1) and release nut (2) below it.

Tightening torque 61 21 4AZ.
Remove positive battery cable (3).
Installation note:
Risk of short circuits!
Make sure positive battery cable is correctly fitted.

Open cover (3) on power distribution box (2) and release nut (1)

underneath.
Tightening torque 61 21 4AZ.
Remove positive battery cable from power distribution box (2).
Remove positive battery cable complete from vehicle.
Installation note:
Risk of short circuits!
Make sure positive battery cable is correctly fitted.
 4/29/2016 1/3

12 42 500 Replacing positive battery cable

between starter motor, alternator and
positive battery connection point (N55)

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Disconnect battery negative lead.
 Remove intake plenum.

Pull off rubber mount (1) and slightly raise service cover (2) until
lock of cover (3) is accessible.
Unlock lock and remove cover (3).

Slacken nut (1).

Tightening torque 12 42 3AZ.
Remove positive battery cable from battery positive terminal.

Release positive battery cable from clamp (1).

 4/29/2016 2/3

Release rear cable strap (1) on cylinder head cover.

Replace cable straps.
Note:
Graphic shows engine removed.

Slacken nut (1).

Tightening torque 12 42 2AZ.
Disconnect positive battery cable from starter motor.
Release cable strap (2).
Replace cable straps.

Remove protective cap and release nut underneath.

Tightening torque 12 42 1AZ.
Disconnect positive battery cable (1) from alternator.
 4/29/2016 3/3

Unclip positive battery cable from holder (1) and remove.

Note:
Check stored fault messages.
Clear diagnostic fault entries from fault memory.
 4/29/2016 1/1

12 63 586 Replacing power distribution module

(N20, N26, N55)

Necessary preliminary work:

 Switch off ignition.
 Disconnect battery negative lead.

Unlock and pull off all connectors (1) from power distribution

module.
Remove cover (2).
Release nut beneath it and set positive battery cable aside.
Tightening torque 12 52 7AZ.
Release lock (3) in direction of arrow.
Feed out and remove power distribution module.

Reassemble the vehicle.

 4/29/2016 1/1

12 14 651 Replacing pressure sensor on charge air

duct (N55)

Unlock connector (1) and remove.

Release screws and pull pressure sensor (2) out of charge air
duct.
Tightening torque 13 62 4AZ.

Installation note:
Check sealing ring for damage, replace if necessary.
When installing, coat sealing ring with suitable lubricant.

Note:
Reassemble the vehicle.
Check stored fault messages.
Delete fault memory.
 4/29/2016 1/2

12 14 650 Replacing pressure sensor on intake

plenum (N55)

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Remove ignition coil cover.
 Partially release ignition coil cover.

Unlock connector (1) and remove.

Release screws and pull differential-pressure sensor (2) out of
intake plenum.
Tightening torque 13 62 4AZ.

Installation note:
Check sealing ring for damage. Replace damaged sealing ring.
When installing, coat sealing ring with suitable lubricant.

Note:
Reassemble the vehicle.
Check stored fault message.
 4/29/2016 2/2

Delete fault memory.

 4/29/2016 1/2

12 14 524 Replacing pulse sensor on exhaust

camshaft (N55)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Remove intake silencer housing.

Release screws (1).
Slide cable channel (2) to one side.

Unlock connector (1) and remove.

Release screw.
Tightening torque 13 62 1AZ.
 4/29/2016 2/2

Remove pulse sensor (2).

Note:
Check stored fault messages.
Delete fault memory.
 4/29/2016 1/2

12 14 523 Replacing pulse sensor on intake

camshaft (N55)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Remove intake silencer housing.

Release screws (1).
Slide cable channel (2) to one side.

Unlock connector (1) and remove.

Release screw.
Tightening torque 13 62 1AZ.
 4/29/2016 2/2

Remove pulse sensor (2).

Note:
Check stored fault messages.
Delete fault memory.
 4/29/2016 1/5

11 14 151 Replacing radial crankshaft seal on

transmission side (N55)

Special tools required:

 11 8 220
 23 0 490
 11 9 180
 11 9 183

Necessary preliminary work:

 Remove flywheel

Important!
Magnet wheel (1) is magnetic.
Keep magnet wheel (1) in a plastic bag away from swarf.

Remove magnet wheel (1) from crankshaft.

Release screw on pulse sensor (1).

Slide pulse sensor (2) upwards.
 4/29/2016 2/5

Important!
Drill size maximum 2.5 millimetres.
Remove swarf immediately.

Drill a hole with a drill (1) in the radial shaft seal (see arrow).

Important!
Immediately carefully remove swarf on the radial shaft
seal (1).

Screw in special tool 23 0 490 in direction of arrow.

Drive out radial shaft seal with impact weight in direction of
arrow.
Important!
Immediately carefully remove residual swarf.
 4/29/2016 3/5

Prepare radial shaft seal (1) on special tool 11 8 220.

Position the radial shaft seal (1) with special tool 11 8 220 on

the crankshaft.

Brush radial shaft seal (1) over the special tool 11 8 220.

Move radial shaft seal (1) parallel up against the crankcase.
 4/29/2016 4/5

Secure special tool 11 9 182 to crankshaft with special tool

11 9 184 from set of special tools 11 9 180.

Installation note:
Prepare special tool 11 9 181 from set of special tools 11 9 180
for installation.

Connect special tool 11 9 185 to special tool 11 9 181 from set

of special tools 11 9 180.

Pull in radial shaft seal with special tool 11 9 181 and 11 9 185
in conjunction with special tool 11 9 183 from set of special
tools 11 9 180.
 4/29/2016 5/5

Screw on radial shaft seal with special tool 11 9 183 to limit

position.

Remove all special tools.

Assemble engine.
 4/30/2016 1/5

33 11 021 Replacing radial shaft seal for drive

flange on rear axle final drive

Special tools required:

 00 5 010
 33 5 050
 33 5 060
 33 5 070
 33 5 080
 00 5 500
 33 3 390
 33 3 470
 33 3 440

Important!
Use only approved gearbox oils.
Failure to comply with this instruction will result in serious
damage to the rear axle final drive!

Necessary preliminary work:

 Remove propeller shaft at final drive.

- Disconnect propeller shaft at rear axle

differential.

- Release centre mount.

- Tie up propeller shaft to underbody.

Attention:
Bending the propeller shaft by an excessive
angle can cause premature damage to the
joint/propeller shaft!
 4/30/2016 2/5

Remove retaining clip (1) and sunk nut (2) with diaphragm seal.

Mark position of flange nut (1) to bevel pinion (2).

Release flange nut with special tools  33 5 050 and  33 5 070

by gripping bevel pinion with special tools  33 5 060 and
 33 5 070.

Pull out radial shaft seal with special tool  00 5 010.

 4/30/2016 3/5

Drive in new radial shaft seal with the following special tools
(depending on  rear axle final drive ) until limit position.

- 168LW: Use special tools 00 5 500 and 33 3 390

- 188LW: Use special tools 00 5 500 and 33 3 470

- 215LW: Use special tool 00 5 500 and 33 3 440 (new

number 33 5 080)

Clean bevel pinion thoroughly to remove remnants of screw

locking agent.

Check dust plate for damage, replace if necessary.

Important!
Clean flange nut thoroughly to remove remnants of grease
and screw locking agent.
Pack collar insert (1) of flange nut with grease.
Apply a thin coating of grease to shaded area (2) of flange
nut.
 4/30/2016 4/5

Coat at least four thread turns of flange nut with

”DREI BOND adhesive type 1385”.

Important!
In order to avoid damaging the rear axle final drive, do not
under any circumstances tighten down the flange nut (1)
beyond the marker point of the bevel pinion (2).

Place insert nut (2) with diaphragm seal in flange nut.

Introduce retaining clip (1).

After installation:
 Check transmission oil level, correct if necessary.
4/30/2016 5/5
 4/30/2016 1/2

23 12 524 Replacing radial shaft seal for drive

shaft (GS6-45BZ/DZ)

Special tools required:

 23 0 490
 23 0 220

Important!
After completion of repair work, check transmission oil
level.
Use only approved transmission oil.
Failure to comply with this requirement will result in
serious damage to the automatic transmission!

Necessary preliminary tasks:

 Remove transmission.
 Remove clutch operator and release lever from
guide tube.

Release screws (1).
Tightening torque: 23 11 2AZ.
Remove guide tube (2).
Installation note:
Clean guide tube.
Do not grease guide tube.
 4/30/2016 2/2

Drive a hole into radial shaft seal using a centre punch.

Important!
Do not use a drill as drillings may result in transmission
malfunction.

Screw special tool 23 0 490 into radial shaft seal.

Withdraw radial shaft seal from transmission housing with aid of
impact weight.

Push radial shaft seal (1) onto special tool 23 0 220.

Installation note:
Coat sealing lips of radial shaft seal with transmission oil.

Slide special tool 23 0 220 onto drive shaft.

Drive in radial shaft seal with plastic hammer as far as it will go.
 4/30/2016 1/2

23 12 092 Replacing radial shaft seal for gearshift

shaft (GS6-45BZ/DZ)

Special tools required:

 2 219 637
 23 0 220

Important!
After completion of repair work, check transmission oil
level.
Use only approved transmission oil.
Failure to comply with this instruction will result in serious
damage to the transmission.

Necessary preliminary tasks:

 Shift transmission into 2nd gear.
 Partially release propeller shaft.

- Disconnect propeller shaft at transmission.

- Release centre mount.

- Tie up propeller shaft to underbody.

Note:
Bending the propeller shaft by an excessive
angle can cause premature damage to the
joint/propeller shaft!

Lever circlamp (1) out of groove with a small screwdriver.

Slide circlamp (1) towards rear.
Drive out cylinder pin (2).
 4/30/2016 2/2

Screw in special tool 2 219 637until it is firmly connected with

radial shaft seal (1).
Pull out radial shaft seal with special tool 2 219 637.

Coat sealing lips of radial shaft seal and gearshift shaft with
transmission oil.
Drive in radial shaft seal with special tool 23 0 220.
 4/30/2016 1/3

23 12 061 Replacing radial shaft seal for output

flange (GS6-45BZ/DZ)

Special tools required:

 23 0 020
 24 2 380
 33 1 150
 33 1 154
 23 3 210
 23 3 230

Important!
After completion of repair work, check transmission oil
level.
Use only approved transmission oil.
Failure to comply with this instruction will result in serious
damage to the transmission.

Necessary preliminary tasks:

 Remove transmission cross member.
 Partially remove propeller shaft.

- Disconnect propeller shaft at transmission.

- Release centre mount.

- Tie up propeller shaft to underbody.

Note:
Bending the propeller shaft by an excessive
angle can cause premature damage to the
joint/propeller shaft!

Brace output flange with special tool 23 0 020.

Undo collar nuts with special tool 24 2 380.
 4/30/2016 2/3

Important!
Do not drive on flange.

Secure collar nut with Loctite 243.

- Loctite 243: BMW Parts Department.

- Tightening torque: 23 21 1AZ.

Detach output flange (1) with special tool 33 1 150 and adapter

plate 33 1 154 from output shaft.

Release screw on special tool 23 3 210.

23 3 210Push special tool over output shaft and screw firmly
into sealing ring.

Insert screw into special tool 23 3 210 again and continue

turning until sealing ring is pulled out of transmission housing.
If necessary, remove ring spring of sealing ring.
 4/30/2016 3/3

Installation note:
Coat sealing lips of new radial shaft seal with transmission oil.
Drive radial shaft seal fully home using special tool 23 3 230
and plastic hammer.
 4/30/2016 1/3

33 10 023 Replacing radial shaft seal for output

shaft at rear axle differential, left or right

Special tools required:

 00 5 010
 33 1 308
 00 5 500
 33 4 320

Necessary preliminary tasks:

 Remove rear axle final drive.

Pull out radial shaft seal with special tools 00 5 010 and

33 1 308.

Note:
The installation protective ring (1) serves to protect the sealing
lips of the radial shaft seal (2) when installing the output shaft.
 4/30/2016 2/3

Important!
Installation protective ring must not slip out of shaft seal!

 
Coat housing sheet metal flange and sealing lips of new radial
shaft seal with approved final drive oil.
Drive new radial shaft seal firmly home with special tools
00 5 500 and 33 4 320.

Important!
High installation forces indicate that the output shaft spline
teeth are damaged or deformed!
 

Installation note:
Check gearing and replace components if damaged.
Check dust plate (1) for damage, renew if necessary.
If the previous output shaft is reinstalled, circlip (2) must be
renewed.
Coat highlighted contact surface (3) of output shaft with
approved final drive oil.

Insert output shaft into rear axle final drive.

Pull out assembly protection ring at lug (1) until one of the two
predetermined breaking points gives.
 4/30/2016 3/3

After installation:
 Check transmission oil level, correct if necessary.
 4/30/2016 1/3

33 31 011 Replacing rear axle support

Warning!
Danger of injury!
Failure to comply with the following instructions may result
in the vehicle slipping off the vehicle hoist and critically
injuring other persons.
Load the luggage compartment with a minimum of 100 kg
before lowering/removing the rear axle support. This
prevents the vehicle from tilting or sliding off the vehicle
hoist!
When supporting components, make sure that:
 the vehicle can no longer be raised or lowered
 the vehicle does not lift off the locating plates on the
vehicle hoist.

Important!
Before lowering/removing rear axle support:
 
Observe safety information for raising the vehicle
 
In order to avoid damage to vehicle hoist, perform weight
compensation on vehicle.

Necessary preliminary tasks:

 Remove rear axle final drive.
 Remove complete rear axle carrier.
 4/30/2016 2/3

Undo anti-roll bar links at the anti-roll bar.

If applicable, remove  ride height sensor with jointed rod from
rear axle support .

Secure wheel carrier against falling out.

 
Release both camber arms on rear axle support.
Release both toe arms on rear axle support.
Release both trailing arms on rear axle support.
Release both control arms on rear axle support.
Release both wishbones on rear axle support.
Remove both wheel carriers with output shaft, all arms, anti-roll
bar link and brake disc.
 
Remove anti-roll bar.

Take the rear axle support off the special tool with a helper and
set onto a suitable support.
Installation note:
Use previous rear axle support as a template for modifying or
replacing small parts.

After installation:
 Carry out wheel alignment procedure.
4/30/2016 3/3
 4/30/2016 1/1

51 12 460 Replacing rear bumper panel trim strip

Release all latch mechanisms (1) along the dotted line on the

inside of the bumper panel.
Removing trim strip (2) from bumper panel.
 4/30/2016 1/2

33 11 271 Replacing rear cover gasket on rear axle

final drive

Important!
In event of oil loss, always check rear differential for traces
of wear and damage.

Necessary preliminary tasks:

 Remove rear axle final drive.

Note:
Read and comply with document ”Rear axle final drive:
Assignment to model series”.

 
Select rear axle final drive:

- 168LW

- 188LW

- 215LW

After installation:
 Add  final drive oil.
4/30/2016 2/2
 4/30/2016 1/1

34 32 980 Replacing rear left or right brake hose

Note:
 Read and comply with General Information.
 Remove wheel.
After completing repair work: Bleed brake system.

Press brake pedal down to floor and secure with pedal support.
Note:
The pedal support may only be released when the brake lines
are reconnected.
This prevents brake fluid from emerging from the expansion
tank and air from entering the system when the brake lines are
opened.

Important!
Grip brake hose at square head (2) so that connecting
piece cannot rotate in retaining bracket.
Never twist brake hose when installing it and avoid all
contact with parts attached rigidly to the body.

Disconnect brake hose from brake line (1).

Installation note:
Tightening torque 34 32 1AZ.

Detach brake hose from brake caliper (3).

Installation note:
Tightening torque 34 32 3AZ.

Installation note:
First tighten brake hose on brake caliper.
Insert brake hose in bracket and screw onto brake pipe.
 4/30/2016 1/2

37 12 310 Replacing rear left or right bumper

(adaptive M suspension)

Special tools required:

 2 355 965
 2 355 966

Important!
- When replacing the shock absorber, renew the
auxiliary damper as well.

- Read and comply with Information on replacing

shock absorbers.

Necessary preliminary tasks:

 Remove shock absorber

Remove protective cap (1) and sealing washer (2).

Installation note:
Replace the faulty components.
 4/30/2016 2/2

Release nut (1) with special tool 2 355 965 and 2 355 966.

Tightening torque 33 52 2AZ.
Installation note:
Replace nut.

Impact
screwdrivers
are prohibited!
Risk of
damage inside
the shock
absorber!

Replace auxiliary damper with protective tube (1).

 4/30/2016 1/2

51 34 171 Replacing rear left or right door window

Necessary preliminary work:

 Remove sound insulation in rear door
 Remove cover for window guide
 Remove outer window cavity weather strip

Move door window until stop (3) of power window regulator

fixture can be activated via recess on guide rails of power
window regulator.
Important!
Unlock and disconnect plug connection (1) from power
window motor (2) (pinch hazard).

Lever out stop (3) with screwdriver (4) in direction of arrow and

push door window up.
Installation note:
The door window must be correctly clipped into stop (3).
Carry out function check on power window regulator and anti-
trap mechanism.
If necessary, normalize power window regulator.

Installation note:
Following parts of window guide (3) must not be damaged or
missing:
1 Catch
2 Bump stop
 4/30/2016 2/2

Remove door window glass (1) towards top.

Installation note:
The door window (1) does not require adjustment.
Make sure door window (1) is correctly fitted on window guides.
 4/30/2016 1/2

33 52 012 Replacing rear left or right side shock

absorber

Special tools required:

 2 355 965
 2 355 966

Important!
- When replacing the shock absorber, renew the
auxiliary damper as well.

- Read and comply with Information on replacing

shock absorbers.

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Necessary preliminary tasks:

 Remove the shock absorber.
 4/30/2016 2/2

Remove protective cap (1) and sealing washer (2).

Installation note:
Replace the faulty components.

Release nut (1) with special tool 2 355 965 and 2 355 966.

Tightening torque 33 52 2AZ.
Installation note:
Replace nut.

Impact
screwdrivers
are prohibited!
Risk of
damage inside
the shock
absorber!

Replace auxiliary damper with protective tube (1).

 4/30/2016 1/2

33 52 161 Replacing rear left or right support

bearing for spring strut/shock absorber

Special tools required:

 2 355 965
 2 355 966

Installation note:
1. All screws, nuts, bolts and hose clamps removed during
the repair must be replaced.
2. Retaining elements on chassis and suspension and
steering parts must be replaced.

Necessary preliminary tasks:

 Remove the shock absorber.

Remove protective cap (1) and sealing washer (2).

Installation note:
Replace the faulty components.
 4/30/2016 2/2

Use special tools 2 355 965 and 2 355 966 to undo the nut (1).
Tightening torque 33 52 2AZ.
Installation note:
Replace nut.

Impact
screwdrivers
are prohibited!
Risk of
damage inside
the shock
absorber!
 4/30/2016 1/4

41 14 505 Replacing rear left outer wheel arch

section (rear side panel removed)

Read contents of Body, General.

Observe procedure for (repair stage  2)!

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Outer wheel arch section, rear

- (2) Shaped part attachment, outer entrance (not shown)

Following consumables are required:

Material Quantity

Adhesive K5a 1

Blind rivets N3 12

Cleaning agent R1 1

Cavity sealing wax remover 1

 4/30/2016 2/4

Sealant D1  

Removal of outer wheel arch section

Remove cavity sealing (1).

Mark severance cut (2) as pictured and cut.
Open welded connections in area (3).
Remove part of the outer wheel arch section.

Preparation of new part:

 4/30/2016 3/4

Mark severance cut on new part according to severance cut on

vehicle + 20 mm material extra and cut.

Adjust new parts in combination with side wall to fit and secure.
In area of bonding surface (1), drill 12 ∅ 4.2 mm holes for blind rivets.

Installation of outer wheel arch section

 4/30/2016 4/4

Important!
Do not grind/sand new part in area of bonding surfaces.

Clean all bonding surfaces on new part and on vehicle with

cleaning agent R1.
Apply adhesive  to bonding surfaces.
Apply sealant to new cavity acoustic baffle.
Install and rivet outer wheel arch section.
 4/30/2016 1/5

41 14 502 Replacing rear left outer wheel arch

section with reinforcement (rear side
panel removed)

Follow procedure for repair stage 3.

Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD CD
(job number 41 14 502).
Use only approved spot-welding apparatus for repairs.

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Support, C-pillar

- (2) Wheel arch, outer, rear

- (3) Closing plate, wheel arch

- (4) C-pillar reinforcement

- (5) Shaped part attachment, entrance (not shown)

Removal of the outer wheel arch section with reinforcement

Mark severance cut

(1) as pictured and
cut.
 4/30/2016 2/5

Important!
Cut outer
panel only.

Open welded
connections in
areas (2).
Remove C-pillar
support and
reinforcement.

Open welded connections in areas (1).

 4/30/2016 3/5

Mark severance cut (1) in accordance with dimension and cut.

Important!
Cut outer panel only.
Dimension a = 20 mm from radius of outer wheel arch section.
Open welded connections in area (2).
Remove part section of outer wheel arch section.

New part preparation

Carry out severance cut on C-pillar reinforcement in
accordance with severance cut on vehicle.
Prepare reinforcement plate at severance cut.

Mark severance cut (1) in accordance with severance cut on

vehicle + 20 mm extra material and cut.
 4/30/2016 4/5

Mark severance cut (2) in radius and cut.

Adjust new parts in conjunction with side panel to fit.
Note:
New parts are installed overlapping in areas of severance cuts.

Installation of the outer wheel arch section with reinforcement

Apply sealant to new cavity sealing.
Install new parts and reinforcement plate and weld in place.

In areas (1) the outer wheel arch section and panel behind are
joined by spot-welding bonding technology.
Apply repair welding spots in areas (1) to existing welding spots
on vehicle.
This is necessary because the adhesive between the spot
flanges acts as an insulator.

Apply repair welding spots in area (1) to existing welding spots

on vehicle.
4/30/2016 5/5
 4/30/2016 1/10

41 35 101 Replacing rear left side panel

Read contents of Body, General.

Strip down vehicle

Procedure Observe repair stage 2!

The following new body parts are required (refer to Electronic

Parts Catalogue).

- (1) Rear side wall

- (2) Reinforcement plates side sill (not shown)

- (3) Reinforcement plates C-pillar (not shown)

- (4) Lock nuts (not pictured)

Following consumables are required:

Material Quantity

Adhesive K5b 1

Adhesive K5a 1
 4/30/2016 2/10

Blind rivets N3 7

Punch rivets N4 32

Punch rivets N5 2

EMC screws 3

Cleaning agent R1 1

Cavity sealing wax remover 1

Sealant D1  

Removing side wall:

 4/30/2016 3/10

Mark severance cuts in accordance with specified dimensions and cut.

Important!
Cut outer panel only.
Compare position of severance cuts with reinforcement plates.
Dimension a = approx. 160 mm from centre point of 20 mm dia. hole.
Dimension b = approx. 170 mm from corner of roof outer skin.
Open welded connections in areas (1).
Open seam adhesive bond in area (2).
Release side wall from cavity sealing (3).

Note:
In addition to the dimensions, the position of the separating cut
can be determined with a template (1).
 4/30/2016 4/10

Mark severance cut (1) on water channel in accordance with schematic diagram and cut.
The severance cut runs down the middle between the attachment points (2) of the gas pressure spring.
Important!
Cut outer panel only.
The severance cut must be partially executed using a belt sander.
Detach welding spots from side wall in area of tailgate seal.
 
Open welded connections in areas (3).
Detach side wall.
 4/30/2016 5/10

Preparation of new part:

Mark severance cuts on the new part according to vehicle and
cut.
Prepare reinforcement plates at severance cuts.

C-pillar water channel severance cut area:

Make an additional 2 shims (1) and (2) in the severance cut
area.
Note:
Before installing the side wall:
Clean bonding surfaces with cleaning agent R1.
Coat shim (1) with adhesive and slide in.
Coat shim (2) with adhesive and secure with a punch rivet N4.

Adjust new part to fit and secure.

Important!
Adjust new part to fit without strain particularly in area of
C-pillar. Straightening after the adhesive has hardened is
not possible.

In areas (1) and (2) set 4.2 mm dia. holes for blind rivets N3:

Area Number

1 3

2 4

Remove new part again and deburr bore holes.

Important!
Do not grind/sand new part in area of bonding surfaces.
 4/30/2016 6/10

Installing side wall:

Clean all bonding surfaces on vehicle, on the new part and on
the reinforcement plate with cleaning agent R1.
Apply adhesive to reinforcement plates. Install reinforcement
plates.
Apply sealant to cavity sealing.
Apply adhesive  to bonding surfaces on vehicle.

Apply adhesive to new part in area of wheel arch.

Apply adhesive (1) to inside of side panel (2) at distance a.
Dimension a = approx. 5 mm.
 4/30/2016 7/10

Install side panel with a second person helping.

Note:
When installing side panel, make sure there is sufficient adhesive on bonding surfaces.
After adjusting side wall to fit, tighten nuts of reinforcement plates.
Secure side wall in area of reinforcement plates with gripping pliers.
Rivet side panel with blind rivets.
Use N4 punch rivets in areas (1) to (3).

Area Number

1 10

2 6

3 5

Use 10 punch rivets N4 in area (1).

 4/30/2016 8/10

Note:
Due to a missing welding spot on the new part, a punch rivet N5 needs to be introduced in area (1) of the water
channel.
 4/30/2016 9/10

Note:
Due to a missing welding spot on the new part, a punch rivet N5 needs to be introduced in area (1).

Also apply adhesive (2) to outer wheel arch section (3).

(1) Rear side wall.

Flange edge of wheel arch (3) of side wall flush to outer wheel

arch section.
Do not create sharp edges when flanging as otherwise the
flange edge may begin to tear.
Dimension (A) = 5 mm.
(1) Adhesive
 4/30/2016 10/10

(2) Rear side wall

Also seal in area (3) according to standard.
Important!
Flange edge must be completely filled with adhesive!

After adhesive has hardened, install one EMC screw in each

case in areas (1).
Additionally, install EMC screw in sill area.
 4/30/2016 1/4

41 12 660 Replacing rear luggage compartment

floor (tail panel removed)

Read contents of Body, General.

Strip down vehicle

Follow procedure for repair stage 2.

Following new body parts are required (refer to Electronic Parts

Catalogue):

- (1) Luggage compartment floor, rear

 
Following consumables are required:

Material Quantity

Adhesive K5a 1

Blind rivet N3 7

Blind rivet N6 6

EMC screws 4
 4/30/2016 2/4

Cleaning agent R1 1

Sealant D1  

Removal of luggage compartment floor, rear

Open welded connections in area (1) and remove luggage

compartment floor.

New part preparation

Adjust new part in conjunction with tail panel and secure.

In areas (1) and (2), set ∅ 4.2 mm bore holes for blind rivets.

 4/30/2016 3/4

Area Number Rivet type

1 3 each Blind rivet N6

2 7 Blind rivet N3

Remove new parts and deburr bore holes.

Important!
Do not grind new part and body in area of bonding
surfaces.

