11 36 046 Remove and install Intake and exhaust camshaft adjuster \PREMIUM

Overview of Activities

Preprocesses

Remove flap in luggage compartment trim panel on right
Disconnect battery earth lead
Remove ignition coil cover
Remove upper section of microfilter housing
Remove lower section of microfilter housing
Remove both windscreen wiper arms.
Remove cowl panel cover
Remove clean air pipe
Remove rear ignition coil cover
Remove ignition coils
Remove intake port
Remove pressure lines
Remove fan cowl with electric fan
Remove wiring harness section for ignition and injectors
Remove cylinder head cover
Remove front underbody protection
Hold engine at TDC setting (N55)
Keyprocesses
Remove intake and exhaust camshaft adjusters
Install intake and exhaust camshaft adjuster
Postprocesses
Remove special tools
Check timing
Install front underbody protection
Install cylinder head cover
Installing the ignition coils
Installing pressure lines
Install rear ignition coil cover
Install wiring harness section for ignition and injectors
Install fan cowl with electric fan
Install intake port
Install clean air pipe
Install cowl panel cover
Install both wiper arms
Adjust wiper arms
Install microfilter housing lower section
Install microfilter housing upper section
Install ignition coil cover
Connect battery earth lead
Install flap in right luggage compartment trim panel

Additional Information

Preprocesses

Remove flap in luggage compartment trim panel on right
- Turn lock (1) 90° to left.
- Open flap (2) in luggage compartment trim panel and remove.
  
  Fig 1: Identifying Luggage Compartment Trim Panel
  Courtesy of BMW OF NORTH AMERICA, INC.
Disconnect battery earth lead
Prerequisite

Ignition switched off.
- Loosen nut (1).
  NOTE: Risk of damage! Do not under any circumstances use force to pull off negative terminal.
- Remove battery terminal (2) with battery earth lead (3) and secure at side.
  
  Fig 2: Identifying Battery Terminal And Battery Earth Lead
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove ignition coil cover
- Pull ignition coil cover upwards off rubber mounts and remove in direction of travel.
  
  Fig 3: Identifying Ignition Coil Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove upper section of microfilter housing
- Release screws (1).
- Unfasten screws (2).
- Release screws (3).
- Remove upper section of microfilter housing (4).
  
  Fig 4: Identifying Microfilter Housing And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove lower section of microfilter housing
- Release holder (1).
- Release catches (3).
- Remove right cover (2).
  
  Fig 5: Identifying Right Cover And Holder
  Courtesy of BMW OF NORTH AMERICA, INC.
- Remove left cover (4):
- Release cable holder (2) and remove hose (1) from cover (4).
  
  Fig 6: Identifying Left Cover And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unlock plug connection (1) and disconnect.
- Unclip cable from guides (2).
  
  Fig 7: Identifying Plug Connection And Guides
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unlock plug connection (1) and disconnect.
- Unclip cable from guides (2).
  
  Fig 8: Identifying Plug Connection
  Courtesy of BMW OF NORTH AMERICA, INC.
- Press retaining lugs (3).
- Release cable strip (1) in direction of arrow from lower section of microfilter housing (2).
  
  Fig 9: Identifying Retaining Lugs And Cable Strip
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release holder (2) on both sides.
- Release screw (1) on both sides on lower section of microfilter housing (3).
  
  Fig 10: Identifying Holder And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
- Feed out microfilter housing lower section (1) in direction of arrow and remove.
  
  Fig 11: Feeding Out Microfilter Housing Lower Section
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove both windscreen wiper arms.
- Take off cap.
  
  Fig 12: Removing Cap
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unfasten nut.
  
  Fig 13: Locating Nut
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  NOTE: Risk of damage! Do not bend wiper arms on disassembly.
- Pull off windscreen wiper arm with special tool 0 495 220 (61 6 210) .
  
  Fig 14: Pulling Off Windscreen Wiper Arm Using Special Tool 0 495 220 (61 6 210)
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove cowl panel cover
- Pull off hose (1).
- Disconnect plug connections (2).
- Detach edge protection (3).
- Remove cover (4) towards top.
  
  Fig 15: Removing Cowl Panel Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove clean air pipe
- Release clamps along line (1).
- Release clamp (2).
- Unlock connector (3) on hot film air mass meter and disconnect.
- Release upper section of intake filter housing (4) at rear from clamps and remove in an upward direction.
  
  Fig 16: Identifying Clamps And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release screw (2).
- Unlock plug (4) from heating element and disconnect.
  NOTE: Risk of damage; do not release vent hose on cylinder head cover.
- Release screws (3) at clean air pipe (1) and pull vent hose off clean air pipe.
- Release screw (5).
- Feed out clean air pipe (1) and remove.
  
  Fig 17: Identifying Heating Element Plugs
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove rear ignition coil cover
- Unlock and remove retainer (1).
- Release wiring harnesses (2) from ignition coil cover (3) and lay to one side.
- Detach ignition coil cover (3) in upward direction from rubber mounts, feed out and remove.
  
  Fig 18: Identifying Retainer And Ignition Coil Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove ignition coils
- Release oxygen sensor connector (1) from bracket.
- Release screw (2).
- Put cable clip aside.
  
  Fig 19: Identifying Oxygen Sensor Connector And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  NOTE: Risk of damage! Pulling ignition coil out abruptly may cause silicone hose to tear.
  
  NOTE: Description is for one component only. Procedure is identical for all further components.
- Unlock plug catch (1) of ignition coil (2) and disconnect plug.
- Pull ignition coil (2) up and out.
  
  Fig 20: Pulling Ignition Coil Out Abruptly
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove intake port
- Release screws (1).
- Unlock intake port on side clamps (2) and pull off the air filter housing.
- Feed out intake port (3) and remove.
  
  Fig 21: Identifying Intake Port On Side Clamps And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove pressure lines
WARNING:
Electric fuel pump starts up automatically when door is opened!
Risk of fire due to short circuit on disassembly
- Observe warning on cylinder