Installation of luggage compartment floor, rear

Clean all bonding surfaces with cleaning agent R1.
Apply adhesive to bonding surfaces.
Install new part and rivet with blind rivets .

After hardening of the adhesive install 4 EMC screws in areas

shown (1).
4/30/2016 4/4
 4/30/2016 1/2

37 14 512 Replacing rear ride height sensor

Important!
Read and comply with notes on protection against
electrostatic damage (ESD protection).

Necessary preliminary tasks:

 Remove camber arm cover.

Slacken nut (1).

Tightening torque 37 14 4AZ.
Detach jointed rod (2).
Disconnect plug connection (3).
Unclip cable with holder (4).
Release screw (5).
Tightening torque 37 14 1AZ.
Remove ride height sensor.
Installation note:
Replace nut (1).
Align holder with corresponding bore hole on rear axle support.
Replace faulty cable clips.
 4/30/2016 2/2

Replacement:
Release screws (1).
Tightening torque 37 14 2AZ.
Take off ride height sensor from holder (2).
Installation note:
Sensor lever (3) points towards wheel when installed.

After installation:
 Check headlight adjustment, correct if necessary.
 4/29/2016 1/3

18 12 031 Replacing rear silencer (N55)

Warning!
Risk of burning!
Only perform this repair work after engine has cooled
down.
Danger of injury!
Removal of the exhaust system must be carried out with
the assistance of a second person.

Necessary preliminary tasks:

 Support rear silencer with a suitable jack and secure
against falling down.
 F31, F34 only:
Remove right trailing link.

Note:
If the separation point line is not marked by a punch mark in the
pipe, determine the separation point by means of the pipe
length on the new rear silencer.
Carry over separation point to faulty rear silencer and mark.
Secure rear silencer against falling off.
Cut through exhaust pipes at marked point with a suitable tool.

Unfasten nut.
Tightening torque 18 20 3AZ.
 4/29/2016 2/3

Unlock connector (1) from exhaust flap and pull off.

Slacken nut (2).
Tightening torque 18 20 3AZ.
Lower and remove the rear silencer carefully with assistance of
a second person.

Installation note:
Adjust rear silencer and connect with clamp.
Align clamping sleeves so that:
 Nuts point downwards.
 Cutting line is in middle of clamping sleeve.
 There is sufficient spacing to adjoining components.
Centre clamp and tighten down.
Tightening torque 18 31 5AZ.

Installation note:
Check rubber mount for damage, replace if necessary.
Check exhaust system for leak tightness.
4/29/2016 3/3
 4/30/2016 1/1

51 31 221 Replacing rear window (rear window

broken)

Important!
Remove all glass splinters, also from underneath seats.
 
In case of bonded rear windows:
If required by the condition, remove bonded window
remnants with an oscillating knife or fold scraper.
 
Check seat belts:
 Condition of seat belt strap
 Function of automatic reel
 Seat belt locking reel
 Check seat belt buckle

Other operations correspond to:

Remove and install rear window.
 4/30/2016 1/2

64 11 ... Replacing retaining ring for

condensation drain hose

Special tools required:

 00 9 325

Necessary preliminary tasks:

 Remove heater/air conditioner

Press out condensation drain hose (1) from retaining ring (2)

towards bottom.

Remove retaining ring (1) with special tool 00 9 325.

 4/30/2016 2/2

Installation note:
Guide of bottom retaining ring (1) must fit correctly in recess of
condensation drain hose (2).

Installation note:
Guide on top retaining ring (1) must fit correctly in recess on
body (2).

Installation note:
Guide on bottom retaining ring (1) must be inserted correctly in
recess on top retaining ring (3).
Make sure condensation drain hose (2) is correctly fitted in top
retaining ring (3).
 4/30/2016 1/1

22 11 001 Replacing right engine mount (N55)

Necessary preliminary work:

 Remove engine support arm.

Installation note:
Rubber part (1) of engine mount must point to centre of vehicle.
 4/30/2016 1/1

22 11 001 Replacing right engine mount (N55)

Necessary preliminary tasks:

 Remove engine support arm.

Release screws (1).
Tightening torque 22 11 1AZ.
Remove engine mount.

Installation note:
Rubber part (1) of engine mount must point to centre of vehicle.
 4/30/2016 1/2

22 11 100 Replacing right engine support arm

(N55)

Necessary preliminary work:

- Secure engine in installation position.

Release bolts (1) on engine mount.

Tightening torque 22 11 2AZ.

Release screw (1) from engine support arm (2).

Tightening torque 22 11 3AZ.

Release screws (1).
Tightening torque 22 11 3AZ.
Remove engine support arm (2).
4/30/2016 2/2
 4/30/2016 1/2

22 11 100 Replacing right engine support arm

(N55)

Necessary preliminary tasks:

- Secure engine in installation position.

Release bolts (1) on engine mount.

Tightening torque 22 11 2AZ.

Release screw (1) from engine support arm (2).

Tightening torque 22 11 3AZ.

Release screws (1).
Tightening torque 22 11 3AZ.
Remove engine support arm (2).
4/30/2016 2/2
 4/30/2016 1/1

61 31 116 Replacing rocker switch for side window

operation (rear)

Special tools required:

 00 9 325

Important!
Carry out the following operation carefully so as to avoid
damaging the door trim panel and switch.
If necessary, tape off working area.

Lever rocker switch for side window operation (1) with special

tool 00 9 325 in direction of arrow out of armrest.
Disconnect associated plug connection and remove rocker
switch for side window operation (1).

Installation note:
Retaining hooks (1) of rocker switch for side window operation
(2) must not be damaged.
Make sure rocker switch for side window operation (2) is
correctly seated in armrest.
 4/30/2016 1/2

11 22 513 Replacing roller bearing for dual-mass

flywheel (N55)

Special tools required:

 21 2 051
 21 2 052

Note:
Flywheel removed!

Using hydraulic press (1) and special tool 21 2 051, press roller

bearing out of dual-mass flywheel downwards on engine side.
Important!
Risk of damage:
Roller bearing must not be driven out.

Push roller bearing (2) onto special tool 21 2 052.

Using hydraulic press (1), press roller bearing into dual-mass
flywheel to limit position on clutch side.
Important!
 4/30/2016 2/2

Risk of damage:
Observe press-in instruction:

- Roller bearing must not be driven in.

- Roller bearing mounting force/travel monitored:

Min. 2000 N 1 mm before end of pressing in.
Max. 15,000 N during entire press-in procedure.
 4/30/2016 1/1

61 31 544 Replacing roof switch cluster (front)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Remove roof switch cluster

Release interior roof light (1) at clamps (2) and feed out of roof
switch cluster (3).
Installation note:
Clips (2) must not be missing or damaged.
Make sure interior roof light (1) is correctly seated in roof switch
cluster (3).

High-spec roof function centre only:

Carry out vehicle programming/coding.
 4/30/2016 1/1

22 31 001 Replacing rubber mount for gearbox

mounting (N13)

Necessary preliminary tasks:

 Remove rear underbody protection.
 Support transmission with lifter.

Unscrew nuts (1).

Tightening torque 22 32 2AZ.
Release screws (3).
Tightening torque 22 32 3AZ.
Remove gearbox cross member (2).
Remove rubber mount from transmission cross member.
Tightening torque 22 32 4AZ.

Note the installation position of rubber mount (1) relative to

transmission cross-member (2).
Arrow shows in direction of front of vehicle.
 4/30/2016 1/3

33 32 031 Replacing rubber mount for trailing arm

in wheel carrier

Special tools required:

 33 3 010
 2 240 471
 2 240 466
 2 240 472

The rubber mount may not be reused after it has been pressed
out!

Necessary preliminary tasks:

 Remove trailing arm.

Pulling out the rubber mount:

Pull out rubber mount with special tools 33 3 010, 2 240 471,
and 2 240 466.
Note:
Align the slots on tool 2 240 471 with the wheel carrier so that it
is resting straight.
 4/30/2016 2/3

Pulling in a new rubber mount:

Align the rubber mount with slot (1) upward in an angle to the
wheel carrier.

Pull on rubber mount (1) with special tools 33 3 010, 2 240 471,

and 2 240 472 until limit position.
Note:
Align the slots on tool 2 240 471 with the wheel carrier so that it
is resting straight.

After installation:
 Carry out wheel alignment.
4/30/2016 3/3
 4/30/2016 1/2

31 12 134 Replacing rubber mount in left or right

trailing link

Special tools required:

 31 3 031
 31 3 032

Important!
Rubber mounts may only be changed once.

Necessary preliminary work:

 Check ball joint of the trailing link in the installed
state.

- If necessary renew trailing link.

 Remove trailing link.

Important!
Mark trailing link with a punch mark in area (A).
 
If the trailing link already features an identification mark
with a centre punch, it is necessary to replace the trailing
link.
 4/30/2016 2/2

Using a press and special tools 31 3 031 and 31 3 032, press

rubber mount out of tension strut.
Note:
Special tool 31 3 031 must be exactly flush with rubber mount
bush.

Installation note:
Keep rubber mount (1) and bushing in tension strut clean and
free from grease.
Note:
The eye of the trailing link has a stage on one side. Press the
rubber mount in from this side.
 
Align rubber mount (1) using notch to marking on trailing link
and press in. The deviation must not exceed ± 5°.

Protrusion (A) equally large.

Note:
The graphic shows the right trailing link. The installation position
is reversed on the left side.
 4/29/2016 1/7

12 42 540 Replacing safety battery terminal (SBK)

Caution!
Observe safety regulations.
Investigate cause of triggering of safety battery
terminal.
To do so, read out fault memory of airbag control unit.
Note fault messages stored in memory. Rectify faults.
Then clear fault memory.

Use of safety battery terminal:

- From model year 1998 in Series E38, E39, E46

- From 4/99 in E36/Z3

- in each of following new Series

The different models have different installation locations:

Battery in engine compartment

Safety battery terminal is replaced with cable up to battery
positive support point.
Safety battery terminal is omitted as from 03/2002 from all E46
LHD models with 4-cylinder engines.

Battery in luggage compartment behind side trim panel

Remove side trim panel.
Follow instructions for disconnecting and connecting battery.
Disconnect and cover battery negative lead.
 4/29/2016 2/7

Release front side trim panel partly and fold forward.

Battery in luggage compartment under floor trim panel

Follow instructions for disconnecting and connecting battery.
Fold back floor trim panel (1).
Lift cover (2) on battery negative lead.
Disconnect and cover battery negative lead (3).
Release nuts (4).
Remove battery cover.

Battery in luggage compartment under spare wheel

Remove spare wheel.
Release screws.
Caution!
Do not kink air pipes.
 4/29/2016 3/7

Set air supply system (1) to one side.

Follow instructions for disconnecting and connecting battery.
Disconnect battery negative lead.

Disconnect supply cable (1) for vehicle electrical system.

Installation:
Remove faulty fuses and carry out troubleshooting.

Caution!
Pay attention to interface.
The repair cable is always a standard length.
The heavy-current connector of the repair cable has a
larger diameter than the battery positive lead.
In some Series (e.g. E46 touring), the heavy-current
connector of the repair cable can lead to installation
problems.
This is the case when the interface is in the area of the
close-fitting trim panels.
Find matching interface (e.g. approx. 10 cm behind rear
seat backrest in E46 touring).

Lay repair cable parallel to battery positive lead.

Mark interface of battery positive lead at end of repair cable.
 4/29/2016 4/7

Release cable ties (1).

Disconnect plug connection (2).

Caution!
Do not use bolt cutters or similar tools to cut through the
cable.
A cable end that has been squashed flat will no longer fit
into the clamping sleeve.

Saw through battery positive cable at marked point with an iron

saw.

Strip insulation - length (A) - from cable end.

Distance (A) = 15 mm.
 4/29/2016 5/7

Push heavy-current connector (1) over stripped cable end and

screw into position.

Push shrink-fit hose (3) over repair cable.

Screw threaded sleeve (1) of repair cable (2) to heavy-current
connector.

Push shrink-fit hose (1) over connecting point and shrink on

with a hot-air blower (2).
 4/29/2016 6/7

Note:
Heat up shrink-fit hose until it has settled completely
around the connection point.

When laying the repaired battery positive cable, observe the

following:
 The shrink-fit hose must not be scuffed during any
movement.
 The repair cable must not cause any disturbing noises
during driving operation.

Note:
Offsetting cutting line by approx. 10 cm produces excess
length of battery positive lead (1).
Lay battery positive lead (1) without kinks or abrasions.
(Shown on E46 touring.)
4/29/2016 7/7
 4/30/2016 1/2

64 53 520 Replacing safety pressure switch

Warning!
Danger of injury!
Refrigerant circuit is under high pressure!
Follow safety informations for handling R 134a refrigerant.
Avoid contact with refrigerant and refrigerant fluid.
Follow safety instructions for handling refrigerant oil.

Important!
Risk of damage!
Restart engine only when air conditioning system has
been correctly filled.
Follow instructions for opening and replacing parts in
refrigerant circuit.
If air conditioning system is open for longer than 24 hours:
replace condenser for air conditioning

Necessary preliminary tasks:

 Drain off air conditioning system
F33 only:
 Remove left front end strut

Unfasten plug connection (1) and disconnect.

Release safety switch (2) and remove.
Tightening torque 64 53 8AZ.
 4/30/2016 2/2

After installation:
 Evacuate and fill A/C system
 4/30/2016 1/1

54 12 117 Replacing seal for glass slide/tilt sunroof

panel

Necessary preliminary tasks:

 Remove glass slide/tilt sunroof panel

Pull off sealing (1) from glass slide/tilt sunroof panel (2).

Installation note:
Coat guide duct (1) and sealing (2) with soapy water.
Installation rear centre, start with sealing joint (3).
Do not pull sealing too tight in the radii (leaks).
 4/29/2016 1/4

11 14 010 Replacing sealing cap for vacuum pump

(N55)

Special tools required:

 11 8 530
 11 8 531
 11 8 532
 11 8 533
 11 8 534
 11 8 535
 11 8 537

Necessary preliminary work:

 Remove fan cowl.
 Remove drive belt tensioning devices.

Remove cover (1) from deflecting element.

Release screw (1) and remove deflecting element.

Tightening torque 11 28 2AZ.
 4/29/2016 2/4

Removing sealing cap:

Prepare special tool 11 8 530.
Remove special tool 11 8 533 from special tool 11 8 532.
Install special tool 11 8 534.
Special tool 11 8 536 is not required.

Attach special tool 11 8 531 to long special tool 11 8 535 .

Short special tool 11 8 535 (short); a 6 mm thick M10 washer
must be placed underneath between crankcase and special tool
11 8 531.
Note:
For purposes of clarity, graphics show alternator and power
steering pump removed.

Special tool 11 8 537 must be positioned manually on sealing

cap.
Screw in special tool 11 8 534 .
Note:
The sealing cap is pressed out diagonally during this work step
 4/29/2016 3/4

Installing sealing cap:

Prepare special tool 11 8 530.
Remove special tool 11 8 534 from special tool.
Install special tools 11 8 533 and 11 8 532.

Screw in new sealing cap (1) with special tools 11 8 532 and

11 8 533 until flush with crankcase upper part.

Assemble engine.
4/29/2016 4/4
 4/30/2016 1/5

52 15 400 Replacing seat cover for front seat

(sport/manual)

Special tools required:

 52 0 050

Necessary preliminary tasks:

 Remove front seat
 Remove thigh support
 Remove inner cover
 Manual version:
Remove outer cover
 Electric version:
Remove outer cover

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Unlock retaining lugs (1).

Remove seat trim (2) downwards.
Installation note:
 4/30/2016 2/5

Seat trim (2) must not be damaged.

Version with seat heating only:

Unlock plug connection (1) for seat heating and disconnect.
Detach cable strap.
Release wiring harness (2) from cable clips on seat
mechanism.
Important!
Feed the wiring harness carefully through the seat and
backrest mechanism as the edges of the frame can be
sharp.

Carefully slide bracing cloth (1) with foam through backrest gap

and seat structure.
If applicable, route cable carefully through seat and backrest
mechanics as the edges of the frame may be sharp.
Installation note:
Slide foam completely through backrest gap and seat structure.
Make sure foam and bracing cloth are correctly fitted.

Fully lift welt of seat cover out of seat frame.

Disengage seat cover at rear.
 4/30/2016 3/5

Version with seat heating:

Pull seat cover (1) with upholstery forward a little and feed
wiring harness (2) out.
Remove seat cover (1) with padding towards front/top.

Remove seat cover (1) with padding towards front/top.

Release all clamps (1) from seat cover (2).

 4/30/2016 4/5

Detach all clamps in side area from longitudinal wires.

Pull trim wires forward out of seat cover.
Carefully fold back seat cover and release clamps from cross-
wires.
Remove seat cover from upholstery.
Important!
Remove all remnants of clamps from seat cover and
upholstery.

Replacement only:
Pull trim wires out of seat cover.
Cut new seat cover to size and insert trim wires.

Installation note:
Bend new clamps (2) with special tool  52 0 050 .
1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in cover
 4/30/2016 5/5

5. Seat cover
 4/30/2016 1/2

52 26 400 Replacing seat cover for rear seat

Special tools required:

 52 0 050

Necessary preliminary tasks:

 Remove rear seat

Unclip ISOFIX cover cap.

Installation note:
Pull cover straps through foam part into Isofix openings.
Make sure Isofix protective caps are correctly engaged.

Lever out welt in area (1) with plastic wedge.

Unhook seat cover in area (2).

Detaching cover and upholstery:

 Release all clamps on trim wires.
 Remove seat cover from upholstery
 Remove remaining clamps from cover and upholstery
 4/30/2016 2/2

Installation note:
Insert new clamps with special tool 52 0 050.

1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in seat cover
5. Seat cover

Replacement only:
 Push trim wires into new seat cover
 If necessary, cut in mounting for trim wires of new cover
 4/30/2016 1/4

52 13 400 Replacing seat cover on left or right front

seat (normal/manual)

Special tools required:

 52 0 050

Necessary preliminary work:

 Remove front seat
 Remove outer cover on front seat
 Remove inner cover on front seat

Warning!
Note airbag safety regulations!
Incorrect handling can activate airbag and cause injury.

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Version with seat heating only:

 4/30/2016 2/4

Unlock plug connection (1) for seat heating and disconnect.

Detach cable strap.
Detach seat heater cable (2) from cable clips on seat
mechanism.
Installation note:
Plug connection is encoded to prevent incorrect connection.
Replace cable strap.

Fully lift welt of seat cover out of seat frame.

Disengage seat cover at rear.

Carefully slide bracing cloth (1) with foam through backrest gap

and seat structure.
If applicable, route cable carefully through seat and backrest
mechanics as the edges of the frame may be sharp.
Installation note:
Slide foam completely through backrest gap and seat structure.
Make sure foam and bracing cloth are correctly fitted.

Front passenger seat only:

Lift seat cover with upholstery (1) at front and unclip
mounting (2) for seat occupancy detection (SBE) (3).
Remove SBE (3) from upholstery (1) and place on flexmat.
 4/30/2016 3/4

Remove seat cover (1) with padding towards front/top.

Release all clamps (1) from seat cover (2).

Release all clamps in marked area of trim wires.

Remove seat cover from upholstery.
Important!
Remove all remnants of clamps from seat cover and
upholstery.
 4/30/2016 4/4

Replacement only:
If applicable, pull trim wires out of seat cover.
Cut new seat cover to size and insert trim wires.

Installation note:
Bend new clamps (2) with special tool 52 0 050.
1. Upholstery
2. Clamp
3. Trim wire in upholstery
4. Trim wire in cover
5. Seat cover
 4/30/2016 1/2

65 77 602 Replacing sensor mat for front

passenger seat occupancy detector

Necessary preliminary tasks:

 Remove front passenger seat

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Remove the central plug from the mounting.

Cut open cable strap (1).
Installation note:
Replace cable tie (1) at central plug.

Raise the tab and pull connector (2) out through the side of the
connector housing (3).

Detach cable for seat occupancy detection (1) from cable clip.
 4/30/2016 2/2

Lift the front seat cover with upholstery (1) and unclip the
mounting (2) for the seat occupancy detection (3).
Remove the seat occupancy detection (3) from upholstery front
passenger seat (1) and feed out connector with cable.
Installation note:
Plug connections are coded against incorrect assembly.
 To avoid malfunctions, make sure seat occupancy mat (3)
is cleanly laid:

- Insert the seat occupancy detection (3) in the

provided recess and clip in mounting.

- Install the cables and connectors for the seat

occupancy detection clean and without kinks.

- Slide and lock connector in central connector

housing.
 4/30/2016 1/2

65 77 602 Replacing sensor mat for front

passenger seat occupancy detector

Necessary preliminary tasks:

 Remove front passenger seat

Important!
Risk of damage on sharp-edged seat mechanism.
Guide all cables carefully through seat and backrest
mechanism.
Make sure cable is routed without kinks and tension.
Make sure plug connections are correctly locked.
Make sure connectors are correctly seated in latch
mechanisms.

Remove the central plug from the mounting.

Cut open cable strap (1).
Installation note:
Replace cable tie (1) at central plug.

Raise the tab and pull connector (2) out through the side of the
connector housing (3).

Detach cable for seat occupancy detection (1) from cable clip.
 4/30/2016 2/2

Lift the front seat cover with upholstery (1) and unclip the
mounting (2) for the seat occupancy detection (3).
Remove the seat occupancy detection (3) from upholstery front
passenger seat (1) and feed out connector with cable.
Installation note:
Plug connections are coded against incorrect assembly.
 To avoid malfunctions, make sure seat occupancy mat (3)
is cleanly laid:

- Insert the seat occupancy detection (3) in the

provided recess and clip in mounting.

- Install the cables and connectors for the seat

occupancy detection clean and without kinks.

- Slide and lock connector in central connector

housing.
 4/30/2016 1/1

54 12 ... Replacing slide sunroof frame

Important!
Make sure operations sequence is followed without
exception. (Risk of damage).

Necessary preliminary tasks:

1. Remove complete glass slide/tilt sunroof
2. Remove glass slide/tilt sunroof panel
3. Remove wind deflector
4. Remove drive unit with transmission
5. Remove water gutter
6. Remove headlining frame

Installation note:
We recommend following the installation sequence of
operations 6 to 1.
 Adjusting glass slide/tilt sunroof panel
 Initialise glass slide/tilt sunroof
 4/29/2016 1/2

12 41 041 Replacing solenoid switch

Turn off ignition.

Remove starter motor.

Release nut (1).

Remove cable lug (2).

Caution!
Do not turn cable lug (2) while tightening down - risk of
short circuit to starter motor housing.
Tightening torque, 12 41 4AZ.

Release screws (1).

Remove solenoid switch (1) and spring (2).

Unhook pin (3).
Installation:
Check pin (3) for wear and apply grease.
4/29/2016 2/2
 4/30/2016 1/1

35 21 041 Replacing spring for brake pedal

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism.

Disconnect return spring (1).

 4/30/2016 1/1

35 31 041 Replacing spring for clutch pedal

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism.

Disconnect return spring (1).

 4/30/2016 1/1

32 31 241 Replacing steering column adjustment

lever

Necessary preliminary tasks:

 Remove trim panel for pedal mechanism

Release nuts (1) from footwell and detach adjustment lever.

Installation note:
Replace nut (1).
In installed or closed condition, the adjustment lever must be
positioned parallel with the steering column!
Tightening torque 32 31 5AZ.
 4/30/2016 1/2

32 31 102 Replacing steering shaft sleeve

Special tools required:

 00 9 321

Necessary preliminary tasks:

 Remove steering column

Press latch mechanism (1) on the bulkhead (from engine

compartment) downward and press sleeve into passenger
compartment and remove.
 

Installation note:
Mount sleeve from passenger compartment!

First insert latch mechanism (1) into recess (1) on bulkhead at

 4/30/2016 2/2

bottom. Then press steering shaft collar upward until latch

mechanism (2) is felt and heard to engage.
Check that latch mechanism (2) is firmly seated from engine
compartment.
 4/30/2016 1/1

61 31 270 Replacing switch for reversing light

Note:
The installation location of the switch for the reversing light can
vary depending on the transmission variant.

Necessary preliminary tasks:

 Remove rear underbody protection if necessary

Version A:
Disconnect plug connection (1).
Release switch for reversing light (2).
Tightening torque 23 14 1AZ.

Version B:
Disconnect plug connection (1).
Release switch for reversing light (2).
Tightening torque 23 14 1AZ.
 4/30/2016 1/7

41 34 041 Replacing tail panel

Read contents of Body, General.

Strip down vehicle.

Procedure Observe repair stage 2!

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Rear trim panel

Following consumables are required:

Material Quantity

Adhesive K5b 1

Blind rivet N3 26

Punch rivet N4 12

Punch rivet N5 6

EMC screw 11
 4/30/2016 2/7

Cleaning agent R1 1

Sealant D1  

Cavity wax remover  

Removing rear trim panel

Operation is partially described on the left side. Right side
identical.

Open welded connections in area (1).

Open welded connections in area (1).

 4/30/2016 3/7

New part preparation

Operation is partially described on the left side. Right side
identical.

Cut separating cut (1) in accordance with schematic diagram and remove section (2).
Length of section approx. 60 mm.

Slide in rear trim panel (1) from bottom upwards. Adjust rear

trim panel in combination with rear lid and rear lights to fit and
secure.
 4/30/2016 4/7

Important!
Retaining screws must not be used in area in area of
tailgate seal.

In areas (1) and (2) set 4.2 mm diameter bore holes for blind
rivets:

Area Number

1 3

2 6

In areas (1) and (2) set 4.2 mm diameter bore holes for blind
rivets:

Area Number

1 1

2 3

Installation note:
Set blind rivet from outside inwards in area (2).

 
Remove new part and deburr bore holes.

Important!
Do not grind/sand new part in area of bonding surfaces.
 4/30/2016 5/7

Installing rear trim panel:

Clean all bonding surfaces on new part and on vehicle with
cleaning agent R1.
Apply adhesive to bonding surfaces.
When inserting new parts, make sure there is sufficient
adhesive on bonding surfaces.

Mount rear trim panel (1) and secure with blind rivets.

Important!
Three-plate connection!

In area (1) use 8 punch rivets N5 offset on both sides.

 4/30/2016 6/7

In area (1) set 6 punch rivets N4.

Press rear trim panel in areas (1) and remove emerging

adhesive.
Then install carrier for bumper panel to secure rear trim panel.
Important!
Prevent emerging adhesive from coming into contact with
support.
Do not use any cleaning agents containing solvents.
 4/30/2016 7/7

After hardening of the adhesive in area (1), install 9 EMC screws.

Graphic similar.

Fit an EMC screw after adhesive has hardened in area (1).

 4/29/2016 1/2

13 90 500 Replacing tank vent valve (N55)

Necessary preliminary tasks:

 Check stored fault message.
 Switch off ignition.
 Remove left charge air duct.

Unlock connector (1) and remove.

Unlock the hose (2) and detach it.
Pull off the tank vent valve (3) from holder in the direction of the
arrow.

Unlock connector (1) and remove.

Release screws (3).
Tightening torque 13 54 1AZ.
Remove throttle body part way and then unlock tank ventilation
line and pull off.
Remove throttle body (4).
Installation note:
Replace gasket on throttle body.
Feed out and remove tank vent valve.

Note:
Read out the fault memory of the DME control unit.
Delete fault memory.
4/29/2016 2/2
 4/29/2016 1/2

11 28 020 Replacing tensioning device for

alternator drive belt (N55)

Special tools required:

 11 0 390

Necessary preliminary tasks:

 Remove drive belt

Remove special tool 11 0 390.

Release screw (1) on belt tensioner.
Tightening torque 11 28 1AZ.

Assemble engine.
4/29/2016 2/2
 4/30/2016 1/2

63 25 004 Replacing the additional brake light

Necessary preliminary work:

 Release aerial amplifier

Note:
Schematic diagram shows additional brake light removed.

Unlock all locks (1) on additional brake light (2) in direction of

arrow.

Note:
Additional brake light is fitted with gasket with double-sided
adhesive and cannot be reused.

 
First press additional brake light (1) up out of the tailgate slightly
and hold.
Press retaining lugs (2) upward, beginning from one side, and
push additional brake light (1) out of the tailgate at the same
time.

Take additional brake light (1) out of tailgate (2) in direction of

arrow.
Cut through the seal with a suitable tool if necessary.
 4/30/2016 2/2

Disconnect plug connection (1).

Unlock and disconnect hose connection (2).
Remove additional brake light (3).

Important!
Risk of damage due to moisture penetration!
Where applicable, thoroughly remove gasket residue from
the tailgate.

Installation note:
Remove protective film from gasket (1) on the new part.
Gaskets (1) and lock (2) must not be damaged or missing.
 4/30/2016 1/7

41 11 201 Replacing the carrier support before the

wheel arch on the left

Read contents of Body, General.

Follow procedure for repair stage 2.
Strip down vehicle.

Following new body parts are required (see Electronic Parts

Catalogue):

- (1) Carrier support, outer wheel arch section

- (2) Wheel arch inner section support member

- (3) Carrier support end plate

Following consumables are required:
 

Material Quantity

Adhesive K1 1

Punch rivets N5 33

Sealant D1  

Cleaning agent R1 1

Removing carrier support

 4/30/2016 2/7

Open welded connections in areas (1).

Open welded connections in area (1).

Mark severance cut (1) in accordance with dimension and

detach carrier support.
Dimension a = approx. 35 mm from 15 mm diameter hole.
 4/30/2016 3/7

Detach welded connections (1) and remove holder (2).

Mark severance cut in accordance with dimension and cut.

Important!
Cut outer metal panel only.

Dimension a = approx. 55 mm from previous separation cut.

Open weld joints in areas (1) and remove metal panel section.

New part preparation

 4/30/2016 4/7

Mark severance cut (1) on inside part of carrier support in

accordance with severance cut on vehicle and cut.
Release welded connections (2) for holder.
Mark severance cut on outside part of carrier support in
accordance with severance cut on vehicle and disconnect.

Adjust new parts with add-on parts to fit and secure.

Prepare reinforcement plates (welded) at severance cuts (1).
Prepare new parts in engine support area (2) for plug-welding.
Note:
In areas (3), the new components are joined using the adhesive
riveting method.

In area (1), prepare new part and engine support for plug-
welding.
Note:
In areas (2), the new parts are joined using the adhesive
riveting method.
 4/30/2016 5/7

Important!
Structure bonding!
Observe preparation of bonding surfaces.

Installing carrier support

Install new part (carrier support for inner wheel arch section)
and reinforcement plate and weld in place.

Install reinforcement plate in area of severance cut (1) and weld

in place.
Clean all bonding surfaces with cleaning agent R1.
Apply adhesive to bonding surfaces, fit new component (outside
part of carrier support) and fasten.
In areas (2) and (3), rivet new part with punch rivets N5.
 4/30/2016 6/7

Area Number

2 11

3 10

Weld new part and reinforcement plate in the area of severence

cut (1).
Important!
Risk of damage to adhesive area!
Avoid applying excessive heat to the neighbouring
adhesive areas!

Note:
Do not seal new parts in the adhesive rivet areas (2) and (3).
(visible area)

Apply adhesive to bonding surfaces, fit new part carrier support

end plate and secure.
In areas (2), rivet new part with 12 punch rivets N5.
Weld new part in area (1).
Important!
Risk of damage to adhesive area!
Avoid applying excessive heat to the neighbouring
adhesive areas!

Note:
Do not seal new parts in the area of the adhesive riveting.
(visible area)

Remove excess adhesive.

Do not use any cleaning agents containing solvents.
4/30/2016 7/7
 4/30/2016 1/1

51 14 001 Replacing the front BMW badge

Special tools required:

 00 9 327

Important!
The notes on component bonding with double-sided
adhesive tape serve as the basis for this repair instruction
and must be observed without fail.

Tape off working area around the BMW badge (1) with
adhesive tape.
Carefully warm up the BMW badge (1) with a hot air blower
(temperature approx. 40 - 55 °C ) and lift it out with the special
tool 00 9 327.

Installation note:
Pull liner* off adhesive tape (2).
Position BMW badge (1) over guides (3) and press down firmly.
* Liner is the protective film on a new plate.
 4/30/2016 1/3

33 17 005 Replacing the rubber mounts for the rear

axle final drive suspension at rear

Special tools required:

 33 0 031
 33 0 032
 33 0 035
 33 0 036
 33 5 105
 33 4 275
 33 5 200

Do not press the rubber mount in and out more than once.

Necessary preliminary tasks:

 Remove rear axle final drive.
 Lower rear axle support.

Important!
Determine the installation position of the bearing before
pressing it out to ensure a correct installation of the rear
axle differential.
 4/30/2016 2/3

For this purpose, attach special tool 33 0 031 from the front.

Measure the protrusion (A) and notate.

Withdrawing rubber mount:

Pull out rubber mount with special tools 33 0 031, 33 0 032,
33 0 035 and 33 0 036.
Note:
Ensure that the33 0 032 special tool is correctly seated on the
rear axle support.
Counter support with spindle 33 0 035.
Use ratchet ring wrench33 5 105.

Installing rubber mount:

Important!
Align rubber mount horizontally by way of elongated
hole (1).

Draw in the rubber mounts (1) with special

tools 33 0 03133 0 035, 33 0 036 and 33 4 275 to previously
determined protrusion (A).
Note:
Make sure that the special tools 33 0 031 and 33 4 275 are set
up correctly.
 4/30/2016 3/3

Counter support with spindle 33 0 035.

Use ratchet ring spanner 33 5 105.

Assembly sequence:
1. Insert the rear axle final drive into the rear axle support
using the workshop jack and special tool33 5 200.
2. Insert screws (1) (do not tighten).
3. Insert bolt from rear and replace nut (2) (do not tighten
down).
4. Release tensioning strap and lower special tool33 5 200
and move away.
5. Tighten down screws (1).
Tightening torque 33 17 1AZ.
6. Tighten nut (2).
Tightening torque 33 17 2AZ.
 4/29/2016 1/7

11 31 051 Replacing timing chain (N55)

Special tools required:

 11 0 300
 11 4 280
 11 8 180
 11 8 660
 11 9 260

Necessary preliminary tasks:

 Remove cylinder head cover.
 Remove all spark plugs.
 Remove crankshaft seal at front
 Remove tensioning device for drive belt.
 Remove vibration damper.
 Check timing.
 Remove sealing cover for vacuum pump.
 Remove sealing cap of chain tensioner for oil pump.

Engine removed:
Block crankshaft with special tool 11 9 260.
Important!
To release central bolt (1), remove special tool 11 0 300.

Important!
When central bolt of crankshaft is released, there is no
longer a secure connection to timing drive.
 4/29/2016 2/7

Mark position of crankshaft using a coloured mark (1).

This will make future insertion of special tool 11 0 300 easier.

Vehicles with automatic transmission:

Block crankshaft with special tool 11 8 660.

Vehicles with manual gearbox:

Attach special tool 11 8 180 to manual transmission with
existing transmission bolts (1).
Block crankshaft in direction of arrow with special tool.

Important!
Before releasing the central bolt, the hydraulic chain
tensioner must be drained.

Carefully press tensioning rail (1) with a suitable screwdriver (2)

in direction of arrow.
As the oil pressure in the chain tensioner can only be drained
 4/29/2016 3/7

pulsating, the tensioning rail (1) must be pressed several times.

Press the tensioning rail (1) and hold down.

Fix chain tensioner piston in position with a suitable lock pin (2).

Important!
Breakaway torque of the central bolt > 600 Newton metres
A 3/4-inch tool (large powered square) is required to
release central bolt.

Release central bolt (1) with 3/4-inch tool (2).

Tightening torque 11 21 1AZ.

Remove chain tensioner.

Screw in vibration absorber screws (1).
Move hub (2) on crankshaft forward in direction of arrow to
remove.
 4/29/2016 4/7

Open screw plug (1).

Tightening torque 11 31 8AZ.

Open screw plug (1).

Tightening torque 11 11 7AZ.
Installation note:
Replace aluminium screws.

Release bearing journal (1) from timing chain module on

cylinder head.
Tightening torque 11 31 6AZ.
 4/29/2016 5/7

Important!
Install special tool 11 4 280 to release the central bolts on
the intake and exhaust camshaft adjusters.

Remove intake and exhaust camshaft adjusters.

Release bearing journal (1) from timing chain module on

crankcase.
Tightening torque 11 31 5AZ.

Release bolts (1) from timing chain module on cylinder head.

Tightening torque 11 31 4AZ.
Remove chain module with timing chain and camshaft sprocket
upwards in direction of arrow.
Note:
Graphic N52.
 4/29/2016 6/7

Important!
Note direction of installation of camshaft sprocket (2).
Collar (see arrow) on camshaft sprocket (2) points to
engine.
Incorrect assembly will result in engine damage.

Pull timing chain (1) upwards until camshaft sprocket (2)

engages chain guide (3).
Install timing chain (1) and sprocket (2) in this position.
Installation note:
Always hold timing chain (1) under tension. Timing chain (1)
may jam on chain guide (3).

Insert central bolt (1) with hub for crankshaft.

Tighten down central bolt (1).
Tightening torque 11 21 1AZ.
Install intake and exhaust camshaft adjusters.
Install chain tensioner.
 4/29/2016 7/7

Crank engine twice.

Check timing.
If necessary, adjust valve timing.
Replace front crankshaft seal.
Assemble engine.
 4/29/2016 1/7

REP-REP-RAE9011N47-1131X03   Replacing top timing chain (N47D/C K/U/O/T 0/1)

VIN: XXXXXXX Vehicle: 1'/F20/5-

DOOR/M135I/N55/MANUAL/EUR/RL/2014/03

System 3.42.40.11060 Data R3.42.40.11060

Version: Version:

11 31 548 Replacing top timing chain

(N47D/C K/U/O/T 0/1)

Special tools required:

 2 354 958
 2 354 984
 2 354 983
 2 353 281
 2 354 976
 2 354 962

Important!
Loose chain sections can fall into the engine!

Necessary preliminary tasks:

 Check camshaft time-lag.

Important!
Screws (1) can fall into the chain drive risk of
damage!

Secure special tool 2 354 958 with bolts (1) to cylinder

head.
Tightening torque. 11 00 2AZ.
 4/29/2016 2/7

Cover cylinder head (1) at chain drive with a suitable

cleaning cloth.
Mark right rivet (2) at cover tab (3) (see arrow).

Opening the timing chain:

Turn back pressing-off bolt (1) on special tool 2 354 984 .

Installation note:
Bore hole (centring aid)

Turn back pressing-off bolt on special tool 2 354 984 up

to short length (see arrow).

Important!
Loose rivet can fall in the engine compartment.
Seal bore hole on special tool 2 354 983 with
suitable auxiliary materials.

Position special tool 2 354 983 on timing chain (rivet)

(centring).
 4/29/2016 3/7

Pretension spindle 2 354 984 up to bolt / limit position of

timing chain by hand.
Press off rivet with pressing-off bolt (1), screw in special
tool up to limit position.

Remove rivet (1) from special tool 2 354 983 with a

magnet (2).
Remove special tool 2 354 983.

Installation note:
Coat ends of chain lock (1) with grease.

Tightening the timing chain:

Attach chain lock (1) in the open timing chain.
Check camshaft sprocket for wear.

Important!
Observe direction of installation!
Oil holes (3) must be visible from the outside.

Attach timing chain (2) in the chain lock (1).

Both timing chains must be aligned with each other.
 4/29/2016 4/7

Outer tab on lock (1) must be aligned with the outer tabs

of the timing chains (see graphic).

Note:
Turn engine in direction of engine rotation until the run-
through timing chain can be removed.

Keep timing chains (1) under tension.

Do not crank engine too far under any circumstances.

Important!
Loose components can fall into the chain drive risk
of damage!

Remove timing chain (3) with chain lock (2).

Remove special tool 2 353 281.

 4/29/2016 5/7

Pressing in the timing chain:

Important!
Loose components can fall into the chain drive risk
of damage!

Press in both end of timing chain (1) on camshaft

sprocket.
Insert chain lock (2) from the rear through both ends of
new timing chain (1).

Installation note:
Rounded sides (2) of cover tab (1) must point towards
timing chain.

Prepare special tool 2 354 976 with cover tab (1) with the

rounded side (see graphic).
Fasten cover tab (1) on magnets of special tool
2 354 976.
 4/29/2016 6/7

Important!
Loose components.

Prepare special tool 2 354 976 with cover tab on special

tool 2 354 962.

Important!
Maximum 20 Nm
Do not increase torque, risk of damage on chain
lock.

Manually join cover tab on chain lock to spindle of

special tool 2 354 976.
Make sure chain locks are positioned exactly in the
matrix risk of damage!
Press on cover tab with 20 Nm.
Graphic shows removed chain drive.

Important!
Do not exceed maximum 20 Nm torque on chain
lock not risk of damage!
For safety purposes, the chain lock must be
pressed in again.
 4/29/2016 7/7

Remount special tool 2 354 976 on special tool

2 354 962 (see graphic).
Press in both rivets singly on chain lock with special
tool 2 354 976 to maximum 20 Nm.

Check both rivets (see graphic).

Installation note:
Install chain tensioner with part number 8 576 201 (AF
24).
Replace sealing ring.

Tightening torque: 11 12 3AZ.

Follow diagnosis instruction.

 4/30/2016 1/3

33 33 101 Replacing two rubber mounts (front) for

rear axle support

Special tools required:

 33 4 140
 33 0 012
 33 4 149
 0 496 887
 2 208 576
 2 155 744
 2 208 574
 33 4 432
 33 4 433

Necessary preliminary tasks:

 Lower rear axle support.

Withdrawing rubber mount:

Complete special tool 33 4 140 using 33 0 012 and 33 4 149, as
shown.

Align notch (1) on special tool 0 496 887 with notch (2) on the

rear axle support.
 4/30/2016 2/3

Pull out rubber mounts using special tools 0 496 887, 33 4 140,

2 208 576,2 155 744 and2 208 574 pull out of the rear axle
support.
Note:
Make sure special tool 33 4 140 is correctly supported on rear
axle support bush.

Installing rubber mount:

Notch (1) and arrow (2) of the rubber mount must point in the
direction of travel.

Draw in rubber mount (1) with special tools33 4 432, 33 4 433,

2 155 744,2 208 574 and2 208 576 to limit position.
Note:
Align recesses on special tool 33 4 433 with rubber mount (1).
4/30/2016 3/3
 4/30/2016 1/3

33 33 101 Replacing two rubber mounts (rear) for

rear axle support

Special tools required:

 33 4 140
 33 0 012
 33 4 149
 2 241 760
 2 208 576
 2 155 744
 2 208 574
 2 241 779
 2 208 780

Necessary preliminary tasks:

 Lower rear axle support.

Withdrawing rubber mount:

Complete special tool 33 4 140 using 33 0 012 and 33 4 149, as
shown.

Align notch (1) on the special tool 2 241 760 with the notch (2)
on the rear axle support.
 4/30/2016 2/3

Pull out rubber mounts using special tools 2 241 760, 33 4 140,

2 208 576, 2 155 744 and 2 208 574 pull out of the rear axle
support.
Note:
Make sure special tool 33 4 140 is correctly supported on rear
axle support bush.

Installing rubber mount:

Notch (1) and arrow (2) of the rubber mount must point in the
direction of travel.

Draw in rubber mount (1) with special tools2 241 779,

2 208 780, 2 155 744, 2 208 574 and 2 208 576 to limit position.
Note:
Align recess on the special tool 2 208 780 with the rubber
mount (1).
4/30/2016 3/3
 4/30/2016 1/2

25 11 ... Replacing U-type bellows

Necessary preliminary tasks:

 Remove gearshift lever.
 Remove vibration damper.

Detach U-type bellows (2) from gearshift lever (1).

If necessary, first rub inside with Circolight (sourcing reference:
BMW Parts Department).

Installation note:
- Degrease gearshift lever (1)

- Coat inside of U-type bellows shaped element (2)

with Circolight (sourcing reference: BMW Parts
Service)

- Pull U-type bellows from above over gearshift lever

and align

- Arrow (4) on upper lip (3) must point crossways to

mount eye in direction of travel

Key:
1. Gearshift lever
2. U-type bellows shaped element
 4/30/2016 2/2

3. U-type bellows lip

4. Direction arrow
 4/30/2016 1/1

34 33 071 Replacing vacuum hose for brake

booster (N43)

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove lower section of microfilter housing
 Remove ignition coil cover

Important!
Before beginning work, fully press the brake pedal several
times to reduce the vacuum pressure in the brake servo.
This makes it easier to detach the vacuum hose.

Unlock quick-release fastener (1) and pull out vacuum line (2).

Unlock quick-release coupling (1) and detach vacuum line.

Disconnect vacuum hose (2) from vacuum line.
Release vacuum hose at clamp (3) and remove.
 4/30/2016 1/2

34 33 071 Replacing vacuum hose for brake

booster (N63)

Important!
Before beginning work, fully press the brake pedal several
times to reduce the vacuum pressure in the brake servo.
This makes it easier to remove the vacuum hose.
Vacuum hose and non-return valve are welded together
and are replaced together as a single unit.

Necessary preliminary tasks:

 Read and comply with General Information.
 Remove partition wall, units compartment

Pull off partition wall seal upper part (1) in direction of arrow.
Remove non-return valve (2) from brake servo.
Installation note:
Check gasket for non-return valve and replace if necessary.

Unclip vacuum line (1) from line clip (2).

Unlock snap fastener (3) and detach vacuum line.
4/30/2016 2/2
 4/29/2016 1/3

12 32 501 Replacing voltage regulator

Necessary preliminary tasks:

 Switch off ignition
 Disconnect battery negative lead
 Notes on removing and installing electronic control units
 Remove alternator

Bosch:
Release protective caps (1).

Bosch:
Release screw (1) and nuts (2), remove cover.

Bosch:
Release screws and remove regulator switch (1) in direction of
arrow.
 4/29/2016 2/3

Bosch:
Installation:
Clean contact surfaces and check pretension of contact
spring, replace regulator switch if necessary.
Measurement A = min. 5 mm.

Check collector ring for wear and recondition if necessary.

Valeo:
Slacken nut (1).
Slacken nut (2).
Release screws (3).
Release cover (4).

Valeo:
Release screws.
Remove regulator switch (1) towards top.
 4/29/2016 3/3

Valeo:
Installation:
Clean contact surfaces and check pretension of contact
spring, replace regulator switch if necessary.
Measurement A = min. 5 mm.

Check collector ring for wear and recondition if necessary.

Installation:
Fit new regulator (1) with attached mounting sleeve (2) or
locked carbon brush.
Pull off mounting sleeve (2) and replace with cover (3).
 4/30/2016 1/1

61 71 061 Replacing washer fluid reservoir for

windscreen washer system

Necessary preliminary tasks:

 Remove front right wheel arch cover

Note:
Shown with side wall removed for purposes of clarity.

 
Release screw (1).
Tightening torque 61 66 1AZ.
Pull the washer fluid reservoir (2) out of the guides (arrow) in
the direction of the arrow).
Unlock and disconnect all plug connections.
Unlock filler hose and pull it off the fitting on the washer fluid
reservoir.
Note:
Catch any escaping washer fluid if necessary.
 
Replacement:
 Modify all windscreen washer pumps

Installation note:
 Replace strainers on washer pumps
 Coat sealing rings of washer pumps with lubricant.
 Lay hose pipes of washer pumps without kinks and clip
into holders on washer fluid reservoir
 Top up the washer fluid reservoir
 4/30/2016 1/2

51 13 061 Replacing wheel arch trim on front left or

right side panel (Japanese national-
market version)

Important!
 The notes on component bonding with double-sided
adhesive tape serve as the basis for this repair
instruction and must be observed without fail.

Important!
 For reasons of optimal adhesion, painting of bonding
surfaces on the inside of the wheel arch trim is
prohibited!
 The application of the adhesive pad (double-sided
adhesive tape) onto the wheel arch trim must
therefore occur prior to painting the wheel arch trim!

(1) = Wheel arch trim primed

(2) = adhesive pad

Removal:
Carefully heat the wheel arch trim (1) with a hot air blower
(temperature approx. 40-55 °C) and pull off.
 4/30/2016 2/2

Installation:
Pull protective film off adhesive pad (double-sided adhesive
tape).
Attach wheel arch trim (1) to side wall according to specified
dimensions and press down firmly.
Measurement a = approx. 2,0 mm.
Dimension b = approx. 2.5 - 3.0 mm.
 4/30/2016 1/2

51 13 063 Replacing wheel arch trim on rear left or

right side panel (Japanese national-
market version)

Important!
 The notes on component bonding with double-sided
adhesive tape serve as the basis for this repair
instruction and must be observed without fail.

Important!
 For reasons of optimal adhesion, painting of bonding
surfaces on the inside of the wheel arch trim is
prohibited!
 The application of the adhesive pad (double-sided
adhesive tape) onto the wheel arch trim must
therefore occur prior to painting the wheel arch trim!

(1) = Wheel arch trim primed

(2) = adhesive pad

Removal:
Carefully heat the wheel arch trim (1) with a hot air blower
(temperature approx. 40-55 °C) and pull off.
 4/30/2016 2/2

Installation:
Pull protective film off adhesive pad (double-sided adhesive
tape).
Attach wheel arch trim (1) to side wall according to specified
dimensions and press down firmly.
Measurement a = approx. 2,0 mm.
Measurement b = approx. 2,5 mm
 4/30/2016 1/2

51 13 063 Replacing wheel arch trim on rear left or

right side panel (Japanese national-
market version)

Important!
 The notes on component bonding with double-sided
adhesive tape serve as the basis for this repair
instruction and must be observed without fail.

Important!
 For reasons of optimal adhesion, painting of bonding
surfaces on the inside of the wheel arch trim is
prohibited!
 The application of the adhesive pad (double-sided
adhesive tape) onto the wheel arch trim must
therefore occur prior to painting the wheel arch trim!

(1) = Wheel arch trim primed

(2) = adhesive pad

Removal:
Carefully heat the wheel arch trim (1) with a hot air blower
(temperature approx. 40-55 °C) and pull off.
 4/30/2016 2/2

Installation:
Pull protective film off adhesive pad (double-sided adhesive
tape).
Attach wheel arch trim (1) to side wall according to specified
dimensions and press down firmly.
Measurement a = approx. 2,0 mm.
Measurement b = approx. 2,5 mm
 4/30/2016 1/1

61 12 062 Replacing wiring harness for front

bumper

Important!
Read and comply with notes on handling wiring harnesses
and cables.

Necessary preliminary tasks:

 Remove front bumper panel

Note:
Similar to graphic.

Unlock plug connections (1) for all ultrasonic sensors and

disconnect.
Unclip wiring harness (2) from the bumper panel (3).
Remove wiring harness (2) from the bumper panel (3).
Installation note:
Make sure wiring harness (2) is laid correctly.
 4/30/2016 1/2

61 12 200 Replacing wiring harness in left or right

front door

Important!
Read and comply with notes on handling wiring harnesses
and cables.

Necessary preliminary tasks:

 Close front side window completely
 Remove front sound insulation
 Remove corner cover for mirror mount.

Note:
Work shown on the F20 by way of example, deviations in detail
are possible in other models.
Similar to graphic.

Release and disconnect plug connection (1) at power window

regulator.
Unlock plug connection (2) on door lock and disconnect.
Unlock and disconnect plug connection (3) on outside door
handle light.
Unlock and disconnect plug connection (4) on speaker.
Unlock and disconnect plug connection (5) on outside door
mirror.
Unclip door wiring harness at associated points (6).
Installation note:
 4/30/2016 2/2

Make sure wiring harness for the door wiring harness is routed
correctly.

Loosen lock (1) in upward direction with suitable tool.

Disconnect connector (2) and detach in direction of arrow to
thereby disconnect the plug connection.
Pull rubber grommet (3) forward out of door.
Feed the door wiring harness out toward the front and remove.
Installation note:
Make sure connector (2) is properly locked.
 4/30/2016 1/2

61 12 210 Replacing wiring harness in left or right

rear door

Important!
Read and comply with notes on handling wiring harnesses
and wiring.

Necessary preliminary tasks:

 Close rear side window completely
 Remove rear sound insulation

Unlock plug connection (1) on door lock and disconnect.

Release and disconnect plug connection (2) at power window
regulator.
Unlock and disconnect plug connection (4) on outside door
handle light.
Unclip door wiring harness at points (3).
 
Installation note:
Make sure wiring harness for the door wiring harness is routed
correctly.

Loosen lock (1) in upward direction with suitable tool.

Disconnect connector (2) and detach in direction of arrow to
 4/30/2016 2/2

thereby disconnect the plug connection.

Pull rubber grommet (3) forward out of door.
Feed the door wiring harness out toward the front and remove.
Installation note:
Make sure connector (2) is properly locked.
 4/29/2016 1/5

12 51 001 Replacing wiring harness section for

engine (N55)

Important!
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Jointing torque and angle of rotation must be observed
without fail (risk of damage).

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Disconnect negative battery cable.
 Remove sound insulation bulkhead upper part, centre.
 Remove intake plenum.
 Partially detach wiring harness for injectors and ignition
coils.
 Remove fan cowl.
 Remove front underbody protection.
 Remove rear underbody protection
 4/29/2016 2/5

Unlock and pull off connector (1) from power distribution

module and cable clips.
Release clamp (2) and expose wiring harnesses.

Release wiring harnesses (1) from cable clip.

Unfasten screws (2).
Unlock and pull off connector (3) from cable clip.
Put cable clip aside.

Unlock all connectors (1) from control unit and disconnect.

Installation note:
Make sure grommets are correctly fitted (watertightness).

Release screws (1) below cable channel (2).

Replace aluminium screws.
Tightening torque 13 53 10AZ.
 4/29/2016 3/5

Release screws (1).
Tightening torque 12 90 4AZ.
Release cable channel (2).
Installation note:
Reconnect the earth connection.
Replace aluminium screws.

Unlock and disconnect following connectors and lines

Unlock connector on charging pressure sensor and disconnect

Unlock connector on hot film air mass meter and disconnect

Unlock connector on intake pressure sensor and disconnect

Unlock connector on oxygen sensor and disconnect

Unlock connector on monitoring sensor and disconnect

Unlock connector on pressure converter and disconnect

Unlock connector on high-pressure fuel sensor and disconnect

Unlock connector on tank vent valve and disconnect

Unlock connector on starter motor and disconnect

Unlock connector on the knock sensors and disconnect

Unlock connector on oil temperature sensor and disconnect

 4/29/2016 4/5

Unlock connector on fuel low-pressure sensor and disconnect

Unlock connector on throttle body and disconnect

Unlock connector on high pressure pump and disconnect

Unlock connector on alternator and disconnect

Unlock connector on air conditioning compressor and disconnect

Unlock connector on oil level sensor and disconnect

Unlock connector on crankshaft sensor and disconnect

Unlock connector on heating element for air duct and disconnect

Unlock connector on coolant thermostat and disconnect

Unlock connector on hydraulic valve and disconnect

Unlock connector on the coolant pump and disconnect

Unlock connector on exhaust turbocharger and disconnect

Unlock connector on both camshaft adjustment solenoid valves and disconnect

Release earth cable on crankcase lower section

Tightening torque 12 90 2AZ.

Release earth cable at rear of cylinder head

Tightening torque 12 90 3AZ.

Unlock connector on intake camshaft pulse sensor and disconnect

Unlock connector on exhaust camshaft pulse sensor and disconnect

Unlock connector on oil pressure switch and disconnect

Unlock connector on switching motor for eccentric shaft and disconnect

Release wiring harness if necessary from existing clips and

clamps.
Feed out wiring harness and remove.
 4/29/2016 5/5

Installation note:
Check wiring harness installation arrangement.
Check plug connections for correct fit.
Check stored fault message.
Delete fault memory.
 4/29/2016 1/3

12 51 100 Replacing wiring harness section for

ignition and injectors (N55)

Important!
Read and comply with notes on protection against
electrostatic discharge (ESD protection).

Necessary preliminary tasks:

 Read out the fault memory of the DME control unit.
 Switch off ignition.
 Disconnect battery earth lead.
 Remove rear ignition coil cover.

Release oxygen sensor connector (1) from bracket.

Release screw (2).
Put cable clip aside.

Unlock rear plug (1) from the control unit and disconnect.
Release rear wiring harness from intake plenum.
 4/29/2016 2/3

Release bolt (1) at rear of cable channel.

Tightening torque 12 90 1AZ.

Release nuts (1) and remove earth cable.

Tightening torque 12 90 5AZ.
Unlock all connectors from ignition coils and injectors and
detach.
Unclip, feed out and remove wiring harness (2).

Note:
Check stored fault messages.
Delete fault memory.
4/29/2016 3/3
 4/29/2016 1/2

11 12 719 Resurfacing cylinder head lower face

(N55)

Necessary preliminary tasks:

 Remove cylinder head.
 Remove exhaust camshaft.
 Remove intermediate lever on inlet side.

Check evenness of cylinder head sealing faces with a standard

straightedge (1).
Note:
Max. deviation from flatness (longitudinal) 0.10 mm

Check evenness of cylinder head sealing faces with a standard

straightedge (1).
Note:
Max. deviation from flatness (transverse) 0.05 mm

Check cylinder head for watertightness.

Assemble engine.
4/29/2016 2/2
 4/30/2016 1/3

41 00 ... Safety at work

Note national regulations.

1.0 Compressed air:

- Air guns must not be pointed at individuals. "Blowing off" the body with compressed air may lead to
serious injury.

- The devices are not permitted to be cleaned with compressed air due to dust contamination.

 

2.0 Electrical systems/devices:

- Only perfectly functioning systems and devices may be used.

- Repairs on electrical systems and devices must only be performed by certified electricians.

 

3.1 Working with aluminium dust:

- Wear a fine dust mask.

- Only applicable to E52 and I01: Use explosion-proof exhaust extraction unit.

- Note national regulations.

 

3.2 Removing sealant.

- Hydrochloric acid is created when PVC sealing material is heated to temperatures in excess of 180 °C.

- Remove PVC sealant with a rotating wire brush only or heat material with a hot air blower to maximum
180 °C and remove with a spatula.

- Ensure that all enclosed areas are well ventilated or are provided with direct extractor facilities.

 

3.3 Arc welding and brazing solder:

 4/30/2016 2/3

Important!

The extremely bright arc during welding may cause serious injury to the eyes if appropriate protective
measures are not taken.

- Use a welding screen suitable for the relevant welding method (metal active gas or metal inert gas).

- Separation of workbays with protective curtains.

- Use a welding-emissions extractor facility.

- The welder must wear protective clothing and gloves which are suitable for welding (i.e. flameproof).

- A fire extinguisher must be located within reach of the welding area.

- Do not carry out any welding work in the proximity of a fuel tank e.g. when it is installed.

- Note national regulations.

 

3.4 Working with chemical products (adhesive, cleaning agents, fillers, etc.):

Heed the manufacturer's material safety data sheets.

Important!

Handling chemical products may result in allergic skin and breathing reactions.

- Do not eat, drink or smoke while working with these products.

- Avoid direct contact with eyes and skin.

- Wear safety goggles, protective gloves and if necessary an apron.

- Ensure that all enclosed areas are well ventilated or extract fumes directly.

- Use a breathing apparatus with a suitable filter type when ventilation is insufficient.

- Wear impermeable protective clothing.

- Immediately change contaminated work clothing.

- After finishing work, thoroughly clean your hands and apply protective skin cream.

- Always keep an eye douche on hand, change the water regularly (once a month).
 4/30/2016 3/3

- Store bonding products in a secure cabinet only.

- Keep bonding products away from naked flames and other ignition sources.

- Protect bonding products against strong heat sources and direct sunlight.

- Note national regulations.

First Aid:

If product comes in contact with eyes, immediately flush with running water for about 10 -15 minutes.
Seek the advice of eye specialist.

In the event of skin contact and where applicable an allergic skin reaction, clean the affected areas
immediately with soap and water and then apply silicone-free skin cream. If necessary, consult a
doctor.

If an adhesive product is swallowed, rinse mouth/parts of mouth thoroughly with running water. Drink
1-2 glasses of water. Do not induce vomiting. Consult a doctor.

After inhaling adhesive vapours ensure ample supply of fresh air. Stay calm. Keep air passages
open. Consult a doctor.

 

3.5 Repair work with carbon:

- Do not eat, drink or smoke while working with these products.

After finishing work, thoroughly clean your hands. Use protective hand cream.

- Fire, smoking and naked flames are forbidden.

- Wear work clothes, safety shoes, safety goggles and protective gloves.

- Only carry out grinding and cutting work with explosion-proof extraction.

Wear ear protectors.

- Wear a dust mask (minimum class FFP2).

- Avoid carbon dust contact with skin, eyes and clothing.

- Regularly clean the working area with a vacuum cleaner and wipe the surfaces with a damp cloth.

- Separate workbay by means of mobile partition walls or protective curtains.

 4/30/2016 1/2

00 Safety information for working on

vehicles with automatic engine start-stop
function (MSA)

Warning!
If the engine hood/bonnet contact is pulled upwards
(workshop mode), the information "switch closed" is
output. The automatic engine start‐stop function is active.
An automatic engine start is possible.

Observe safety precautions when working on MSA vehicles.

Before carrying out practical work on the engine, always
ensure that the MSA functionality is deactivated so as to
prevent automatic engine starting while work is being carried
out in the engine compartment.

MSA function is deactivated by:

 Deactivate MSA by means of button (1) in passenger

compartment
 Open seat belt buckle and driver's door

 Open engine bonnet/hood and ensure that engine

hood/bonnet contact is not in workshop mode
 Workshop mode
A = 10 mm
 Basic setting (engine hood/bonnet open)
B = 7 mm
To make sure that the engine hood/bonnet contact is at
the basic setting, if necessary press the hood/bonnet
contact up to the limit position before starting work and
 4/30/2016 2/2

slowly release.

When working with diagnosis tools:

 Observe instructions in diagnosis tool

Note:
For further information on automatic engine start‐stop function
(MSA):
 Refer to the Service Information (bulletin) (for manual
transmissions)  Service Information
(bulletin) 61 01 07 335 
 Refer to the Service Information (bulletin) (for automatic
transmissions or twin-clutch gearboxes)  Service
Information (bulletin) 61 01 10 629
 4/30/2016 1/2

00 Safety information for working on

vehicles with automatic engine start-stop
function (MSA)

Warning!
If the engine hood/bonnet contact is pulled upwards
(workshop mode), the information "switch closed" is
output. The automatic engine start‐stop function is active.
An automatic engine start is possible.

Observe safety precautions when working on MSA vehicles.

Before carrying out practical work on the engine, always
ensure that the MSA functionality is deactivated so as to
prevent automatic engine starting while work is being carried
out in the engine compartment.

MSA function is deactivated by:

 Deactivate MSA by means of button (1) in passenger

compartment
 Open seat belt buckle and driver's door

 Open engine bonnet/hood and ensure that engine

hood/bonnet contact is not in workshop mode
 Workshop mode
A = 10 mm
 Basic setting (engine hood/bonnet open)
B = 7 mm
To make sure that the engine hood/bonnet contact is at
the basic setting, if necessary press the hood/bonnet
contact up to the limit position before starting work and
 4/30/2016 2/2

slowly release.

When working with diagnosis tools:

 Observe instructions in diagnosis tool

Note:
For further information on automatic engine start‐stop function
(MSA):
 Refer to the Service Information (bulletin) (for manual
transmissions)  Service Information
(bulletin) 61 01 07 335 
 Refer to the Service Information (bulletin) (for automatic
transmissions or twin-clutch gearboxes)  Service
Information (bulletin) 61 01 10 629
 4/29/2016 1/2

00 Safety information for working on

vehicles with automatic engine start-stop
function (MSA)

Warning!
If the engine hood/bonnet contact is pulled upwards
(workshop mode), the information "switch closed" is
output. The automatic engine start‐stop function is active.
An automatic engine start is possible.

Observe safety precautions when working on MSA vehicles.

Before carrying out practical work on the engine, always
ensure that the MSA functionality is deactivated so as to
prevent automatic engine starting while work is being carried
out in the engine compartment.

MSA function is deactivated by:

 Deactivate MSA by means of button (1) in passenger

compartment
 Open seat belt buckle and driver's door

 Open engine bonnet/hood and ensure that engine

hood/bonnet contact is not in workshop mode
 Workshop mode
A = 10 mm
 Basic setting (engine hood/bonnet open)
B = 7 mm
To make sure that the engine hood/bonnet contact is at
the basic setting, if necessary press the hood/bonnet
contact up to the limit position before starting work and
 4/29/2016 2/2

slowly release.

When working with diagnosis tools:

 Observe instructions in diagnosis tool

Note:
For further information on automatic engine start‐stop function
(MSA):
 Refer to the Service Information (bulletin) (for manual
transmissions)  Service Information
(bulletin) 61 01 07 335 
 Refer to the Service Information (bulletin) (for automatic
transmissions or twin-clutch gearboxes)  Service
Information (bulletin) 61 01 10 629
 4/30/2016 1/2

64 50 ... Safety informations for handling

refrigerant oil

Warning!
Danger of injury!
Refrigerant circuit is under high pressure! Work on the
refrigerant circuit may only be carried out by experts!
Draw off refrigerant without fail BEFORE all repair work on
the refrigerant circuit.
The refrigerant circuit is depressurised AFTER drawing
off!
 Before conducting repairs, check the actual pressure
drop on the pressure gauge of the A/C service
station
Read and comply with the relevant operating instructions
for the A/C service station used!

Protective measures/rules of conduct:

 Wear safety goggles
 Wear oil-resistant protective gloves
 Do not smoke!
 Observe country-specific safety regulations.

First aid measures:

 If swallowed: Do NOT induce vomiting, unless expressly
instructed to do so by medical personnel. Do not
administer anything to an unconscious person through
their mouth. Consult a doctor immediately if larger
quantities of this substance are swallowed. Loosen tight-
fitting items of clothing (e.g. collar, tie, belt or similar).
 Eye contact: Remove contact lenses if worn. In the event
of eye contact, rinse eyes for at least 15 minutes with
plenty of water. It is essential to use WARM WATER.
Consult a doctor.
 Skin contact: In the event of skin contact, rinse
immediately with plenty of water. Remove contaminated
clothes and shoes. Wash affected clothes before wearing
again. Clean shoes thoroughly before reusing. Call for a
doctor.
 4/30/2016 2/2

 After inhalation: If inhaled, take the person affected

outside into fresh air immediately and keep them under
supervision. Call for a doctor. If breathing difficulties are
experienced, administer additional oxygen. If the person
affected stops breathing, administer the kiss of life.

Important!
Refrigerant is hygroscopic and must therefore be stored in
suitable containers that are sealed airtight!
refrigerant oil is non-combustible and non-explosive at
normal temperatures. Nevertheless, the following points
must be observed:
 Do not store in the vicinity of flames, heat sources or
strongly oxidising materials
 Suitable extinguishants are carbon dioxide (CO2) dry
extinguishant and foam

Recycling
Catch and dispose of emerging refrigerant oil.
Observe country-specific waste disposal regulations.
Absorb escaping refrigerant oil with fluid-binding material.
Notify the relevant authorities if larger amounts of
refrigerant are discharged into aboveground water
supplies, drainage systems or subsoil.
 4/30/2016 1/1

64 50 ... Safety informations for handling

tetrafluorethane refrigerant R134a

Warning!
Danger of injury!
Refrigerant circuit is under high pressure! Work on the
refrigerant circuit may only be carried out by experts!
Draw off refrigerant without fail BEFORE all repair work on
the refrigerant circuit.
The refrigerant circuit is depressurised AFTER drawing
off.
 The pressure gauge on the A/C service unit must be
checked for the actual pressure drop prior to repair
work.
It is absolutely essential to read and observe the relevant
operating instructions for the A/C service unit used!

Protective measures/rules of conduct:

 Wear safety goggles
 Wear oil-resistant protective gloves
 Do not smoke!
 Observe country-specific safety regulations.

First aid measures:

 Eye contact: In the event of contact with the eyes, rinse
immediately with plenty of running water and consult an
ophthalmologist.
 Skin contact: In the event of contact with skin, remove
affected clothing immediately and rinse with plenty of
water.
 After inhalation: If refrigerant vapours are inhaled in
greater concentrations, remove the person affected to an
area of fresh air and keep them under supervision. Call
for a doctor. If breathing problems are experienced,
breathe additional oxygen. If the person affected is
breathing with difficulty or has stopped breathing, incline
the person's head at the neck and administer the kiss of
life.
 4/30/2016 1/1

41 00 ... Safety instructions for handling magnets

Precautionary measures are necessary when handling magnets in order to exclude any potential danger.

If the distance between the magnets falls below the minimum distance, the magnets will be abruptly attracted
to each other. The brittle magnets will then collide with each other at high speed.

Very sharp splinters (similar to glass splinters) may then be chipped off.

Crush or cut injuries may also be caused.

Observe the manufacturer's safety data sheets.

Warning!
- Danger of crush injuries

- Danger of injury due to splinters

- Danger of injury due to magnetic fields

Handling instructions

- Wear safety goggles and protective gloves.

- Persons with heart pacemakers must not use the magnets.

- Do not store any iron parts (tools, small parts) close to the magnets.

- Keep magnets away from magnetic data media (credit cards, memory cards).

- Do not machine the magnets.

- Keep the magnets away direct heat and naked flames.

- Do not eat, drink or smoke while working with these products.

 4/29/2016 1/1

00 Safety instructions for handling oil

Warning!
Danger of poisoning if oil is ingested/absorbed through the
skin!
Risk of injury if oil comes into contact with eyes and skin!

Recycling:
Observe country-specific waste disposal regulations.

Measures if oil is unintentionally released:

 Personal precautionary measures: Danger of slipping!
Keep non-involved persons away from the work area.
Wear personal protective clothing/equipment.
 Environmental protection measures: Prevent oil from
draining into drain channels, sewerage systems, pits,
cellars, water and the ground.
 Limiting spread: Use oil blocks to prevent the surface
spread of oil.
 Cleaning procedure: Bind and dispose of escaped oil with
nonflammable absorbents.
Note: Do not flush oil away with water or aqueous
cleaning agents.
 4/30/2016 1/1

61 00 ... Safety instructions for handling vehicle battery

 

Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear
protective clothing, gloves and eye protection.

Do not tilt the battery, acid may emerge from the vent hole.

If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then
consult a doctor without delay.

If acid is splashed onto the skin or clothing, neutralise it immediately with a soap solutionand rinse with lots of
water.

Seek medical attention immediately if battery acid is accidentally swallowed.

Strictly no flames, sparks, naked light or smoking!

A highly explosive detonating gas is created when batteries are charged. The rooms where charging is
carried out must therefore always be well ventilated.

Avoid the formation of sparks when handling cables, wiring and electrical devices.

Turn the ignition lock to the 0 position before disconnecting or connecting the battery.

Do not place tools or any similar object on the battery (danger of short circuit and explosion hazard!).
 4/30/2016 1/1

51 00 ... Safety instructions for working on cars

with airbag systems

Warning!
If work is carried out in area of airbag systems, e.g. on:

- Door trim panels

- Interior trims

- Instrument panel etc.

the ignition must be turned off in each case.

- The ignition must always be off.

- The ignition key must be removed from the ignition

lock.
This eliminates the risk of injury.
 4/30/2016 1/2

72 Safety precautions and general information

Notes on safety > Safety regulations for handling airbag modules, airbag components and
pyrotechnical seat belt tensioners

> Notes on scrapping vehicles with gas generators

> Deactivation/activation pyrotechnical components

Handling electrical system > Unlocking/locking airbag plug connections

and electronics

> Repairing airbag lines

> Handling optical fibres

Check > Check seat belt

> Checklist for seat belt

Airbag system > Functional description and checking, refer to Diagnosis system

> Deactivating airbags

> Procedure after airbag deployment .

 4/30/2016 2/2

Active pedestrian protection > Procedure after actuator triggering

\n(AFGS)
 4/30/2016 1/3

72 00 ... Safety regulations for handling components with gas generators

 

It is essential to comply with the regulations as specified in the law relating to the use of explosives when
working on airbag units and seat belt tensioners.

Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different
danger classes on the basis of the quantity of propellant that they contain. The assignment can be
ascertained from the identification marking on the product:

Important!

Failure to comply with the warning notices and repair instructions for gas generator components can
cause accidental deployment and result in injury and vehicle damage!

This applies in particular to the following components:

- Airbag modules (driver's/front passenger airbags, side airbags)

- Buckle/belt tensioner

- Head airbag

- Active knee protection

- Active head restraint

- Safety battery terminal

 

1. Regulations

The regulations quoted in the following refer to the Federal Republic of Germany.

In all other countries, the relevant legislation and regulations must be observed in each case. Country-specific
legal regulations that go beyond this information or court decisions based thereon must be followed in each
case or given precedence over these regulations.

The following components used by BMW:

 Pyrotechnical restraint systems are subject to danger class PT1

 Gas generators are pyrotechnical objects belonging to danger class T1

 4/30/2016 2/3

Handling, transporting and storing non-fired gas generators are subject to the ”Explosive Materials Act” (law
relating to the use of explosives dated 13/09/1976).

The relevant trade supervisory authority must be notified at least 2 weeks before pyrotechnical objects are
handled for the first time. Here the relevant authority must be notified in writing of the person responsible (e.g.
dealership owner, holder of general power of attorney or if necessary workshop supervisor). A certificate of
qualification, i.e. specific training, is not required for the person responsible.

2. Dismantling and installation

- Inspection, testing and installation work may only be carried out by expert trained personnel in BMW
Service.

- Work on components of the airbag system should only ever be carried out with the battery
disconnected, the negative terminal post covered and the plug connection of the cable leading to the
gas generator disconnected. If only the battery is disconnected, the following prescribed waiting period
must be observed without fail:

 30 min. for vehicles up to 9/93

 1 min. for vehicles from 9/93 onward

- In the event of breaks in work, a component with a gas generator that has been removed must be
secured against access by other persons.

- Individual components must never be repaired. Instead, always replace them.

- Do not treat airbag system components with cleaning agents or grease.

- Components of the airbag system must not be exposed to temperatures in excess of 75 °C.

- Airbag system components, including electronic diagnostic components, which have been dropped from
heights in excess of 0.5 m must not be reinstalled in the vehicles.

- Do not remove components of the airbag system from the original packaging until immediately before
they are to be installed in the vehicle.

- Before installing, subject components such as housing, connector pins ,etc. of the airbag system
(including diagnosis electronics) to a visual inspection for damage and replace if necessary.

- Airbag system components may only be electrically tested while they are installed and only with the
BMW ISTA.

- Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.
Otherwise the alternator will be thrown upwards if it is ignited.

- Do not point the ignition squib of a gas generator at other persons.

 4/30/2016 3/3

- Components with gas generators must not be fired while they are removed. They must be disposed of
by special disposal companies or returned to BMW in the packaging of the new components.

- When carrying out straightening and welding work with an electric welder:

 Disconnect battery

 Cover negative terminal (post)

- Avoid all contact with the skin when removing a fired airbag module ‐ wear gloves. Wash with water
after contact with the skin.

 

3. Transport

- Components with gas generators must be sent off in the packaging of the new components.

 

4. Storage

- Observe the regulations of the relevant trade supervisory authority and the applicable national
regulations.
 4/30/2016 1/3

72 00 ... Safety regulations for handling components with gas generators

 

It is essential to comply with the regulations as specified in the law relating to the use of explosives when
working on airbag units and seat belt tensioners.

Airbags, seat belt tensioners etc. are pyrotechnical objects. Pyrotechnical objects are assigned to different
danger classes on the basis of the quantity of propellant that they contain. The assignment can be
ascertained from the identification marking on the product:

Important!

Failure to comply with the warning notices and repair instructions for gas generator components can
cause accidental deployment and result in injury and vehicle damage!

This applies in particular to the following components:

- Airbag modules (driver's/front passenger airbags, side airbags)

- Buckle/belt tensioner

- Head airbag

- Active knee protection

- Active head restraint

- Safety battery terminal

 

1. Regulations

The regulations quoted in the following refer to the Federal Republic of Germany.

In all other countries, the relevant legislation and regulations must be observed in each case. Country-specific
legal regulations that go beyond this information or court decisions based thereon must be followed in each
case or given precedence over these regulations.

The following components used by BMW:

 Pyrotechnical restraint systems are subject to danger class PT1

 Gas generators are pyrotechnical objects belonging to danger class T1

 4/30/2016 2/3

Handling, transporting and storing non-fired gas generators are subject to the ”Explosive Materials Act” (law
relating to the use of explosives dated 13/09/1976).

The relevant trade supervisory authority must be notified at least 2 weeks before pyrotechnical objects are
handled for the first time. Here the relevant authority must be notified in writing of the person responsible (e.g.
dealership owner, holder of general power of attorney or if necessary workshop supervisor). A certificate of
qualification, i.e. specific training, is not required for the person responsible.

2. Dismantling and installation

- Inspection, testing and installation work may only be carried out by expert trained personnel in BMW
Service.

- Work on components of the airbag system should only ever be carried out with the battery
disconnected, the negative terminal post covered and the plug connection of the cable leading to the
gas generator disconnected. If only the battery is disconnected, the following prescribed waiting period
must be observed without fail:

 30 min. for vehicles up to 9/93

 1 min. for vehicles from 9/93 onward

- In the event of breaks in work, a component with a gas generator that has been removed must be
secured against access by other persons.

- Individual components must never be repaired. Instead, always replace them.

- Do not treat airbag system components with cleaning agents or grease.

- Components of the airbag system must not be exposed to temperatures in excess of 75 °C.

- Airbag system components, including electronic diagnostic components, which have been dropped from
heights in excess of 0.5 m must not be reinstalled in the vehicles.

- Do not remove components of the airbag system from the original packaging until immediately before
they are to be installed in the vehicle.

- Before installing, subject components such as housing, connector pins ,etc. of the airbag system
(including diagnosis electronics) to a visual inspection for damage and replace if necessary.

- Airbag system components may only be electrically tested while they are installed and only with the
BMW ISTA.

- Danger of injury: The airbag module may only be set down with the airbag itself facing upwards.
Otherwise the alternator will be thrown upwards if it is ignited.

- Do not point the ignition squib of a gas generator at other persons.

 4/30/2016 3/3

- Components with gas generators must not be fired while they are removed. They must be disposed of
by special disposal companies or returned to BMW in the packaging of the new components.

- When carrying out straightening and welding work with an electric welder:

 Disconnect battery

 Cover negative terminal (post)

- Avoid all contact with the skin when removing a fired airbag module ‐ wear gloves. Wash with water
after contact with the skin.

 

3. Transport

- Components with gas generators must be sent off in the packaging of the new components.

 

4. Storage

- Observe the regulations of the relevant trade supervisory authority and the applicable national
regulations.
 4/29/2016 1/19

11 21 505 Sealing crankcase lower section (N55)

Special tools required:

 00 9 120
 11 0 300
 11 4 180
 11 4 370
 11 4 470
 11 8 181
 11 8 220
 11 8 640
 11 9 181
 11 9 182
 11 9 183
 11 9 184
 11 9 185
 11 9 231
 11 9 233
 11 9 234
 11 9 235
 11 9 260
 11 9 360

Important!
Aluminium‐magnesium materials.
No steel screws/bolts may be used due to the threat of
electrochemical corrosion.
A magnesium crankcase requires aluminium screws/bolts
exclusively.
Aluminium screws/bolts must be replaced each time they
are released.
Aluminium screws/bolts are permitted with and without
colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
 4/29/2016 2/19

Risk of damage!
Jointing torque and angle of rotation must be observed
without fail.

Important!
Changed procedure.
It is not necessary to remove the cylinder head and the
crankshaft.

Necessary preliminary tasks:

 Remove engine.
 Mount engine on assembly stand.
 Remove clutch (if fitted).
 Remove engine support arm on left and right.
 Remove oil sump.

Release screws (1).
Pull out oil pump intake pipe (2).
Tightening torque: 11 13 

Release screws (1).
 4/29/2016 3/19

Tightening torque: 11 13 5AZ.

Installation note:
Replace aluminium screws.

Remove oil deflector (2).

Secure oil pump drive gear with 6.0 mm dia. steel pin (3) to oil
pump.
Important!
Release central bolt (2) only together with 6.0 mm dia.
steel pin (3).
Do not remove sprocket.

Release central bolt (2).

Tightening torque: 11 41 5AZ.

Unfasten screws (2).

Tightening torque: 11 41 3AZ.
Installation note:
Replace aluminium screws.

Remove screw plug (1) from crankcase at front.

Note:
Replace gasket.
 4/29/2016 4/19

Release screw (1) for oil pump triangular drive with special tool
11 8 640.
Note:
It is not necessary to remove the triangular drive.

Version 1:
Attention!
Observe different screw lengths.
Release screws (1).
Tightening torque 11 41 2AZ.
Tightening torque 11 41 2AZ.
Installation note:
Replace aluminium screws.

Version 2:
Attention!
Observe different screw lengths.
Release oil pump screws (1).
Tightening torque: 11 41 2AZ.
Installation note:
 4/29/2016 5/19

Replace aluminium screws.

Detach sprocket (1) in direction of arrow.

Note:
The chain tensioner pushes the timing chain (3) of the triangular
drive upward.
Do not remove camshaft sprocket.

Remove oil pump (2) in direction of arrow.

Installation note:
Check spacer bushings (1) for secure seating and damage;
replace if necessary.
Align twin surface (3) on oil pump (2) to sprocket wheel.
Install oil pump (2).

Note:
The dowel hole for the TDC setting is located on the intake side
underneath the starter motor.

Rotate engine at central bolt and secure flywheel in position

with special tool 11 0 300.
 4/29/2016 6/19

Secure flywheel with special tool (1) 11 9 260 and special tool
(2) 11 9 266.
Tightening torque
Note:
Make sure that the special tool (1) completely engages in the
flywheel teeth (see arrow)

Automatic transmission:
Release flywheel bolts (1).
Release special tool (2).
Remove flywheel (3).

Manual transmission:
Important!
Position crankshaft at TDC.

Remove dual-mass flywheel.

Secure flywheel with special tool 11 9 260.
 4/29/2016 7/19

Remove vibration damper.

Release flywheel bolts with special tool 11 4 180/

Release all crankcase bolts (1) along line (2).

 4/29/2016 8/19

Release crankcase bolts M10 in sequence 14 to 1.

Release crankcase lower section (1) from crankcase upper

section (2) with suitable tool (3)
Remove crankcase lower section (1) upwards.
Important!
Do not rotate crankshaft without crankcase lower
section (1) (risk of damage).

Important!
Timing chain is preloaded.
Do not raise crankshaft.

Carefully remove radial shaft seal (1).

Catch escaping engine oil with a cloth (2).
 4/29/2016 9/19

Carefully remove radial shaft seal (1) towards front.

Catch escaping engine oil with a cloth (2).

Important!
Protect crankcase against sealant residues with a
cloth (1).

Remove sealing compound residues (1) with special tool

11 4 470.
Remove injector nozzles (2) for liquid sealing compound on left
and right.
Installation note:
Replace injector nozzles (2).
 4/29/2016 10/19

Clean all threads with compressed air.

Position crankcase lower section (1) on crankcase upper

section.
Screw in all M10 crankcase bolts.
Joint all M10 crankcase bolts (1) 20 Nm from inside outwards.

Identify all M10 crankcase bolts with a coloured marking (1) for

checking.
 4/29/2016 11/19

Secure crankcase bolts M10 in sequence 1 to 14 with special tool 00 9 120.
Tightening torque: 11 11 1AZ.
 4/29/2016 12/19

Insert all crankcase bolts (1).

Important!
Observe different lengths and sizes of the bolts.
Tightening torque: 11 11 2,3 and 4AZ.

Tighten screw (1) for oil pump triangular drive with special tool
11 8 640.
Note:
Replace screw.
Tightening torque: 11 41 4 AZ.

Tighten screw plug on front of crankcase.

Tightening torque: 11 11 9
Installation note:
Replace sealing ring.
 4/29/2016 13/19

Prepare radial shaft seal (1) on special tool 11 8 220.

Position radial shaft seal (1) with special tool 11 8 220 on

crankshaft.

Brush radial shaft seal (1) over special tool 11 8 220.

Move radial shaft seal (1) parallel up against the crankcase.
 4/29/2016 14/19

Screw special tool 11 9 182 with screws (special tool 11 9 184 )

to crankshaft.

Installation note:
Prepare special tool 11 9 181 for installation. Connect special
tool 11 9 185 onto special tool 11 8 181.

Pull on radial shaft seal with special tool 11 9 181 and 11 9 185

in combination with special tool 11 9 183.
 4/29/2016 15/19

Screw on radial shaft seal with special tool 11 9 183 to limit

position.

Installation note:
Clean sealing surface (1) and degrease thoroughly in area of
housing partition.
Apply a light coat of oil to running surface (2) of radial shaft
seal.

Note:
Graphic N42.

Push radial shaft seal (1) 11 9 235carefully in direction of arrow

on the special tool .
 4/29/2016 16/19

Important!
11 9 235Special tool can only be fastened with
2 opposite bolts.
Determine hole pattern on special tool.

Screw special tool 11 9 235 with special tool 11 9 234 on

crankshaft.

Align groove (2) of radial shaft seal (1) centred to the housing

partition (3.
Important!
After installation, the grooves must be filled with sealing
compound.

Draw in radial shaft seal with special tool 11 9 231 in

conjunction with special tool 11 9 233 until flush.
 4/29/2016 17/19

Drive both injector nozzles (1) on left and right with special tool
11 9 360 into crankcase up to stop.

After fitting both sealing rings, check both sealing ducts for
clearance.
Blow compressed air (1) at max. 6 bar into injector nozzle (2).
Compressed air must emerge at both sealing rings on left and
right from the outlet bores.
Important!
If the compressed air does not flow out of all ducts. the
crankcase must again be taken apart and cleaned.

Installation note:
Use primer 1.3 and liquid seal 1.4.
As an alternative,
primer 1.3 and liquid seal 1.2 can also be used.

Prepare liquid sealing compound (1) in special tool 11 4 370.

 4/29/2016 18/19

Injector nozzles for injecting sealing compound are not

required.
Take note of the expiry date!

Slowly insert liquid sealing compound (1) with special tool

11 4 370 in direction of arrow.
Liquid sealing compound must emerge at radial shaft seals at
front and rear.

Stop (seal off) escaping liquid sealing compound with primer

1.3.

Stop (seal off) escaping liquid sealing compound with primer

1.3.
 4/29/2016 19/19

Assemble engine.
 4/30/2016 1/2

51 72 ... Sealing installation

Note:
The utmost care must be taken when removing all sealings on
the vehicle. Incorrect fitting can lead to wind noise and water
ingress among other things and can affect the ease of closing
and opening.

 In general, the following applies:

Sealings on the side frame can be fitted and removed any
number of times.
 Sealings must not be damaged or torn.
 The clamping area must be compressed by hand far
enough to ensure that a tight connection on the side
flange is still possible. The sealing shanks may touch
each other slightly. A completely compressed sealing is
not permitted.

 It is not necessary to use special tools for compressing

the clamping area. This can be done carefully by hand.
 The sealings must always be fitted except in the case of
blockages. There is no defined contact pressure.
 A new gasket must be fitted if sealings in the tailgate area
are repeatedly fitted and removed (water ingress due to
cracked sheet metal).
 Sealings must be checked for correct positioning after
fitting. If necessary, sealings should be lifted over the
adjacent components using the appropriate tool.
Neighbouring components must not be damaged.
 Sealings must be replaced if the metal inlay of the sealing
is visible (corrosion).

 Ensure that the clamping area is smooth.

 4/30/2016 2/2

 Sealings that are installed with plastic clips fit tightly

against the body. If this is not the case, replace the clips
or sealings.
 4/29/2016 1/5

11 00 670 Secure engine in installation position

Special tools required:

  00 6 100
 00 6 130
 00 6 050
 00 6 070-072
  00 6 070-071
 00 6 050-053

Warning!
Danger of injury!
Observe following instructions relating to special tool:
1. Prior to each use, check the special tools for
defects, modifications and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the
special tools!
4. Keep special tools dry, clean and free of grease.

Note:
 Numbering system for special tools has been re-encoded.
 
 4/29/2016 2/5

Special tools

Necessary preliminary work:

 Secure the engine compartment lid in the service position.
 Remove front underbody protection.

Assemble cross-member 00 6 100 with the special tools, 00 6

130, 00 6 050, 00 6 070-072,  00 6 070-071, 00 6 050-053.

Unclip Bowden cable (1) for hood opening.

 4/29/2016 3/5

Fit cross-member  00 6 100 with a 2nd person

helping.

Screw towing hook (1) into engine block.

Attach chain to towing eye.
 4/29/2016 4/5

Warning!
Danger of injury!
Tighten down all screws and nuts on transverse member
 00 6 100.

Important!
Before lifting the engine, check the lifting lugs for damage
(cracks) and to ensure they are seated securely.
Avoid a change of engine position in the transverse or
longitudinal direction.
Always make sure there is sufficient clearance between
the engine (or its add-on parts) and the body.

Note:
4WD

Release bolts (1) on engine mount.

Tightening torque 22 11 2AZ.

Note:
Rear-wheel drive

Release screws (1) from both engine mounts.

 4/29/2016 5/5

Raise engine approx. 10 mm with cross member.

Tightening torque 22 11 1AZ.
Important!
Observe installation note!
To ensure play between engine mount and front axle
support, lower the engine completely before tightening the
screw connection (engine mount/front axle support).
Tightening torque 22 11 1AZ.
 4/30/2016 1/2

41 00 ... Separating cut determination with a

template

In the case of a partial replacement piece, a body component is

cut at a point described in the repair instructions.
A template may be used for the exact position determination for
the separating cut.
The template is made from the reinforcement plate and can be
reused.
Carry over schematic diagram at the separation cut C-pillar to
the relevant vehicle type.

Remove stud bolts (1).

Set bore holes Ø 4 mm at the positions of the removed stud
bolts.
If applicable, place additional bore holes in the area of the
edges.

Insert the template (1) into the new part (in direction of arrow)
until it is flush (without gap).
Carry over the positions of the holes (2) to the new part.
Remove reinforcement plate again.

Connect marks (positions of holes) to the separating cut line

(1).
Carry out the separating cut.
 4/30/2016 2/2

Tear and separate the separating cut on the vehicle according

to the new part.
 4/29/2016 1/4

11 00 ... Service - engine oil (N55)

Special tools required:

 11 9 240

Warning!
Risk of scalding!
Carry out work on the vehicle only when wearing oil- and
heat-resistant protective gloves incl. forearm protection,
face guard and protective apron.

Important!
Carry out the engine oil service only when the engine is at
operating temperature.
Observe the exact engine oil filling capacity.
Overfilling the engine with engine oil will result in engine
damage.
Checking and drip-off times (at least 10 minutes) must be
observed.

Important!
Risk of damage!
Protect belt drive against dirt.
Cover with suitable materials.
 4/29/2016 2/4

Recycling:
Catch and dispose of drained engine oil in a suitable
collecting vessel.
Observe country-specific waste disposal regulations.

Release oil filter cover with special tool  11 9 240.

Tightening torque 11 42 1AZ.
Note:
Engine oil flows out of the oil filter housing and back into the oil
sump.

Rear wheel drive:

Open oil drain plug (1) on oil sump.
Drain engine oil.
Installation note:
Replace sealing ring.

Tightening torque 11 13 1AZ.

Four-wheel drive:
Open oil drain plug (1) of oil sump and drain engine oil.
Installation note:
Replace sealing ring.

Tightening torque 11 13 1AZ.

 4/29/2016 3/4

Remove and insert oil filter element (1) in direction of arrow.

Installation note:
Replace oil filter element (1) and sealing ring (2).
Replace gasket (3) and renew if necessary.

Note:
Coat sealing rings (2,3) with engine oil.

Secure oil filter cover with special tool 11 9 240.

Tightening torque 11 42 1AZ.
Note:
Pour in engine oil.
Start engine and run at idle until oil pressure indicator light goes
out.
Switch off engine
Check oil filter cover and screw plug on oil sump for leaks.
Assemble engine.

Checking engine oil level:

 Park vehicle on a horizontal surface
 Allow engine to run at operating temperature for three
minutes with increased engine speed (approx. 1100 rpm)
 Read off engine oil level in instrument panel or on Control
 4/29/2016 4/4

Display
 Top up engine oil if necessary
 4/30/2016 1/1

51 00 ... Service position of engine compartment

lid

Special tools required:

 2 353 020

Warning!
Danger of injury and damage!
Engine compartment lid must be held by a second person
helping.

Note:
Graphic shows F01.

If necessary, open engine compartment lid.

Remove ball socket (1).
Unclip gas pressure spring (2) in direction of arrow from ball
stud (3).

Push special tool 2 353 020 over gas pressure spring (1).

Clip ball socket of special tool 2 353 020 onto ball stud (2).
 4/30/2016 1/1

41 00 ... Setting blind rivet nuts and bolts

 

- Studs welded as standard are always replaced by blind rivet bolts.

- Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet bolts).

- Blind rivet nuts and studs must have a special coating for anti-corrosion purposes (sourcing reference:
BMW Parts Department).

 

Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only!

- It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this event, set a clip nut
(sourcing reference: BMW Parts Department). This nut tightens itself automatically when screwed to the
component.

- Insert blind rivet nuts or bolts and tighten down with rivet tool .

- Seal blind rivet nuts and blind rivet bolts with sealantD1 (risk of corrosion).
 4/30/2016 1/4

61 13 ... Socket housing (radio connector),

Hybrid System MQS/MPQ

Special tools required:

 61 0 314

Manufactured by AMP: The following contact types without

strand sealing can be fitted in the connector housings:

- MQS (Micro Quadlock System)

- MPQ, width 2.8 mm (Micro Power Quadlock)

- MPQ, width 5.2 mm (Micro Power Quadlock)

Removing MPQ contacts from radio connector:

Press lock (1) in direction of arrow.
Detach secondary lock (2) from radio plug.

Feed special tool 61 0 314 (61 1 135) past side of contact.

Press special tool 61 0 314 (61 1 135) in direction of arrow.
Pull wire (1) with socket contact out of radio connector (2).

Removing MQS contacts from contact carrier:

Press lock (1) in direction of arrow and pull housing (2) out of
radio connector.
 4/30/2016 2/4

Press lock (1) in direction of arrow. Pull contact carrier (2) out of
housing (3).
Note:
When the contact carrier is pulled out, the secondary locks of
the socket contacts are raised.

Note:
Schematic diagram shows the 8‐pin socket housing by way of
example.

Hold down retaining hook (1) of socket contact in opening of

contact carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as
secondary lock (2).

Hold down retaining hook in secondary lock (1) again. Pull wire
with socket contact (2) out of contact carrier (3).
 4/30/2016 3/4

Removing MPQ contacts from contact carrier:

Remove contact carrier (1) with MQS contacts from radio
connector.
Raise lock (2) on radio connector.
Pull contact carrier (3) out of radio connector.

Press lock (1) in direction of arrow.

Pull secondary lock (2) in direction of arrow completely out of
contact carrier (3).

Press special tool 61 0 314 (61 1 135) on inside of contact into

contact carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
4/30/2016 4/4
 4/30/2016 1/1

61 13 ... Socket housing 42-, 43-pin, Hybrid

System MQS / MPQ

Special tools required:

 61 0 312

Manufactured by AMP: The following contact types without

strand sealing can be fitted in the socket housings:

- MQS (Micro Quadlock System)

- MPQ, width 2.8 mm (Micro Power Quadlock)

- MPQ, width 5.2 mm (Micro Power Quadlock)

Open secondary locks (1) on socket housing.

Press back retaining hook of MQS contacts (2) with special tool
61 0 312 61 1 134 and pull out cable with contact.
Press back retaining hook of MPQ contacts (3) with screwdriver
and pull out cable with contact.

Installation note:
Bend open retaining hook of contacts gently before inserting
into connector housing.

For installation of contacts, observe chamber numbers on

reverse side of socket housing.
 4/30/2016 1/2

61 13 ... Socket housings, 2x21-, 2x27-pin,

Hybrid Systems MQS/MPQ, Elo/Elo
Power

Manufactured by AMP: The following contact types without

strand sealing can be fitted in the socket housings:

- MQS (Micro Quadlock System)

- MPQ, width 2.8 mm (Micro Power Quadlock)

- MPQ, width 5.2 mm (Micro Power Quadlock)

Manufactured by Siemens: The following contact types without
strand sealing can be fitted in the socket housings:

- Elo (electrical contact)

- Elo Power 2.8 mm width (electrical contact for heavy

loads)

- Elo Power 5.2 mm width (electrical contact for heavy

loads)

Raise lock (1) on housing (2).

Push contact carrier (3) from rear out of housing.
Note:
The second contact carrier is pushed out in the same way.
Pushing out the contact carrier releases the secondary locks of
the socket contacts.

Hold down retaining hook (1) of socket contact in opening of

contact carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as
secondary lock (2).
 4/30/2016 2/2

Hold down retaining hook in secondary lock (1) again and pull
cable with socket contact (2) completely out of contact carrier
(3).
 4/30/2016 1/2

61 13 ... Socket housings, 5-pin, 8-pin, System

MQS/MPQ

Manufactured by AMP: The following contact types without

strand sealing can be fitted in the connector housings:

- MQS (Micro Quadlock System)

- MPQ, width 2.8 mm (Micro Power Quadlock)

- MPQ, width 5.2 mm (Micro Power Quadlock)

Socket housing, 5-pin (Hybrid System MQS/MPQ)

Raise fastener (1) over retaining lug (2) and pull off from
contact carrier (3).

Socket housing, 8-pin (MQS):

Raise fastener (1) over retaining lug (2) and pull off from
contact carrier (3).

Hold down retaining hook (1) of contact and pull cable with
contact as far as secondary lock (2).
 4/30/2016 2/2

Hold down retaining hook in secondary lock (1) again and pull
cable with contact (2) completely out of contact carrier (3).
 4/30/2016 1/2

41 00 ... Soldering steel components

 

Important!

Comply with the following topics from ”Body, General”:

Safety regulations.

Handling electrical system, electronics, airbags and restraint systems.

 

1. General information

- For repair cases the following procedure will implemented:

 Autogenous brazing solder

- The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams
used in standard production are replaced during repairs by MAG weld seams.

- Brazed areas from vehicle production are bonded following the same procedure.

 

2. Work materials

- Tube pack and torch (autogenous torch)

- Brazing solder

- Gas bottles (oxygen and acetylene)

- Welding goggles

 

3. Preparation

- Remove the paint and zinc layer in an area of approx. 30 mm around the seam to be soldered.

 
 4/30/2016 2/2

4. Implementation

- Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use
heat protecting paste.

 

5. Subsequent treatment of brazed connections:

- Remove burnt residual zinc completely. Align and grind visible connection faces.

- Remove burnt paint with a stainless steel wire brush.

 

6. Notes on melting/tinning:

Only applicable within the European Union!

European used-vehicle regulations prohibit the use of tin containing lead in motor vehicles introduced after
01.07.2003!

Even out unevenness smaller than 2 mm with filler according to painting handbook

If an exceptional unevenness is larger than 2 mm, use metal filler.

Only perform in visible areas of the outer skin and on the carrier support.

All areas which have covers on the vehicle are not to be processed.
 4/30/2016 1/2

61 13 ... Special tools for wiring harness repairs

Special tools required:

 61 0 300
 61 0 400
 61 1 100
 61 4 320
 61 0 200
 61 0 210
 61 0 220
 61 0 230
 61 0 240

Repair range, vehicle electrical system:

Single parts for wiring harness repairs*
* Sourcing reference: BMW Parts Department
Note:
 Refer to Service Information:
SI 2 04 07 341

Release and press-out tool:

 Special tool61 0 300
 Special tool 61 0 400 (MINI N12/N14)
 Special tool 61 1 100 (engine)
Handling:
 Notes for opening contacts and locks of different
connector contact systems

Cutting to length and stripping insulation from cables:

Wire stripper MultiStrip10*
 4/30/2016 2/2

*Sourcing reference BMW Workshop Equipment Catalogue

Handling:
 Cutting cables to length and strip insulation

Crimping stop parts (small contacts) and butt connectors:

 Special tool61 4 320
1. Tool without crimping head
2. Crimping head (stripping insulation and cutting
fibre-optic cables to length)
3. Crimping head (crimping fibre-optic cable contacts)
4. Crimping head (crimping MQS contacts)
5. Crimping head (crimping MPQ contacts)
6. Replacement blade (face-cutting fibre-optic cables)
7. Replacement blade with tool (insulation stripping
unit)
8. Universal crimping head (SI 2 04 06 293)

Crimping stop parts (large contacts) and butt connectors:

 Special tool 61 0 200 (crimping set)
 Special tool 61 0 210 (matrix set SLK 8)
 Special tool 61 0 220 (matrix set SLK 2.8)
 Special tool 61 0 230(matrix set MAK 8 / DFK4)
 Special tool 61 0 240 (butt connector 4.0 - 6.0 mm²)
Handling:
 Refer to Service Information:
SI 2 02 05 194
SI 2 07 05 233
 4/30/2016 1/3

41 00 ... Spot-weld bonding steel components

 

Important!

Comply with the following topics from ”Body, General”:

Safety regulations .

Handling electrical system, electronics, airbags and restraint systems.

Welding steel components.

 

- Beginning with E65 the spot-weld bonding process is used to increase vehicle rigidity. In partial body
areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance pressure
spot welding. The adhesive is hardened only after the paint drying process (at approx. 180 °C).

- In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is
doubled as a substitute for the omitted adhesive.

- Minimum distance between welding spots (1) is 25 mm. Important! The minimum distance must not be
undershot! If there is not enough space for twice the number of resistance weld points, each non-made
resistance weld point must be replaced by a MAG weld seam (2). Length of a MAG weld
seam = 20 mm. Set the MAG weld seams at equal intervals distributed on the face.
 4/30/2016 2/3

- The following procedures are used as

a substitute for spot-weld bonding:

 MAG welding (Metal Active Gas

welding)

 Resistance pressure spot

welding (referred to in the
following and in the repair
instructions as spot welding).
 4/30/2016 3/3

- Adhesive is not applied between the

spot flanges on new parts in the case
of 2- or multi-sheet joints. Areas which
cannot be reached by the spot-
welding tongs can be joined by MAG
plug welding. The number of welding
spots is doubled as a substitute for the
omitted adhesive.

- Exceptions (e.g.E65) are described in

the relevant repair instructions. Apply
welding spots to existing welding
spots on new part. This is necessary
because the adhesive between the
spot flanges of the new part acts as an
insulator.

- Caution: Extract smoke and fumes

during welding work.
 4/30/2016 1/3

41 00 ... Spray gun for cavity sealant

1.0 Delivery specification:

- Owner's Handbook

- Pressure reservoir spray gun (1) for cavity sealant

- Spray set, consisting of spray hoses: Angle nozzle (2) and round spray nozzle (3)
 
Important!
Prior to start-up read and familiarise yourself with the manufacturer's operating and safety instructions.
 
2.0 Start-up:

- Open the pressure reservoir and insert the cavity sealant in the form of a 1-litre can.
Close the pressure reservoir.

- Connect the spray hose to the quick-release coupling.

- Connect the device to the compressed air supply.

Operating pressure 2-6 bar, max. 8 bar!
 
 4/30/2016 2/3

3.0 Operating principle:

Note:
Unlike previous devices you can alter the spray pattern on this device with the air volume regulating screw
(large knurled screw).
 

- Twisting the air volume regulating screw in decreases the air volume and thus reduces the formation of
material mist.
This facilitates optimum working when preserving open components/surfaces.
 

- Twisting the air volume regulating screw out increases the air volume and thus increases the formation
of material mist. (For closed cavities)

- The trigger has two settings.

1st setting - air discharge only.
2nd setting - air and material discharge.

- After finishing work, press the first setting to clean the spray hose with compressed air.

- Prior to storing, remember to twist the air volume regulating screw closed to reduce the risk of the
material drying out.

- Prior to an extended period of non-use (2 weeks and more), clean the gun.

- To ensure that the spray hoses function properly, do not store them coiled up e.g. in the side member
area!
Store the spray hoses stretched out.
 
4.0 Application examples:

- Use the appropriate spray hoses for the different types of cavity and surface.

- Example - doors, lids and hatches:

Spray hose with angle nozzle. Reduce air volume to keep the formation of mist low.

- Example - side members:

Long spray hose with round spray nozzle. The air volume must be increased a little, depending on the
type used.

- Basically, keep the formation of mist low to avoid fouling and unpleasant odours.
 
5.0 Safety instructions:

- Do not inhale spray mist.

 4/30/2016 3/3

- Use in well ventilated rooms only.

- Operating pressure max. 8 bar.

 4/30/2016 1/6

41 00 ... Stamping vehicle identification number

(needle stamping unit)

Read and comply with General Information.

The needle stamping system 360 - VRM - BMW is required to
stamp the vehicle identification number.
Order number: 81 43 2 155 736

- Sourcing reference:
BMW Workshop Equipment Catalogue

The needle stamping system 360 tool set comprises:

- (1) Display

- (2) Mains adapter

- (3) Needle stamping unit

- (4) Connecting cable

 4/30/2016 2/6

- (5) Power cable

- (6) Compressed-air hose

Note:
A compressed-air connection is also required.
 Operating pressure approx. 6 bar
 Use only dry, oil-free air

Procedure when stamping a substitute vehicle identification

number
Necessary preliminary tasks:
 Remove right front side panel.

Cross through original vehicle identification number.

Note:
On this vehicle the substitute vehicle identification number is
stamped below the original vehicle identification number.
Substitute vehicle identification number = line 1
Original vehicle identification number = line 2
 4/30/2016 3/6

(1) = original vehicle identification number (line 2).

Pull off protective film from vehicle identification number.
Mark position lines (2) according to schematic diagram.
Dimension a = 12 mm
Horizontal position line is directly against vehicle identification number.

Display input:

- Select Layout 6 with arrow button.

- Enter vehicle identification number with F10.

- Press ”ENTER” button.

 
Note:
With Layout 6 the vehicle identification number (line 2) is
crossed through.

Important!
Perform stamping operation with position lines in advance
 4/30/2016 4/6

on a test sheet.

Note:
The contact surface for the suction cups of the needle imprint device must be dry and free of dust and grease!
Make sure the unit is resting securely in position. If necessary, adjust the height and position of the suction feet.
 
Move suction feet of needle stamping unit to positions (1) and (2) shown.

Press pushbutton (1) for vacuum pressure.

Then start stamping operation with pushbutton (2).
Graphic representation similar.
Important!
 4/30/2016 5/6

After completing the stamping operation, do not alter the

position of the unit.
Do not switch off vacuum pressure.

Stamping substitute vehicle identification number

Display input:

- Select Layout 1 with arrow button.

- Press ”ENTER” button.

 
Note:
With Layout 1 the already entered substitute vehicle
identification number is embossed in line 1.

Start stamping operation with pushbutton (2).

 4/30/2016 6/6

Following layout functions are available:

Layout selection Vehicle identification number

Layout 1 In line 1

Layout 2 In line 2

Layout 3 Turned through 180° in line 1

Layout 4 Turned through 180° in line 2

Layout 5 Cross through in line 1

Layout 6 Cross through in line 2

 4/30/2016 1/1

34 52 .. Start-up of ICM control unit

Note:
Start-up of ICM control unit must be carried out:
 After replacement or removal and installation of ICM
control unit

Connect vehicle to BMW diagnosis system.

Select and carry out start-up of ICM control unit under Service
functions.
 4/30/2016 1/4

36 10 508 Stationary wheel balancing

Special tools required:

 36 1 010
 36 1 020

Necessary preliminary tasks:

 Remove wheel

Important!
Use only BMW-approved balance weights.

Remove any fitted balancing weights, stones in tread pattern

and larger dirt contaminations.
Check tyre pressure and tyre for condition, damage, flat spots
(irregularities caused by e.g. parking of vehicle with tyres which
 4/30/2016 2/4

have run hot). If necessary, check wheel and tyre for radial and
lateral runout.

Use BMW-approved wheel centring elements of relevant

balancing machine manufacturers.
1. Basic flange
2. Wheel centring element
3. Type flange
4. Clamping nut
Also refer to section on Workshop Equipment.

Important!
To avoid clamping errors, it will be necessary to fit the
wheel on the balancing machine in the same way (e.g.
valve facing down) as it is then fitted on the vehicle.
Balance wheel in accordance with operating instructions of
relevant balancing machine.

On light-alloy rims with distinctive J-shape rim flange, proceed

as follows:
1. Gently force off tyre sidewall with special tool 36 1 020 at
appropriate point from rim flange.
2. Install retaining clip (1).
3. Remove special tool 36 1 020.
 4/30/2016 3/4

Raise retaining clip with special tool .36 1 010 Slide balance

weight underneath and allow it to snap into place.

Arrangement of balance weights for light-alloy rims with

distinctive J-shape rim flanges.
1. Retaining spring
2. Balance weight
Adhesive weights must be used on all other light-alloy rims.
Max. imbalance per wheel.

Note:
When using adhesive weights, proceed as follows:

1. Carefully remove any adhesive weights. Do not damage

wheel rim when doing so.
2. Select suitable location for fitting.
 4/30/2016 4/4

3. Clean adhesive area thoroughly.

 4/29/2016 1/2

00 00 ... Steering components: Check for play,

damage and, if nec., tightness

Checking play:
Note:
Observe notes on checking the steering backlash!
1. Check the tie rod backlash only in loaded condition or in
the design position.
2. Checking with front axle raised:

- To evaluate the play of the steering gear, it is

necessary to pressurise the steering gear via its
servo system!

- The combustion engine must be running during

hydraulically or electrically assisted steering for this
purpose

Steering wheel:
Move steering wheel back and forth and check for play.
Track rod joint:
There must be no play between the track rod joint (1) and track-
rod arm (2).

Check for damage:

Check gaiter, axle and gaiter for damage (e.g. cracks, holes)
and leaks.
Check gaiter for missing tensioning straps.

Check for tightness (only for hydraulically supported steering):

Check all visible connections, hoses, lines and steering box for traces of fluid.

 
The following image shows the principal arrangement of the hydraulic steering components and lines.
 4/29/2016 2/2

1 Pump 6 Hollow bolt

2 Power steering cooler 7 Expansion tank

3 Return line 8 Suction hose

4 Steering box {D} Sealing ring

5 Pressure line    
 4/30/2016 1/1

41 00 ... Straightening aluminium component on the outer skin

 

1.0 Recommended tools

- Only use tools specifically designed for aluminium repairs.

- Do not use tools and operating fluids that have already been used for steel repairs (e. g. grinding
wheel). Danger of contact corrosion.

- Do not use any sharp-edged tools (notch effect).

- Sourcing reference BMW Workshop Equipment Catalogue.

 

2.0 Straightening outer skin

- ”Cold” straightening: Press dents out from their centre and smooth in an outwards direction with gentle
taps.

In the case of small, soft dents (hail and parking damage), this is also possible without damaging the
paintwork. Special tools and a trained employee are needed.

- ”Hot” straightening: Heat the component in the damaged area with a hot air blower to approx. 60 °C.
This significantly reduces the force that needs to be applied for straightening.

- Avoid notching and cracking.

- Avoid hardening and overstretching.

- Avoid heating and excess temperature the outer skin over large areas.
 4/30/2016 1/2

41 00 ... Straightening aluminium components in structure

 

- Reshaping or heating extruded profiles and cast parts is not permitted!

Failure to comply with this requirement would have the following results:

In the case of reshaping, weld seams (E52) or bonded connections (E60, E61, E63, E64) tear in the
surrounding area.

In the case of reshaping, the material loses up to 40 % of its original strength.

In the case of heating, the material loses up to 40 % of its original strength.

The adhesive is destroyed at temperatures ≥120 °C (E60, E61, E63, E64).

 

Extruded profiles and cast parts which show visible or measurable signs of deformation must be
replaced.

Perform the check for deformation with the aid of the straightening system.

For optical testing, strip adjoining components in cases of doubt.

Extruded profiles are used in the E52 as engine supports, door posts, side members, etc.

Extruded profiles are used in the E60, E61, E63, E64 as engine supports.

Cast parts are used in the E60, E61, E63, E64, E70, E71 as spring supports.

- Reshaping of extruded profiles and cast parts may only be used to achieve optimum joining of
connection faces (e.g. when bulkhead is damaged). Reshaped parts must be replaced.

- Repairs which affect the attachment points of mechanical assemblies and chassis/suspension
components must be carried out on the straightening bench. Use the vehicle-specific set of attachments
set or vehicle-specific data sheet.

Straightening attachment supports and data sheets are also available for the top section, e.g.: door
posts, soft top mounts, cowl panel, tailgate hinges, etc.

- Check windscreen and rear window apertures for curvature by inserting the original glass.

- Take the gap dimensions for doors, engine compartment lid and tailgate from the vehicle-specific gap
dimension diagram.
 4/30/2016 2/2

- Exceptions on the E60, E61, E63, E64:

Carrier support and bulkhead may be straightened if they do not have any cracks, sharp-edged damage
or holes. After repair work, check parts again for cracks.

Examine adjoining adhesive flanges for peeling off. If necessary, seal and preserve with sealant.

Observe the frame reference dimension for the carrier support.

Any repairs to the bulkhead if cracked outside the approved scope of repair work are only permitted
after consultation with and approval by BMW. Should you have any questions, please contact the
country-specific Hotline.
 4/30/2016 1/1

41 00 ... Straightening steel components in the structure

 

- High-strength and super-high-strength steel plates as a rule cannot be reshaped. Reshaping only
serves as a preparatory measure to replacing the component in order to achieve optimal joining of the
connection points.

- Bearing body components such as e.g. engine supports, door pillars, side members etc. with
deformations which can no longer be returned to their original shape by ”cold straightening” must be
replaced.

Heating bearing body components for better reshaping is not permitted!

Failure to comply with this requirement would result in a loss of original strength of up to 40 %.

- The body must be anchored as follows for reshaping:

If using vehicle-specific/universal straightening attachment sets (Carbench/ Celette/ Car-O-Liner), it is

necessary to secure the body additionally with 4 retaining clips to the spot flange of the entrance or to
the 4 jacking points. The spot flange (if available) is to be preferred.

If using universal electronic or mechanical straightening systems (Car-O-liner/ Celette), it is necessary

to secure the body with 4 retaining clips to the spot flange of the entrance or to the 4 jacking points. The
spot flange (if available) is to be preferred. In addition anchor at least 2 points with the securing set.

Failure to comply with these instructions will result in damage to the body during reshaping in non-
damaged areas. Vehicle-specific straightening attachments and universal mounts may be damaged.

- Repairs affecting the mounting points of assemblies and chassis/suspension components must be
carried out on the straightening bench with the matching straightening attachment set or specification
sheet for the vehicle.

Straightening attachments and specification sheets are also available for the top section, e.g.: door
pillars, convertible top mounts, cowl, rear lid hinges, etc.

- Check windshield and rear window apertures for curvature by inserting the original glass.

- Take the gap dimensions for doors, engine hood and rear lid from the vehicle-specific gap dimension
diagram.
 4/30/2016 1/2

41 00 ... Straightening steel components on the outer skin

1.0 Recommended tools.

Only use those tools designed for steel repairs (sourcing reference BMW Workshop Equipment Catalogue).

 

2.0 Straightening outer skin.

- ”Cold” straightening: Press dents out from their centre and smooth in an inwards direction with gentle
taps.

In the case of small, soft dents (hail and parking damage), this is also possible without damaging the
paintwork. This work requires a special tool (refer to Service Information 5 04 98 328) and a trained
employee.

- In the case of damaged areas which are only accessible from one side, a repair system with welding
can be used.

- Avoid cracking.

- Avoid hardening and overstretching.

- Avoid heating and excess temperature the outer skin over large areas.

- When the surface exhibits an unevenness no greater than 2 mm after straightening, putty compound
can be used to even out the area (see Painting Handbook).

Unevenness greater than 2 mm with metal putty.

Note:

Only applicable within the European Union!

European used-vehicle regulations prohibit the use of tin containing lead in motor vehicles introduced
after 01.07.2003!

- For high-security vehicle, note the special information in the repair instructions!

 

2.1 Straightening the wheel arch (rear side panel).

Vehicles in which the wheel arch is not welded but bonded and bordered can be straightened.

This is possible in the following situations:

 4/30/2016 2/2

- Rear side panel (wheel arch) is not torn in the area of the bonding. Welding in this area is not
permissible.

- The outer skin has not become separated from the outer wheel arch section.

In general, the following applies:

When performing straightening work on the wheel arch, apply sealant to the inside. After straightening, the
area must be primed and resealed with sealant D1.
 4/30/2016 1/1

41 31 100 Stripping operations - Replace roof outer

skin with slide/tilt sunroof

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove front windscreen (job number: 51 31 000)
 Remove headlining (job number: 51 44 011)
 Remove slide/tilt sunroof (FR number: 54 12 211)
 Remove tailgate (job number: 41 62 000)
 Remove both tailgate hinges (job number: 41 62 070)
 Remove left roof trim strip (job number: 51 13 280)
 Remove right roof trim strip (job number: 51 13 280)
 Remove roof aerial (job number: 65 20 035)
 Slightly release tailgate seal
 4/30/2016 1/3

41 12 700 Stripping operations - Replace the left

side member and luggage compartment
floor (removed left side wall and tail
panel)

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Remove exhaust system (job number: petrol engine 18 00

020, diesel engine 18 00 018)
 Remove exhaust system heat shield
 Remove rear left wheel well cover (FR number: 51 71
041)

Remove battery (1).

Remove negative terminal battery cable (2).
Remove positive terminal battery cable (3).
Remove power distribution box (4)
Remove the tray for the flat tyre system (5).

Turn the lock (1) counterclockwise and remove.

Push the positive battery wire connector (2) through the
luggage compartment floor to the outside.
Push the grommet (3) with the positive battery cable out.
Set the positive battery cables (4) aside.
 4/30/2016 2/3

Remove the first aid set bag (1) and warning triangle (2).

Unfasten plug connection (1) and disconnect.

Release the screw connections (2) and slowly remove the
holder (3).

Unlock plug connections (1) and disconnect.

Release the wiring harness (2) at the attachment points and
remove the holder.

Lift up the holder (1).

Disengage the plug connection and wiring harness (2) and
remove the holder.
Remove the insert (3) for the toolkit.
Release latch mechanisms and remove rear ventilation (4).
Release the wiring harness from the attachment point (5).
 4/30/2016 3/3

Partially release the insulating mat (6) and set aside.

Installation note:
The rear ventilation must not be damaged! (watertightness).
All latch mechanisms must engage audibly.

View of the left vehicle underside.

Slacken nut (1) and remove trim panel (2).
 4/30/2016 1/1

41 11 201 Stripping operations - replacing carrier

support in front of left wheel arch

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect battery earth lead (FR number: 61 20 900)

 Remove bumper trim (FR number: 51 11 156)
 Remove intake silencer housing (FR number: 13 71 000)
 Remove coolant expansion tank (job number: 17 11 100)
 Remove front underbody protection assembly (job
number: 51 47 490)
 Remove centre front panel (job number: 41 33 050)
 Remove deformation element for front left bumper panel
(job number: 51 11 770)
 Release line for air conditioning on capacitor
 Remove left wishbone (FR number: 31 12 000)
 Trim panel for cover on side member (job number: 51 71
447)
 Remove front wheel arch cover (front section) (job
number: 51 71 038)
 Remove front side panel (job number: 41 35 081)
 Partially release left wiring harness
 4/30/2016 1/1

41 11 205 Stripping operations - Replacing

complete left carrier support

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect battery earth lead (FR number: 61 20 900)

 Remove bumper trim (FR number: 51 11 156)
 Remove intake silencer housing (FR number: 13 71 000)
 Remove coolant expansion tank (job number: 17 11 00)
 Remove front underbody protection assembly (job
number: 51 47 490)
 Remove centre front panel (job number: 41 33 050)
 Remove deformation element for front left bumper panel
(job number: 51 11 770)
 Remove DSC hydraulic unit (job number: 34 51 527)
 Release line for air conditioning on capacitor
 Remove left wishbone (FR number: 31 12 000)
 Remove trim panel for cover on side member (job
number: 51 71 447)
 Remove front wheel arch cover (front section) (job
number: 51 71 038)
 Remove front wheel arch cover (rear section) (job
number: 51 71 039)
 Remove front side panel (job number: 41 35 081)
 Partially release left wiring harness
 4/30/2016 1/1

41 11 095 Stripping operations - replacing engine

support in front of left wheel arch

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove front panel (job number: 41 33 039)
 Remove cooling package
 Remove anti-roll bar (job number: 31 35 000)
(anti-roll bar is removed without lowering the front axle
support)
 4/30/2016 1/2

41 14 020 Stripping operations - Replacing front

left wheel arch

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect battery earth lead (FR number: 61 20 900)

 Remove bumper trim (FR number: 51 11 156)
 Remove front underbody protection assembly (job
number: 51 49 490)
 Remove coolant expansion tank (job number: 17 11 100)
 Remove intake silencer housing (FR number: 41 35 111)
 Remove front panel (FR number: 41 33 039)
 Remove radiator (job number: 17 11 100)
 Remove front wheel arch cover (front section) (job
number: 51 71 038)
 Remove front wheel arch cover (rear section) (job
number: 51 71 039)
 Remove panel for cover on left side member (job number:
51 71 447)
 Remove front side panel left (FR number: 41 35 081)
 Remove trailing link on left spring strut dome (job number:
51 71 371)
 Remove engine compartment lid (job number: 41 61 000)
 Remove left hinge for engine compartment lid (job
number: 41 61 060)
 Remove left front door (job number: 41 51 080)
 Remove left partition wall for units compartment (job
number: 51 71)
 Remove DSC hydraulic unit (job number: 34 51 527)
 Remove tandem brake master cylinder (job number: 34
31 002)
 Remove brake booster (FR number: 34 33 505)
 Remove left trailing link (job number: 31 12 050)
 4/30/2016 2/2

 Remove left wishbone (FR number: 31 12 000)

 Remove front left spring strut complete (job number: 31
31 000)
 Release left wiring harness
 4/30/2016 1/2

41 14 030 Stripping operations - Replacing front

right wheel arch

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect battery earth lead (FR number: 61 20 900)

 Remove bumper trim (FR number: 51 11 156)
 Remove front underbody protection assembly (job
number: 51 49 490)
 Remove intake silencer housing (FR number: 41 35 111)
 Remove front panel (FR number: 41 33 039)
 Remove radiator (job number: 17 11 100)
 Remove power distribution module (job number: 12 63
586)
 Remove front wheel arch cover (front section) (job
number: 51 71 038)
 Remove front wheel arch cover (rear section) (job
number: 51 71 039)
 Remove trim panel for cover on right side member (job
number: 51 71 447)
 Remove front right side wall (job number: 41 35 082)
 Remove trailing link on right spring strut dome (job
number: 51 71 371)
 Remove engine compartment lid (job number: 41 61 000)
 Remove right hinge for engine compartment lid (job
number: 41 61 050)
 Remove right front door (job number: 41 51 080)
 Remove right partition wall for units compartment (job
number: 51 71)
 Release right wiring harness
 Remove right trailing link (job number: 31 12 080)
 Remove right wishbone (job number: 31 12 000)
 Remove front right spring strut complete (job number: 31
 4/30/2016 2/2

31 000)
 4/30/2016 1/1

41 12 653 Stripping operations - Replacing left

luggage compartment floor (rear side
wall and tail panel removed)

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove rear left wheel arch cover (FR number: 51 71
041)
 Remove exhaust system (job number: petrol engine 18 00
020, diesel engine 18 00 018)
 Remove heat shield

Remove the insert (1) for the toolkit.

Release latch mechanisms and remove rear ventilation (2).
Partially release the insulating mat (3) and set aside.
Installation note:
The rear ventilation must not be damaged! (watertightness).
All latch mechanisms must engage audibly.

Slacken nut (1) and remove trim panel (2).

 4/30/2016 1/1

41 12 557 Stripping operations - Replacing

luggage compartment floor, middle (tail
panel removed)

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Remove exhaust system (job number: 18 00 020)

 Remove exhaust system heat shield

Remove battery (1).

Remove negative terminal battery cable (2).
Remove positive terminal battery cable (3).
Remove power distribution box (4)
Remove the tray for the flat tyre system (5).

Turn the lock (1) counterclockwise and remove.

Push the positive battery wire connector (2) through the
luggage compartment floor to the outside.
Push the grommet (3) with the positive battery cable out.
Set the positive battery cables (4) aside.
 4/30/2016 1/1

41 12 660 Stripping operations - Replacing

luggage compartment floor, rear (tail
panel removed)

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Remove battery (FR number: 61 21 010)

 Remove the insert for the flat tyre system
 Remove exhaust system (job number: 18 00 020)
 Remove the exhaust system heat shield

Remove battery (1).

Remove the tray for the flat tyre system (2).
 4/30/2016 1/2

41 35 101 Stripping operations - Replacing rear

side panel, left

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove bumper trim panel (job number: 51 12 156)
 Remove centre bumper guide (job number: 51 12 825)
 Remove left bumper guide (job number: 51 12 828)
 Remove luggage compartment floor trim panel (job
number: 51 47 101)
 Remove tail panel cover at top (job number: 51 46 050)
 Remove left rear light (job number: 63 21 260)
 Remove left luggage compartment wheel arch panel (job
number: 51 47 151)
 Remove rear left wheel arch cover (job number: 51 71
041)
 Remove left lock striker (job number: 51 21 003)
 Remove rear seat (job number: 52 26 005)
 Remove backrest side section (job number: 52 26 008)
 Remove both backrests (job number: 52 26 020)
 Remove rear left door sill cover strip (job number: 51 47
030)
 Remove the rear left rocker panel trim (outer) (job
number: 51 47 072)
 Remove rear left door edge protection (job number: 51 72
000)
 Remove trim panel for cover on left side member (job
number: 51 71 447)
 Remove trim strip on left roof frame (job number: 51 13
280)
 Remove left gas pressure spring for rear lid (job number:
 4/30/2016 2/2

51 24 300)
 Remove rear left door.
 Partially detach tailgate seal
 Remove holder for gas pressure spring on left
 Partially release wiring harness

Remove the insert (1) for the toolkit.

Release latch mechanisms and remove rear ventilation (2).
Installation note:
The rear ventilation must not be damaged! (watertightness).
All latch mechanisms must engage audibly.
 4/30/2016 1/2

41 35 111 Stripping operations - Replacing rear

side panel, right

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove bumper trim panel (job number: 51 12 156)
 Remove centre bumper guide (job number: 51 12 825)
 Remove right bumper guide (job number: 51 12 828)
 Remove luggage compartment floor trim panel (job
number: 51 47 101)
 Remove tail panel cover at top (job number: 51 46 050)
 Remove right rear light (job number: 63 21 265)
 Remove right luggage compartment wheel arch panel (job
number: 51 47 161)
 Remove right rear wheel arch cover (job number: 51 71
041)
 Remove right lock striker (job number: 51 21 003)
 Remove rear seat (job number: 52 26 005)
 Remove backrest side section (job number: 52 26 008)
 Remove both backrests (job number: 52 26 020)
 Remove right rear left door sill cover strip (job number: 51
47 030)
 Remove the rear right rocker panel trim (outer) (job
number: 51 47 072)
 Remove rear right door edge protection (job number: 51
72 010)
 Remove trim panel for cover on right side member (job
number: 51 71 447)
 Remove trim strip on right roof frame (FR number: 51 13
280)
 Remove right gas pressure spring for rear lid (job number:
 4/30/2016 2/2

51 24 300)
 Remove right rear door
 Partially detach tailgate seal
 Remove holder for gas pressure spring on right
 Partially release wiring harness

Remove the insert (1) for the control units.

Undo the wiring harness (2) from the tail panel and side wall
and set aside.
Release latch mechanisms and remove rear ventilation (3).
Installation note:
The rear ventilation must not be damaged! (watertightness).
All latch mechanisms must engage audibly.
 4/30/2016 1/1

41 31 000 Stripping operations - Replacing roof

outer skin

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove front windscreen (FR number: 51 31 000)
 Remove headlining (job number: 51 44 001)
 Remove tailgate (FR number: 41 62 000)
 Remove both tailgate hinges (job number: 41 62 070)
 Remove left roof trim strip (FR number: 51 13 280)
 Remove right roof trim strip (FR number: 51 13 280)
 Remove roof antenna (FR number: 65 20 035)
 Slightly release tailgate seal
 4/30/2016 1/3

41 34 041 Stripping operations - Replacing tail

panel

Note:
Owing to the different engine variants and equipment
specifications, not all the components are taken into
consideration.
The following list basically represents the removal sequence.
 

 Disconnect negative battery cable (job number:. 61 20

900)
 Remove bumper trim (FR number: 51 121 56)
 Remove bumper carrier (FR number: 51 12 050)
 Remove guide for rear bumper in the centre (job number:
51 12 825)
 Remove guide for bumper on rear left (FR number: 51 12
801)
 Remove guide for bumper on rear right (FR number: 51
12 801)
 Remove both rear lights (job number: 63 21 180)
 Remove luggage compartment floor trim panel
 Upper tail panel trim (FR number: 51 46 050)
 Remove and install tailgate striker (FR number: 51 24
130)
 Remove left luggage compartment wheel arch panel (FR
number: 51 47 151)
 Remove right luggage compartment wheel arch panel (FR
number: 51 47 161)
 Lower rear silencer
 Remove heat shields
 Partially detach tailgate seal

Remove the first aid set bag (1) and warning triangle (2).

 4/30/2016 2/3

Unfasten plug connection (1) and disconnect.

Release the screw connections (2) and slowly remove the
holder (3).

Unlock plug connections (1) and disconnect.

Release the wiring harness (2) at the attachment points and
remove the holder.

Lift up the holder (1).

Disengage the plug connection and wiring harness (2) and
remove the holder.
Remove the insert (3) for the toolkit.
Release latch mechanisms and remove rear ventilation (4).
Installation note:
 4/30/2016 3/3

The rear ventilation must not be damaged! (watertightness).

All latch mechanisms must engage audibly.

Disconnect the plug connections for the control units and

remove the insert (1).
Undo the wiring harness (2) from the tail panel and side wall
and set aside.
Release latch mechanisms and remove rear ventilation (3).
Installation note:
The rear ventilation must not be damaged. (watertightness).
All latch mechanisms must engage audibly.
 4/29/2016 1/7

00 .. ... Symbols used and information in repair

instructions

Warning!
Precautionary rules and measures which protect
mechanics and other personnel against injury (including
life-threatening injuries).

For example:
Warning!
Risk of scalding!
Only perform this work after engine has cooled down.

Important!
Specific instructions and precautionary measures which
prevent damage to the vehicle or to vehicle parts. Failure
to comply with the above will invalidate any warranty
claims.
The caution symbol is used in all repair instructions.
However, use of the warning word ”Caution!” is not binding
in every case.
The notes, instructions and precautionary measures
mentioned above retain their validity.

Warning!
High-voltage system - danger to life!
Before beginning work, follow the applicable safety rules
and perform the necessary preliminary work.

Note:
High-voltage symbol for hybrid cars (electrically powered
vehicles) E72 and MINI E.

Warning!
High-voltage system - danger to life!
Before beginning work, follow the applicable safety rules
 4/29/2016 2/7

and perform the necessary preliminary work.

Note:
High-voltage symbol for hybrid car (electrically powered vehicle)
from F04.

Note:
Particular information on improved procedures for operation,
testing, adjustment and upkeep.
Also indicates the end of a repair section.

Recycling:
Observe country-specific waste disposal regulations

General information:
Refers to other instructions: such as e.g.:
Necessary preliminary tasks;
Further instructions: refer to operating instructions for balancing
machine.
 4/29/2016 3/7

Replacement:
Carry out programming/encoding.
Note:
Many electronic control units must be programmed/coded (e.g.
when replaced).

Note (previous symbol):

 Connect BMW diagnosis system

Note (symbol for new diagnosis system ISID):

 Connect BMW diagnosis system
 4/29/2016 4/7

Important!
Read and comply with notes on protection against
damage from electrostatic damage (ESD protection).

Note:
Electronic control units and other electronic components - if
handled incorrectly - can be damaged or destroyed by
electrostatic discharge.

Special tools required:

Note:
List of special tools needed in these repair instructions.

Warning!
Laser beam!

For example:
Laser beam at adjustment unit. Do not look into the beam!
Note on laser class.
 4/29/2016 5/7

Important!
Use eye protection for the following operations.

For example:
Fuel can emerge spontaneously at high speed when the fuel
delivery line is released!

Important!
Use eye protection and ear protection for the following
operations.

Important!
Use face protection for the following operations.
 4/29/2016 6/7

Important!
Use protective gloves for the following operations.
Avoid skin contact.

Important!
Use eye protection and protective gloves for the following
operations.
Avoid eye contact and skin contact.

Warning!
Danger of explosion!
 4/29/2016 7/7

First aid measures:

Note on first aid measures that need to be administered
immediately.
 4/30/2016 1/1

32 10 ... Teaching in end stop software for

electric steering gear (EPS)

Note:
The end stop software must be taught in:
 after the steering gear is replaced
 after programming/coding

Connect vehicle to BMW diagnosis system.

Select and perform end stop under Service functions.
 4/30/2016 1/6

63 10 ... Test requirements for headlights vertical

aim adjustment

Important!
Do not perform headlight adjustment
immediately after lowering the vehicle on the
vehicle hoist. In this case, move the vehicle for
approx. 15 m on its own wheels before headlight
adjustment.

Important!
Refer to the operating instructions for the
headlight adjustment device!
Headlight adjustment position must comply with
the specifications as set out in StVZO (German
road traffic licensing regulations) § 29 Annex 8d
(or ISO 10604)!
These specifications are described in “Planning
principles for layout of BMW service workshops”.
(Can be found in the ASAP portal, Chapter
3.2.6.1 Headlight adjustment position)

 Park vehicle on flat and even surface.

 Replace faulty glass and mirrors and blackened light
bulbs.
 Check correct adjustment of headlights in relation to
engine compartment lid (gap dimensions).
 Check tyre pressure and correct if necessary.
 
Only halogen headlight, fog light and headlight for
Dynamic Light Spot:
 Apply load equivalent to one person on driver's seat
(approx. 75 kg).
 Vehicle with full fuel tank or appropriate additional weight
in luggage compartment.
 4/30/2016 2/6

 Switch the ignition on.

 Manual headlight beam throw adjustment: Move
handwheel to neutral position (1).
 Light switch must be in "low beam/driving light"
position (3).
 Do not carry out the headlight adjustment in the
"automatic driving lights control" light switch position (2).
 Version with Xenon or LED (automatic headlight beam
throw adjustment): Wait 80 s after switching on lights.
During this time, do not move the vehicle and avoid
vibrations.

Important!
Do not move the vehicle and steering wheel
during the measuring and adjustment
procedures!
Wheels must be in the straight-ahead position!

Important!
 4/30/2016 3/6

A correct measurement/adjustment requires exact positioning of the headlight adjustment

device (1)!
Headlight adjustment device (1) must stand vertically to the vehicle longitudinal axis!
This applies to all headlights!

Position headlight adjustment device (1) centrally in front of vehicle (2) at distance (A) = 10 cm.

Align headlight adjustment device (1) by laser beam (3). Laser beam (3) must hit two suitable points, e.g.
marked by arrows.

Important!
Points must be vehicle proof!
Points must be separated as wide as possible!
Trim panels are not suitable!

If the headlight adjustment device (1) does not have a laser beam (3), complete the alignment analogous with
the line in the mirror.

Important!
Always perform positioning of the headlight
adjustment device (1) at the outer headlight (2).

The centre of the collecting lens (1) must match the centre of

headlight (2) horizontally.
Corrections are made by raising or lowering the headlight
adjustment device.
 4/30/2016 4/6

When positioned correctly, the light/dark

boundary of the headlight (marked with arrow)
must hit the collecting lens of the adjusting
device in the centre:
1. The headlight adjusting device is too
low.
2. The headlight adjusting device is
positioned correctly.
3. The headlight adjusting device is too
high.

The centre of the collecting lens (1) must match the centre of

headlight (2) vertically.
Corrections are made by sliding the side of the headlight
adjusting device to the left or right.
 
 
 
 
 
 4/30/2016 5/6

 
 
 

Note:
The figure shows an example for the transparent screen of halogen headlights.
Overview of transparent screens of different headlight types.

 
Set marker line {M} on aimer to {e}. Scale graduations on the headlight adjustment device are equal to a
gradient in cm at a distance of 10 metres.
 
Light/dark boundary of headlights in the headlight adjustment device
 
{e} Setting dimension, headlights:

- Value is indicated on the headlight housing and on vehicles with production date up to 2011 on the
type plate in %.
 4/30/2016 6/6

(e.g.: 1.0 % = -10 cm/10 m = - 1.0 % on the headlight adjusting device)

- Value 1.0 % (adjustment value - 1.0 %) applies to all BMW Group vehicles.

- Exception: E53, E70, E71, E72, E83, F25, R60, R61. Value 1.1 % (adjustment value - 1.1 %) applies
to these vehicles.
Setting dimension, fog lights:

- Value 2.0 % = -20 cm/10 m = - 2.0 % on the headlight adjusting device applies to all BMW Group
vehicles.
Setting dimension, dynamic light spot headlight:

- Value 0.0 % = 0 cm/10 m = 0 % on the headlight adjusting device applies to all BMW Group vehicles.
 

{H} Height of headlight centre above parking surface

{h} {H} - {e} = height of marking line above parking surface
+ Central mark = centre point of high beam headlight.
{M} Marker line of the headlight adjustment device
{S} Standing surface of the vehicle and headlight adjustment device
 
Adjustment dimension {e} is only valid for EUR. Observe differing national regulations.
 4/30/2016 1/2

61 20 005 Testing battery with battery tester

Important!
Check is not permissible for AGM batteries!
Check does not apply to F-series!

Warning!
Read and comply with safety informations pertaining to
vehicle battery.

Necessary preliminary tasks:

Remove luggage compartment floor trim panel.

Note:
Use BMW-recommended battery tester* to test the battery.
*Sourcing reference BMW Workshop Equipment Catalogue
 4/30/2016 2/2

Procedure:
 Turn off ignition and close doors
 Connect battery tester directly to battery terminals
 Select Battery test and confirm
 Enter vehicle identification number
 Enter battery data
 Carry out battery test
 4/29/2016 1/1

AZD-AZD-AZD00-05   M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2

VIN: XXXXXXX Vehicle: 1'/F20/5-

DOOR/M135I/N55/MANUAL/EUR/RL/2014/03
System 3.42.40.11060 Data R3.42.40.11060
Version: Version:

00 00 M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2

Type Thread Tightening Measure
specification
Surface colour /
Scope of applicability of tightening
(surface coating)
torques,
refer to excerpt from company
standard BMW GS 90003-2
yellow (ZN) M10 8.8 47 Nm
M10 thread
silver (ZNS) M10 8.8 38 Nm
yellow (ZN) M10 10.9 66 Nm
silver (ZNS) M10 10.9 56 Nm
yellow (ZN) M10 12.9 79 Nm
silver (ZNS) M10 12.9 62 Nm
yellow (ZN) M10 x 1 54 Nm
M10x1 thread
8.8
silver (ZNS) M10 x 1 41 Nm
8.8
yellow (ZN) M10 x 1 75 Nm
10.9
silver (ZNS) M10 x 1 60 Nm
10.9
yellow (ZN) M10 x 1 91 Nm
12.9
silver (ZNS) M10 x 1 67 Nm
12.9
 4/30/2016 1/1

99 00 ... Touching up paintwork damage

These notes apply to paintwork damage on the body aperture that occurred when detaching bonded window
glass.

 

To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!

The ”BMW Color System” painting handbook forms the basis of these repair instructions and must be
observed without fail.

Ground down damage to paintwork on body aperture and touch up with BMW multibase filler.

Grind larger areas or damage down to the bare sheet metal and coat with BMW multibase filler (layer
thickness 30 to 40 μm).

Hardening time:

- With infrared, at least 10 minutes

- Without infrared for at least 60 °C, at least 30 minutes

- Without infrared for at least 20 °C, at least 24 hours

 

If a complete build-up of paint is required in the visible area:

- Tape off primed adhesive flange before applying top coat

Important!

Observe hardening time of BMW multibase filler otherwise a perfect bond cannot be guaranteed!
 4/30/2016 1/5

23 Transmission designations

Breakdown of BMW designation:

A5S 300J (former designation)

A Transmission type

- S = Manual gearbox

- A = Automatic transmission

5 Number of forward gears

S Type of top gear

- D = Direct gear

- S = Overdrive gear

300 Max. input torque (Nm)

J Code letter of transmission manufacturer

- G = Getrag

- J = Jatco

- R = GMPT (General Motors Powertrain)

- Z = ZF (Zahnradfabrik Friedrichshafen)

SMG Notes SMG = Sequential M gearbox/transmission

GS6-37BZ (new designation according to BMW Group Standard GS 90007)

G Transmission

S Transmission type

- S = Manual gearbox

- A = Automatic transmission

6 Number of forward gears

-
 4/30/2016 2/5

- - = Standard with manual gearshift

- HP = Hydraulic planetary gear

- DKG= twin-clutch gearbox

37 Transmission type

- 26 = D-transmission

- 31 = C-transmission

- 39 = F-transmission

- 37 = H-transmission

- 53 = G-transmission

- 17 = I-transmission

- 47= J transmission SMG -7-speed

- 45 = K transmission

- 36= Transmission DKG

B Gear set

- B = Petrol gear ratio

- D = Diesel gear ratio

- S= Sport gear ratio

Z Code letter of transmission manufacturer

- G = Getrag

- Z = ZF (Zahnradfabrik Friedrichshafen)

 

Manual gearbox:

BMW designation Manufacturer Manufacturer designation Remarks

 4/30/2016 3/5

S5D 200G Getrag B transmission (220/5)

S5D 200G Getrag B transmission (221/5) for M41 engine only

S5D 250G Getrag B transmission (220/5) Reinforced version

S5D 260Z ZF C-transmission (S5-31 D) for M51 engine only

S5D 280Z ZF C-transmission (S5-31)

S5D 310Z ZF C-transmission (S5-31) up to 9.95

S5D 320Z ZF C-transmission (S5-31) from 9.95 (reinforced version)

GS5S31BZ (SMG) ZF C transmission SMG

GS5-39DZ ZF F transmission

S6S 420G Getrag D-transmission (226/6)

S6S 420G (SMG) Getrag D transmission SMG

S6S 560G Getrag E-transmission (286/6)

GS6-37BZ ZF H-transmission

GS6S37BZ (SMG) ZF H-transmission

GS6-37DZ ZF H-transmission

GS6-37BG Getrag H-transmission

GS6-53BZ ZF G-transmission

GS6-53DZ ZF G-transmission

GS6-17BG Getrag I-transmission

GS6-17DG Getrag I-transmission

 4/30/2016 4/5

GS7S47BG (SMG) Getrag J‐transmission (247) SMG -7-gear

GS7D36SG Getrag DKG (436) DKG -7-gear

GS6- 45BZ ZF K transmission

GS6- 45DZ ZF K transmission

 

Automatic transmission:

BMW designation Manufacturer Manufacturer designation Remarks

A4S 200R General Motors Powertrain GM4

A4S 270R General Motors Powertrain THM-R1w Transmission wide-stepped

A4S 310R General Motors Powertrain THM-R1

A5S 300J Jatco Jatco

A5S 310Z ZF 5HP-18

A5S 325Z ZF 5HP-19

A5S 440Z ZF 5HP-24

A5S 560Z ZF 5HP-30

A5S 360R / 390R GM GM5

 4/30/2016 5/5

GA6HP19Z ZF 6HP19

GA6HP26Z ZF 6HP26

GA6HP32Z ZF 6HP32

GA6L45R GM GM6

GA8HP45Z ZF 8HP45

GA8HP70Z ZF 8HP70

GA8P70H ZF 8P70 Hybrid

GA8HP90Z ZF 8HP90

GA7AHSCD Daimler AHS-C Hybrid

 4/30/2016 1/3

23 03 98 (347)

Transmission difficult to shift/diagnostic aid

all model series

Complaint:
- Gears difficult to engage, especially 1st gear
- Gearshift mechanism catches
Note:
Field observations have shown the cause of transmissions being difficult to
shift, especially of 1st gear being difficult to engage, to be primarily the clutch
and only in a few cases to be the transmission itself. In order to trace the
cause in the event of a complaint, the diagnostic aid described below under
the heading Procedure has been compiled.
Cause:

1. For possible causes if a clutch problem is diagnosed, please refer to procedure described below:

- Taper spline of transmission input shaft not greased or grease dried out

Note on greasing taper spline:

Analyses have shown that grease used until now for greasing the taper spline ”Microlube GL261 BMW” is
suitable for prolonged exposure to high bell housing temperatures.
- Drive plate on transmission input shaft difficult to move
- Drive plate wobble
- Air in hydraulic system of clutch mechanism
- Release bearing defective or difficult to move in the guide sleeve
- Drive plate or clutch pressure plate broken
2. For possible causes if a transmission problem is diagnosed:

- External gearshifts difficult, e.g. shift rod joints stiff

- Gear lever rubber bellows incorrectly fitted, e.g. positioned too high or too low on the gear lever
- Soundproofing between the outer gear mechanism and the body incorrectly inserted, e.g. on the wrong sid
crumpled
Cause in transmission

- Synchronization faulty
- Inner gearshift mechanism stiff
- Water in transmission fluid (rare)
Affected All Models
vehicles:
Remedy: Actions to remedy difficult to move drive plate on transmission input shaft taper spline:
 4/30/2016 2/3

In 04/1998, the grease used to date to grease the taper spline ”Microlube GL261 BMW”
was superseded by the more temperature-resistant grease ”Esso UNIREX S2”.

In case of repair, the transmission input shaft taper spline is now only to be lubricated
using the new ”Esso UNIREX S2” grease.
The old grease ”Microlube GL261 BMW” is no longer to be used.
Procedure: In case of customer complaint, localize the cause by following the diagnostic aid described
below:

- The engine runs at idling speed

- Depress the clutch
- Try to engage 1st gear from neutral
If 1st gear is difficult to engage, hold the gear lever at the resistance point (about half total
travel) with constant force. Then switch the engine off with the other hand (ignition off).

Diagnosis 1:
If 1st gear is then engaged completely, i.e. the gear lever moves to the end position
without any additional pressure, there is a problem in the clutch.

Explanation:
Because the clutch does not uncouple completely, the transmission drive shaft transmits a
residual torque when the engine is running. This inhibits the release and meshing of the
sliding sleeve at the end of the synchronization process. Switching the engine off relieves
the drive shaft of this torque.
A completely uncoupled clutch is thus simulated.

Remedial action for diagnosis 1:

Carefully clean the transmission input shaft taper spline and guide spigot to ensure that
they are free from any residue.
Then apply the taper spline grease ”Esso UNIREX 2” evenly and thinly with a paintbrush
in the entire area of the taper spline, including in the taper groove, and on the guide
spigot.
Renew the drive plate.

For additional notes on troubleshooting and remedy:

Please refer to Service Information bulletin 21 01 97 (251).

Diagnosis 2:
If the gear lever remains at the resistance point, there is a problem in the outer gearshift
mechanism or in the transmission .

Remedial action for diagnosis 2:

troubleshooting as per cause 2.

Note on transmission installation:

Apply the taper spline grease ”Esso UNIREX 2” evenly and thinly with a paintbrush in the
entire area of the taper spline, including in the taper groove, and on the guide spigot. If the
transmission is to be used again, the taper spline must be thoroughly cleaned to ensure
that it is free from any residue.
Parts: The new taper spline grease ”Esso UNIREX S2” is available through the customary parts
 4/30/2016 3/3

ordering channels.

Description Part number

”Esso UNIREX S2” (40g tube) 83 23 9 416 138

 4/30/2016 1/3

63 10 ... Transparent screens of different

headlight types (halogen, xenon, LED)

The following equipment-specific and model-specific headlight

types are used in BMW Group vehicles:
 Halogen headlights
 Xenon headlights
 LED headlight
 
Every headlight type has its specific transparent screen. In spite
of these differences, all headlight types meet statutory
specifications.
 
The images below show transparent screens from the left
headlight in the low-beam headlight switch position projected
onto a wall (no automatic setting!).
The transparent screens from the right headlight are the same.
The transparent screens correspond with those in an
accumulator box of a headlight adjusting device.
 4/30/2016 2/3

Important!
For headlight adjustments with
electronic headlight adjustment
devices, e.g. MAHA Lite 3, it is
absolutely required to
determine the type of
transparent screen!

Type I: Light pattern shows a continuous

increase in the light/dark boundary.
Type II: Light pattern screen shows a short
increase in the light/dark boundary.

1. Halogen headlight
Type I

2. Halogen headlight US version R60 only

3. Xenon headlights
Type II
 4/30/2016 3/3

4. LED headlight e.g. F01, F02, F03

Type II

5. LED headlight e.g. F06, F12, F13, E71

Type I
 4/30/2016 1/1

61 13 ... Treating cables and optical fibres

Special tools required:

 61 4 320
 61 0 200

Note:
Special tools referred to in the repair instructions below are
contained in the following special tool sets:

Repair range for vehicle electrical system SI 2 04 07 341

Crimping set with pliers for optical fibres, 61 4 320

Micro Power Quadlock (MPQ), Micro 61 0 200
Quadlock System (MQS) contacts and
universal crimping head

Subject of repair instructions

 Special tools for wiring harness repairs

 Cutting cables to length and strip insulation
 Crimping stop parts (contacts)
 Butt connector for repairing a plug connection
 Comb connector for retrofitting/repairs
 Cutting to length and stripping insulation from optical fibres
Crimping optical fibres
 4/30/2016 1/5

61 13 ... Unlocking and disconnecting different

plug connections

Note:
Examples of unlocking and disconnecting different plug
connections.

Press lock and open clamp in direction of arrow.

Disconnect plug connection.

Press lock and open clamp in direction of arrow.

Disconnect plug connection.

Open clip in direction of arrow and disconnect plug connection

in direction of arrow.
 4/30/2016 2/5

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

 4/30/2016 3/5

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

Press lock and disconnect plug connection in direction of arrow.

 4/30/2016 4/5

Press the lock and detach plug connection.

Press the lock and detach plug connection.

Press the lock on both sides and detach plug connection.

 4/30/2016 5/5

Press the lock and detach plug connection.

 4/30/2016 1/5

72 12 ... Unlocking/locking airbag plug

connections

Warning!
Read and comply with safety regulations for handling
airbag modules and pyrotechnical belt tensioners.

Important!
An airbag plug connection must be replaced if it is
damaged.
Sourcing reference for airbag repair instructions (with plug
connection), refer to BMW Parts Service.

Following versions of plug connections on airbag module/gas

generator are possible:

- Airbag plug connection on gas generator/airbag module is

offset by 90°

- Airbag plug connection on gas generator/airbag module is

straight (3 versions)

Airbag plug connection on gas generator/airbag module offset

by 90°:
There are two ways of unlocking this airbag plug connection on
the gas generator/airbag module:
Method 1:
Simultaneously pull cover (1) upwards at lugs on left and
right (2).

Method 2:
Insert a narrow screwdriver into recess (1) in housing (2).
Carefully prise cover (3) off (4).
 4/30/2016 2/5

Cover (1) is not positioned higher than housing (2).

The airbag plug connection is unlocked and can now be
detached from the gas generator/airbag module.

Installation note:
After attaching airbag plug connection to gas generator/airbag
module, press cover (1) downwards until it rests flat on housing.

Check that it catches properly.

Airbag plug connection on gas generator/airbag module is

straight (2 versions)
Version 1:
Press locking/unlocking plate (1) at edge (4).
Locking/unlocking plate (1) snaps upwards at opposite edge (3)
and releases detent lug (2).
 4/30/2016 3/5

The airbag plug connection is unlocked and can now be

detached from the gas generator/airbag module.

Installation note:
After attaching airbag plug connection to gas generator/airbag
module, check whether detent lug (2) is visible in opening of
locking/unlocking plate (1).
Only if the detent lug (2) is visible will the airbag plug
connection gas generator/airbag module be correctly engaged.

Version 2:
Press locking/unlocking plate (1) on edge (3) and pull plug (2)
out of plug housing (4).
Installation note:
Only if the detent lug is visible in opening (5) will the gas
generator/airbag module plug connection be correctly engaged.
 4/30/2016 4/5

Version 3:
Press lock button (1) and pull out plug (2) up to initial
engagement position.
Detach connector (2) from firing pellet.
Installation note:
Insert plug connection in initial engagement position in gas
generator/airbag module and engage in final engagement
position.

Illustration of version 3 with gas generator:

A. Initial engagement position
B. Final engagement position
1. Lock button
2. Gas generator

Version 4 - Crash-active head restraint:

Press locking clip at edge and disconnect plug (1).
Installation note:
Check for correct engagement.
4/30/2016 5/5
 4/30/2016 1/2

41 00 ... Use of materials in outer skin

The following illustration is a schematic diagram of all the body variants.

Apply this illustration to the relevant vehicle.

All components not listed in the table below are composed of established sheet steel qualities.

Component Vehicle Material

(1) Side wall, front F01, F02, F04, F10, F11 Aluminium

  F12, F13, F06 Plastic (thermoplastic)

 4/30/2016 2/2

(2) Front door F01, F02, F04, F06, F07, F10, F11, F12, F13 Aluminium

(3) Rear door F01, F02, F04, F06, F07, F10, F11 Aluminium

(5) Engine compartment lid F01, F02, F04, F06, F07, F10, F11, F12, F13 Aluminium

(6) Hardtop/ roof F01, F02, F04 Aluminium

(7) Soft top compartment lid F12 Plastic (thermoplastic)

(8) Tailgate F07 Aluminium

  F06, F12, F13 Plastic (thermoplastic)

 4/29/2016 1/4

11 02 05 (130)

Vacuum supply

All models

 
Introduction

Vacuum is principally used for the brake booster.

The vacuum in the inlet pipe depends on the varying engine load.

Diesel engines do not normally have any vacuum in the inlet pipe. Vacuum on diesel engines is provided by a
pump that generates the required vacuum.
On spark-ignition engines with Valvetronic, the throttle valve is almost always open when driving. This means
 4/29/2016 2/4

that there is a lower low air pressure in the intake manifold.

Spark-ignition engines with low vacuum in the inlet pipe also have a pump that generates additional vacuum.
[System overview ...]
Brief description of components

The following components are involved in the vacuum supply system:

- Mechanical vacuum pump

A mechanic vacuum pump is fitted to diesel engines and spark-ignition engines with Valvetronic.

The vacuum pump is mechanically driven by the engine, e.g. via the exhaust camshaft.

- Suction-jet pump

As a rule, the suction-jet pump boosts the vacuum in the inlet pipe.

[more ...]

- Electric vacuum pump

On some engines, an electric vacuum pump is fitted for additional vacuum supply.
In certain temporary operating situations, the vacuum in the inlet pipe may be too low. In such cases, the
inlet pipe vacuum cannot be adequately boosted by the suction-jet pump. In these situations, the electric
vacuum pump ensures that sufficient vacuum is available.

Reason: After a cold start, an operating situation occurs in which there is very little inlet pipe vacuum due
to the higher load. The electric vacuum pump is actuated for a certain time. This ensures that the brake is
sufficiently boosted when manoeuvring.

After a cold start, the DME will actuate the electric vacuum pump once only for max. 60 seconds.

The electric vacuum pump is actuated in the following situations:

 Engine-running signal from DME
 Coolant temperature below 60 °C

The electric vacuum pump is a vane-cell pump.

- Throttle valve

The throttle valve changes the cross-sectional area of the inlet pipe. This creates an inlet pipe vacuum
behind the throttle valve, especially in overrun mode.

- DME or DDE: Digital engine electronics or digital diesel electronics

The DME or DDE actuates the components needed for system functions (e.g. solenoid valves, electric
switching valves, electropneumatic pressure converters).
System functions

The system functions of the vacuum system are described using the following examples:
 4/29/2016 3/4

- Power assist for brakes

- Actuation of exhaust flaps

- Adjustment of variable turbine geometry

- Actuation of controlled damping mounts

- Exhaust gas recirculation

- Drawing off of blow-by gases from crankcase

- Blowing out activated charcoal filter

 
Power assist for brakes

The brake booster amplifies the force excerpted at the brake pedal. To do this, the brake booster stores part of
the vacuum generated by the engine. The vacuum then amplifies the force generated by pressure on the
brake pedal.
Actuation of exhaust flap

A controlled electropneumatic exhaust flap is fitted in the exhaust system. The exhaust flap enhances active
sound-damping. The exhaust flap is closed by vacuum.

 
Adjustment of variable turbine geometry

The variable turbine geometry controls the boost pressure via adjustable guide vanes. The guide vanes are
actuated by vacuum.
Actuation of controlled damping mounts

In the basic setting, there is no vacuum at the control component od the mount. The bypass in the mount is
closed. Hydraulic fluid flows back and forth through a ring channel between the upper and lower chambers in
the mount. The mount acts like a conventional hydraulic bearing. The mount has hard damping.
If a vacuum is applied to the mount's control component, the bypass will open. The hydraulic fluid then flows
back and forth between the chambers through a larger cross-sectional area. The mount has softer damping.
Exhaust gas recirculation

With exhaust gas recirculation, part of the exhaust gas is take from behind the exhaust manifold. This is then
fed back into the engine through the intake air duct. The exhaust gas recirculation pipe is located at the inlet to
the intake manifold.
If a vacuum is applied to the exhaust gas recirculation valve, the exhaust gas recirculation pipe will open. The
level of vacuum is determined by the opening in the exhaust gas recirculation valve.
Exhaust gases flow through a connecting pipe to the exhaust manifold and into the intake manifold.

 
Drawing off of blow-by gases from crankcase

The crankcase ventilation system uses vacuum to bleed the blow-by gases out of the engine block.
 4/29/2016 4/4

Blow-by gases are the small portion of the cyinder fill that passes by the piston rings and into the crankcase
during compression. If the blow-by gases are not bled from the engine block through the crankcase ventilation
system, they will accumulate in the crankcase. The blow-by gases would then apply pressure on the pistons
from below. This would have a negative effect on the downward movement of the pistons in the intake stroke
and operating stroke.

 
Blowing out activated charcoal filter

The fuel tank vent hose is connected to an activated charcoal filter. Vapours from the fuel tank are collected in
the activated charcoal filter. The activated charcoal filter is connected to the intake manifold by a pipe. A fuel
evaporation control valve is fitted in this pipe. When the fuel evaporation control valve is opened, the vacuum
in the manifold draws in fresh air. At the same time, the fresh air blows out the fuel vapours collected in the
activated charcoal filter.

 
Notes for service staff

Service staff should note the following points:

- General information: ---

- Diagnosis: ---

- Encoding/programming: ---

- Car and Key Memory: ---

 
Subject to change.
 4/30/2016 1/2

41 00 ... Vehicle identification number, general

In the event of repair 2 procedures are used, depending on the vehicle. Refer to the vehicle-specific repair
instructions for the correct procedure.

1. General notes for stamped vehicle identification numbers:

The vehicle identification number is stamped with a special tool. There are different special tool numbers and
stamping procedures for the various vehicles. Refer to the relevant repair instructions.

In repair work, the vehicle identification number is always stamped into a replacement vehicle identification
number surface. The replacement surface is usually situated under the original VIN surface.

The IGEF number (bodyshell number) is omitted when the wheel arch is replaced.

In the event of component or body replacement by the BMW garages/workshops, clearly delimit the vehicle
identification number at front and rear by stamping a + in place of the BMW badge.

If a VIN is stamped into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The original VIN must be crossed out. To do so, stamp the letter I
from the punch digits lengthways through the original VIN.

Important!

Do not use an angle grinder in conjunction with a cutting disk!

The protective film used as standard is omitted after the VIN has been manually stamped in. Paint area in
accordance with BMW Painting Handbook. Ensure that layer thicknesses are small.

Observe national/country-specific regulations.

2. General notes for embossed vehicle identification numbers:

This procedure is used for all vehicles on which the vehicle identification number can not be stamped.

For the repair new parts with an embossed vehicle identification number can as a rule be ordered from the
BMW Parts Department. If this is not possible, observe country-specific regulations.

The IGEF number (bodyshell number) is omitted when the wheel arch is replaced.

If a VIN is embossed into the replacement surface in addition to the original VIN (e.g. if the original VIN has
been tampered with), the following applies: The vehicle-specific repair instructions describe the procedure.

The protective film used as standard is omitted after the VIN has been embossed. Paint area in accordance
with BMW Painting Handbook. Ensure that layer thicknesses are small.
 4/30/2016 2/2

Observe national/country-specific regulations.

 4/29/2016 1/10

17 00 039 Venting and filling cooling system with

vacuum filling unit

Special tools required:

 00 2 030
 17 0 100

Type Engine Adapter Y from

17 0 100

E60 / E61 / E63 / E64 All 17 0 113

E65/E66 M54 / N52 / N62 / N62T / N73 17 0 105

E65/E66 M57S / M57T / M67 / M67T 17 0 113

E70 / E71 / E72 All 17 0 113

E81/ E82/ E84/ E87/ E88/ E89 All 17 0 113

E83 M54/ N46/ N52K 17 0 105

E83 M47S / M57S / M57T / M57Y / 17 0 113

N47

E85 / E86 All 17 0 105

E90 / E91 / E92 / E93 All 17 0 113

R50 / R52 W10 17 0 107 and 17 0 102

R50 W17 17 0 109

R52 / R53 W11 17 0 109

R55 / R56 / R57 / R58 / R60 / R61 All 17 0 109

F25 All 17 0 113

F20 / F21 / F22 // F30 / F31 / F32 / F33 / F34 N47 D20 K/U/O/T 1 17 0 113
 4/29/2016 2/10

F20 / F21 / F22 / F30 / F31 / F32 / F33 / N13 / N20 17 0 113
F34 / F35

F20 / F21 / F22 /F30 / F31 / F32 / F33 /F34 / N55 / N55 hybrid car 17 0 113
F35

F30 / F31 / F32 N57 D30 O/T 1 17 0 113

F15 All 17 0 113

F56 All 17 0 109

Important!
Lifetime coolant filling:
Never reuse used coolant!
When replacing and removing components which rely on
the corrosion protection effect of the coolant, it is essential
to change the coolant. The cooling system must therefore
be drained and refilled.
In the case of other removal work involving the draining of
part quantities of coolant, replace these quantities which
have been drained with new coolant.

Important!
You must protect the alternator against contamination by
coolant when carrying out repair work on the cooling
circuit.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an
alternator malfunction.

Note on ordering:

- Workshop equipment

- Workshop equipment catalogue

- Filler unit no. 81 39 2 152 473

 4/29/2016 3/10

- Collecting vessel no. 81 49 2 152 347

- Adapter: 17 0 100

Important!
Risk of slipping due to coolant on the floor.
Danger of injury!

Catch and dispose of emerging coolant in drip tray (1) and if

necessary special tool 00 2 030 (universal hydraulic lifting
equipment).
Recycling:
Observe country-specific waste disposal regulations.

Important!
Check all the coolant hoses before filling the cooling
system with the vacuum filling unit.
If necessary, replace damaged and porous coolant hoses.

 
 4/29/2016 4/10

 1) Filling unit with vacuum meter and shutoff valves

 2) Filler hose
 3) Coolant container
 4) Venturi nozzle
 5) Compressed air connection (max. 6 bar)
 6) Outgoing-air hose (lead outgoing-air hose into a collecting container)

Preconditions
 Cooling system expansion tank must be empty.
 There must be sufficiently premixed coolant in the filling
unit container, 1 - 2 litres more than the vehicle filling
capacity.

- Use only recommended coolant.

- Observe mixture ratio.

- Observe capacities.

 Position the filling unit container at the same height as the

 4/29/2016 5/10

coolant expansion tank.

 Compressed-air connection with 6 bar pressure present.
 Set vehicle heater to maximum temperature.

Select adapter (Y) according to table and connect to coolant

expansion tank.
Connect filler unit to adapter connection (X).

Shutoff valves (A) and (B) of the filling unit (1) must be closed.
(X) Expansion tank connection

Connect venturi nozzle (1) to filling unit (2).

(X) Expansion tank connection

Connect compressed air (1).

(X) Expansion tank connection
 4/29/2016 6/10

Open shutoff valve (B).

The venturi nozzle produces a flow noise.

Then open shutoff valve (A) until the filling hose (1) is free of

bubbles.
Close shutoff valve (A) again. The filling hose (1) is vented in
this way.

Shutoff valve (B) will remain open. Generate vacuum in coolant

system for approx. 2 minutes. The end vacuum is reached at a
vacuum of -0.7 to -0.95 bar. Green scale on the vacuum meter.
Note:
The coolant hoses contract during vacuum build-up.

Then close shutoff valve (B) again.

 4/29/2016 7/10

Both shutoff valves (A) and (B) must be closed. Then seal

Venturi nozzle (1).

The cooling system must hold the vacuum for 30 s. If the
needle in the vacuum meter falls, this indicates a leak in the
cooling system.
If the vacuum remains constant, proceed with filling.
In event of leaks, check cooling system for leaks.

Important!
There must be sufficiently premixed coolant in the filling
unit container: 1 -2 litres more than the vehicle filling
capacity.
Position the filling unit container at the same height as the
coolant expansion tank.
 4/29/2016 8/10

Shut-off valve (B) remains closed during the filling process.

To fill the cooling system, open shutoff valve (A) to filling unit
container.

Coolant is now added.

The filling procedure is finished when the needle in the vacuum
meter is at 0 bar or no longer falls.
If necessary, reduce remaining vacuum. Open shutoff valve (B)
to do so.

Remove filling unit with adapter from expansion tank.

Adjust coolant level to maximum.

Close coolant expansion tank.
 4/29/2016 9/10

After the cooling system has been filled with the vacuum filling
unit, another bleeding procedure must be performed for the
following vehicles:
 E84 N20
 F25 N52T, N55
 F25 N20
 E70, E71 N63, S63
 E70, E71 N57 D30 S 1
 E72 N63
 F20, F21, F30, F31 N13
 F20, F21, F22, F30, F31, F32, F33, F34, F35 N20, N26
 F20, F21, F22, F30, F31, F32, F33, F34, F35 N55
 F30 N55 Hybrid
 F15 N55
 F15 N63 B44 O1
 F15 N57 D30 S 1

After the cooling system has been filled with the vacuum filling
unit, another bleeding procedure must be performed for
vehicles with an electric coolant pump:
Note:
Do not open the coolant expansion tank cap during the bleeding
procedure.
Switch on the low-beam headlights to perform the bleeding
procedure. If the low-beam headlights are not switched on, the
ignition (Terminal 15) will switch off automatically after a certain
period of time and interrupt the bleeding procedure.
 4/29/2016 10/10

1. Connect battery charger.

2. Switch the ignition on.
3. Switch on low-beam headlight.
4. Set heating to maximum temperature. Take back blower
to smallest stage.
5. FES (driving experience switch) must not be in ECO
PRO!
6. Press accelerator pedal for 10 seconds to floor. Engine
must not be started.
7. The venting procedure is started when the accelerator
pedal is pressed and takes approx. 12 minutes. (Electric
coolant pump was activated and shuts down
automatically after approx. 12 min).
8. Then adjust fluid level in the coolant expansion tank to
maximum.
9. Check cooling system for leaks.
10. If the ventilation has to be performed again, deactivate
DME completely (remove ignition key for approx. 3
minutes). Then repeat from point 3.

Check function of cooling system.

Check cooling system for tightness.
 4/29/2016 1/3

17 00 039 Venting cooling system and checking for

watertightness (N55)

Warning!
Risk of scalding!
Open sealing cap only after engine has cooled down.

Important!
Electric coolant pump!
Follow notes for carrying out repair work on the cooling
system.

Important!
Lifetime coolant filling:
Never reuse used coolant!
When replacing and removing components which rely on
the corrosion protection effect of the coolant, it is essential
to change the coolant. The cooling system must therefore
be drained and refilled.
In the case of other removal work involving the draining of
part quantities of coolant, replace these quantities which
have been drained with new coolant.

Only when refilling!

Use only recommended coolant.
Observe mixture ratio.
 4/29/2016 2/3

Perform filling operation slowly.

Adjust coolant level to maximum.
Close coolant expansion tank.
Installation note:
Close the sealing cap (1) until the arrows line up.

Important!
The following bleeding procedure is necessary e.g. when
a part is replaced in the cooling system or when the
cooling system is refilled.

Adding coolant:
Fill cooling system with a vacuum filling unit.
Use only recommended coolant.
Observe mixture ratio.

Only when venting!

Note:
Do not leave the coolant expansion tank sealing cap open
during the bleeding procedure.
Switch on the low-beam headlights to perform the bleeding
procedure. If the low-beam headlights are not switched on, the
ignition (Terminal 15) will switch off automatically after a certain
 4/29/2016 3/3

period of time and interrupt the bleeding procedure.

1. Connect battery charger.

2. Switch the ignition on.
3. Switch on low-beam headlight.
4. Set heater to maximum temperature and turn blower
down to lowest speed.
5. Driving experience switch must not be set to ECO PRO!
6. Press accelerator pedal for 10 seconds to floor. Engine
must not be started.
7. The bleeding procedure was started by pressing the
accelerator pedal and takes approx. 12 mins. (the
electrical coolant pump was activated and switches off
automatically after approx. 12 mins.).
8. Then adjust fluid level in the coolant expansion tank to
maximum.
9. Check cooling system on watertightness.
10. If venting has to be carried out again (e.g. if cooling
system is leaking), allow DME to fall completely (leave
ignition key removed for approx. 3 mins.), then repeat
from Point 2.

Close coolant expansion tank.

Installation note:
Close the sealing cap (1) until the arrows line up.
 4/29/2016 1/3

13 53 ... Warnings for the removal of

injectors (N55)

Warning!
Fuel, oil and dirt particles may get into your
eyes!
Wear full face guard and protective gloves.
Observe warning on cylinder head cover.
Disconnect negative battery terminal (risk of
fire due to short circuit on removal).
Carry out installation work on fuel system only
with coolant temperature below 40 °C.
Electric fuel pump starts up automatically
when door is opened!
Fuel can emerge spontaneously at high
velocity from the fuel injectors!
To reduce the fuel pressure, place rag over
fuel injector and carefully tap against the fuel
injector with a spanner.
There is a danger of injury if the fuel pressure
is not reduced!
Before removing the injectors, clean or
vacuum off injector slots.
 4/29/2016 2/3

Important!
There are two different injector versions for
the N55 engine.
A mixed installation of the components (hold-
down device, spark plug shafts, injectors,
cylinder heads, and screws) between the two
hold-down device versions is not
possible/permitted!
Compliance with the following notes regarding
the removal of the injectors is absolutely
mandatory:
 Injectors may be pulled out with a
maximum tensile force of 2000 N and
twisted only to 6 Nm (torsion
movement). If these values are
exceeded, the injectors must be
replaced!
 When assembling, it is essential to
adhere to screwing sequences and
tightening torques!
Failure to comply with this regulation
may result in leaks!
 Adhere to conditions of absolute
cleanliness when working on the high-
pressure fuel system.
Introduced dirt contamination can cause
malfunctions in the system!

- Do not allow any dirt particles or foreign

bodies to get into the system.

- Remove all traces of dirt before

removing lines or separate components.
 4/29/2016 3/3

- Use only fluff-free cloths.

- Seal all fuel system openings with

protective caps or plugs.

- High pressure lines may be rescrewed a

maximum of 10 times.

 Carry out engine washing only with

ignition coil cover fitted.
No water may penetrate into injector
slots and corrosion between injectors
and cylinder head must be prevented.
 Prior to removing injectors, remove the
ignition coil of the corresponding
cylinder.

- Ignition coils must not become coated

with fuel!

- The resistance of the silicone material is

reduced significantly by contact with
fuel, which may cause the ignition coil to
fail! It is therefore essential to protect the
spark plug slot against ingress of fuel
with a cloth!

- Clean spark plug slots before installing

ignition coils.

- Make sure the spark plug slot is

absolutely clean.
 4/30/2016 1/3

41 00 ... Welding in reinforcement plate (sheet

steel)

In the case of a partial replacement piece, a body component is

cut at a point described in the repair instructions.
A reinforcement plate is welded in to ensure sufficient strength.
Follow notes for welding steel components.
 
Note:
The following graphics serve as general illustrations of
reinforcement plate repair work. They are applicable to all
sectional repairs.

Mark component in accordance with dimension A and cut.

Cut new part (1) in accordance with cut and if necessary adjust

to fit with alignment bracket or universal mount.
Installation note:
Maintain a distance of approximately one to no more than two
material thicknesses at the severance cut to ensure welding
with the reinforcement metal and enable more tolerant
adjustment.

Clean inner and outer sides of connection faces (1) on new part
and (2) on body.
Coat insides with welding primer.
 4/30/2016 2/3

Drill bore holes (1) and (2) at distance of 25 mm to each other.
Hole diameter approx. 8 mm.

Make reinforcement plate (1) from trim of new part.

If applicable, produce more reinforcement plates.
Length of reinforcement plates is min. 40 mm.
Coat reinforcement plates (1) and (2) on both sides with
welding primer.

Push reinforcement plate (1) into component on body up to half

way and plug-weld (3).
 4/30/2016 3/3

If applicable, adjust the new part (1) with the alignment bracket
or universal tool and plug-weld (2)
MAG weld the joint (3).
Grind and clean weld seam and plug weld spots.
Only visible areas of the outer skin and on the carrier support
must be tinned.
All areas which have covers on the vehicle are not to be tinned.
Note:
Only applicable within the European Union!
European used-vehicle regulations prohibit the use of tin
containing lead in motor vehicles introduced after 01.07.2003!
 4/30/2016 1/3

41 00 ... Welding steel components

 

Important!

Comply with the following topics from ”Body, General”:

Safety regulations.

Handling electrical system, electronics, airbags and restraint systems.

 

1. General information

- The following procedures are used for repairs:

 MAG welding (Metal Active Gas welding)

 Resistance pressure spot welding (referred to in the following and in the repair instructions as spot
welding).

- Take the number and position of welding spots and MAG weld seams from the separated part. Replace
areas inaccessible to spot-welding tongs with MAG plug weldings at the same distance. Diameter of
bore holes for plug weldings 8 mm.

- In the case of emissions extraction, observe a minimum distance of 30 cm for MAG welding during the
welding process. Otherwise the inert gas would be drawn off.

- Follow the equipment manufacturer's instructions for use.

 

2. Work materials

- MAG welding:

 Steel welder (see Workshop Equipment).

 Steel welding wire ‐ G3SI1 (SG2) or alternatively G4SI1 (SG3)

 Welding mask
 4/30/2016 2/3

 Gas bottle containing inert gas (82 % argon, 18 % CO2)

- Resistance pressure spot welding:

 Spot-welding apparatus (see Workshop Equipment).

 Safety goggles

 

3. Preparations for MAG and spot-welding

- Remove the paint coating in an area of approx. 30 mm around the weld seam or spot.

 The zinc layer underneath must be removed during the MAG welding method.

 It is not necessary to remove the zinc layer underneath during spot-welding.

- Remove the paint coating on the reverse side of the weld seam or spot.

 Contaminants will otherwise enter the weld pool via the root of the weld seam.

 An insufficient electron flow prevents an optimum spot-weld joint.

- Coat all metal overlaps and weld spot flanges with welding primer.

- To determine the optimum electrode contact force for spot-welding, carry out spot-weld shear tests on
sample sheet metal.

- In order to keep the electron flow short during MAG welding on the body, you must if possible attach the
ground terminal directly to the component to be welded.

 

4. Welding

- During MAG welding, the weld gap must be kept as small as possible. The larger the weld gap, the
lower will be the strength of the joint.

- During spot-welding, the sheet metal flanges to be joined must be placed as close together as possible
without gaps.

The larger the gap, the lower will be the strength of the joint.

Minimum distance between welding spots 25 mm.

 4/30/2016 3/3

 

5. Subsequent treatment of welded connections:

- When grinding a weld seam, do not grind thin the base material next to the seam.

- After joining, clean all weld seams and spots with a stainless steel wire brush.

- Remove burnt paint with a stainless steel wire brush.

- All welded connections sealed off with body sealing compound in original condition must be primed and
sealed off again thoroughly after repairing. Replace damaged or removed anti-drumming layers.
 4/30/2016 1/1

32 00 Wheel Alignment F20 / REAR WHEEL Rough road package with height adjustment
Observe test conditions!
Front axle:
Total toe-in 0° 14' ± 12’
Adjustment total toe-in* 0° 14' ± 4'
Toe difference** single wheel between left/ right max. 12'
Camber ‐ 0° 01' ±  30’
(difference between left/right max. 30')
Adjustment camber* ‐ 0° 01' ±  25’
Toe difference angle (difference between left/right max. 30')
Castor angle (difference between
left/right max. 30')
Front wheel offset 0° ± 15'
Maximum steering angle
‐ Inner cornering wheel approx. ° 40° 48'
‐ Outer cornering wheel approx. ° 34° 18'
Rear axle:
Total toe-in 0° 18' ± 12'
Adjustment total toe-in*     0° 18' ± 4'
Camber (difference between left/right max. 30') -1° 06' ± 25'
Adjustment camber* -1° 06' ± 5'
Geometrical driving axis 0° ± 12'
*Note: To minimise adjusting errors (measuring inaccuracies), use a narrower
tolerance for adjusting toe/camber.
**Note: Toe difference front axle = criterion for steering wheel inclination
 4/30/2016 1/3

51 31 ... Window glass removal with wire pull

handle

Special tools required:

 2 150 267

Warning!
Follow safety instructions for working on vehicles with airbag systems (risk of injury).
Always wear safety goggles and protective gloves for your own safety.
Attention!
Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).

Attention!
Follow the vehicle-specific repair instructions!
Protect inner and outer working area (body, trim panels, cables etc.) against damage.

Depending on the area of application, a separating cord can also be used as an alternative to
wire.
Using the separating cord prevents any damage to the body.
Do not pull the separating cord over any sharp edges (risk of tearing)!

Used tool:
 Wire pull handles
 Dashboard protection
 Wire starter (special tool 2 150 267)

Use suction cups (51 3 010) to lift out the window glass.

Always keep both suction cups dry and clean to ensure their
optimum adhesion on the windscreen.
Secure window glass (if necessary with adhesive tape) against
falling out.

Pulling cutting wire into vehicle:

 4/30/2016 2/3

- Grip wire with pliers

(If access is difficult: using wire starter 2 150 267, feed
wire through adhesive bead.)

- Wire end (1) must be bent towards window glass.

- Heat wire end (1) and use it to pierce adhesive bead (2).

- Pull approximately half of the wire into the passenger

compartment
Note:
When using the separating cord, always pull it in using the wire
starter 2 150 267.

Using wire starter:

Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive
bead, wire end (bent part) must be positioned on window glass.

Attach wire pull handles:

Feed in cutting wire (1) in cutting handle (2) and clamping
element (3) as illustrated.
Move back cutting handle (2) over clamping element (3) and
trap wire end (4).

Danger of injury!
Wire end (4) must not protrude out of cutting
handle (2).

Cutting handle (2) can be secured with suction cup (5) to the

vehicle window or body during each of the work operations.
This prevents damage to the paint.
Fit second wire pull handle to other wire end.
 4/30/2016 3/3

Perform repair work with the aid of a second person.

Cutting wire (4) must be guided in cutting direction at an acute
as possible angle (>45°) to adhesive bead (1).
Cut through adhesive bead (1) by pulling cutting handle (2) and
at the same time providing counter support with cutting
handle (3).
Pull back cutting wire (4) with cutting handle (3) and make sure
that cutting wire (4) is always held under tension.
Cut through remaining adhesive bead in the same way.
 4/30/2016 1/1

51 04 98 (371)

Window glue

All models

Situation:
In the course of general product improvements, the glue used to fix car windows in their
frames has been changed. This demands a new procedure, which must be observed.

The current process (version 1) can be used until the expiry date.

The new process (version 2) has a simplified preparation. This process will be
incorporated in the next edition of the repair instructions.
Effect: If the two glues are mixed (procedure or repair kit material), the window will not be
adequately fixed.
Procedure: Version 1

Description Part number

Original BMW repair kit 83 19 9 407 850

contains cartridge with red stripes 83 19 9 407 851

Preliminary treatment of window:

- Apply glass activator W 000 with a clean soft cloth, then wipe over again with a fresh
soft cloth.
- Air drying time at least one minute.
- Shake the glass primer V 500 thoroughly for about 1 minute
(after releasing the steel ball in the bottle).
- Transfer the glass primer V 500 into the plastic bottle and apply to the window with the
felt pad on the bottle.
- Air drying time at least ten minutes.
Version 2

Description Part number

Original BMW repair kit 81 22 9 407 497

Cartridge 81 22 9 407 526

Preliminary treatment of window:

- Apply a thin coat of Original BMW Cleaner.

- Air drying time at least ten minutes.
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51 01 99 (392)

Windscreen wipers making noises

All models

Complaint:
Windscreen wiper blades scraping.
Wiping area is not properly wiped.
Cause: - When the windscreen is dirty and greasy, the windscreen wipers increasingly tend to
scrape.
- The wiper arm contact angle is not set correctly.
- Wiper blade faulty - worn
Affected All models
vehicles:
Remedy: Check for all of the causes listed above.

Procedure:

- Clean the windscreen and wiper blades with BMW silicone remover.
- Check and if necessary adjust the contact angle of the wiper blades to the windscreen using the special tool.

See Repair Instructions 61 61 010.

- Check the wiper blades for damage. Replace them if necessary.
Important notes:
- Only disassemble the wiper arms using the appropriate special puller.

See Repair Instructions 61 61 100.

- Broken wiper arms are not covered by the vehicle warranty.
Important note for the German market:

- Wiper blades must be cleaned and sent in in the original packaging, otherwise they cannot be repla

Parts: Order number for special tools

Description Order number Vehicle type

Wiper arm puller 61 6 060 all model series

Wiper arm puller 61 6 000 E36, E38, E39

Contact angle 00 9 230 E36, E38, E39

test gauge

Contact angle 00 9 331 E46

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test gauge

Wiper arm 00 9 261 / 00 9 262 E39

setting tool

Wiper arm 00 9 220 E36, E38

setting tool

Wiper arm 00 9 332 / 00 9 333 E46

setting tool

Silicone remover 83 19 9 407 906

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41 00 ... Working with 2-component PU cavity foam

Sourcing reference for cavity foam, refer to BMW Parts Service.

Properties of cavity foam:

- 2-component PU foam, solvent-free.

- Excellent flow capacity, enabling complete sealing of cavities.

- Good strength, preventing slipping in cavities.

- Low water absorption, preventing corrosion.

- Ideal for use as insulating and sealing compound

 

Information on dangers/hazards:

- Avoid eye and skin contact.

Wear protective goggles, solvent-resistant protective gloves and protective clothing.

- Do not inhale.

Apply in well ventilated rooms only.

 

- Warning!

Application time after mixing: within 8 minutes!

Completely empty open can after use.

- Remaining amounts which are not used can cause the can to explode on account of a chemical reaction
(buildup of heat)!

Alternatively, cool the can containing the non-removed remaining amount for several hours in cold
water.

- Do not eat, drink or smoke during this operation.

- Keep heat and ignition sources well away.

- Read the manufacturer's information on hazards/dangers (printed on the can) prior to application.
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Application instructions:

- Use by date on can.

Do not use the spray can after the Use by date on the can has expired. After the Use by date the
properties of the cavity foam will no longer meet the requirements of the BMW Group.

- Cavity sealing of repair area possible after an air drying time of 1 hour.

- Backing surface must be

clean and free from

dust,

grease,

oil and stripping agent.

- Application temperature at least 15 °C. Optimally 20 °C.

- Remove fresh, non-hardened PU foam with adhesive cleaner 208.

Sourcing reference: BMW Parts Service.

Hardened PU foam can only be removed by mechanical means (machine).

- Excess, hardened PU foam can be disposed of as residual waste.

Cans which are not entirely empty and unused whose Use by date has expired are classed as
hazardous waste.

Observe country-specific waste-disposal regulations.

- Observe the manufacturer's application instructions (printed on the can).

- Important!

Foam expands many times over as it sets (change in volume).

- Setting takes approx. 30 minutes. Mechanical processing (e.g. drilling, cutting, etc.) is then possible.
 4/30/2016 1/4

41 00 ... Workshop equipment (BMW and MINI vehicles)

 

Minimum workshop equipment requirements in order to ensure the correct and expert performance of body
repairs:

The tools listed below must be used.

 

Repair stage 1:

Tool)* Sourcing reference Screwed parts (steel Screwed parts

BMW or plastic) (aluminium)

Body tool trolley x x

Aluminium bodywork tool x

assortment

Pressure cup spray gun for 81 45 2 148 795 x x

cavity preservation

Drill x x

Blind riveting tongs x x

Electrical or pneumatic

With rivet head extension

Manual riveting machine for 81 43 2 155 739 (up to x x

blind rivet nuts M12) or

81 43 9 429 204 (up to
M8)

 

Repair stage 2:

Steel Aluminium

Tool)* Sourcing reference BMW Structure Outer Structure Outer

skin skin
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Body tool trolley accessory x x

set

Bodywork saw 81 43 2 299 088 or x x

81 43 2 299 089

Belt sander 81 43 2 236 488 (230V) or x x x x

81 43 2 333 873 (100-
115V)

Single-handed grinder x x x x

Welding spot remover 81 43 9 428 600 x x

Punch riveting tool 81 43 2 158 708 x x x

MAG welding apparatus x x

Cartridge gun for adhesives x x x x

Infrared heater 81 44 2 211 107 (220V) or x

81 45 2 211 615 (110V)

In addition, the repair stage 1 tools are required.

 

Repair stage 3:

Steel Aluminium

Tool)* Structure Outer skin Structure Outer skin

Spot welding apparatus x x

Straightening system x x

Stud welding apparatus x x

Flame coating set x

MIG welding apparatus x (E52 only)

In addition, the repair stage 1 and 2 tools are required.

 
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)*Sourcing reference BMW Workshop Equipment Catalogue

 

Important!

In vehicles from model year 2001, higher-tensile and high-tensile steels are used in certain areas.

It is essential to check whether the spot-welding apparatus used conforms to the technical
requirements of the currently recommended welding sets. Should you have any questions, please
contact the country-specific Hotline.

The use of technically obsolete equipment may have serious consequences for the structure of the
vehicle (e.g. in the event of a crash). In the end, this can result in safety and product liability risks
which cannot be calculated.

 

Use and restrictions:

Definition of recommendation:

All currently recommended spot welding sets comply according to the latest information with the requirements
relating to reliable welding of today's and future BMW Group vehicles. A spot welding unit will lose its
recommendation as soon as tests with materials and material combinations designated for future use in BMW
Group vehicles return negative results (see Table Group 1). All previous application before the withdrawal of
the recommendation shall remain unaffected.

Device designation Manufacturer

Group 1 CR500 Car-O-Liner

Devices currently no longer recommended Spot9000 Tecna

  ATL 400V Wieländer&Schill

Group 2 MIDIspot QSVM9000 Celette)*

Devices currently recommended MIDIspot QSVM9000 Elmatech)*

CR600 QSM Car-O-Liner)*

 
MIDIspot QSVM12000T Car-O-Liner
 
MIDIspot QSVM12000T Elmatech)*

Multispot MI-100 Control Elektron

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Inverta Spot GT BM Wieländer&Schill

3664 BM Tecna

)* no longer produced

 

Application options and restrictions of above devices.

Vehicle Group 1 Group 2

All BMW convertibles from E64 x x

Except A-pillar, B-pillar, sill

All BMW model series from E70 x x

Except B-pillar

Note:

April 2012

All BMW and MINI vehicles not mentioned can be repaired with the equipment of Group 1 and Group 2.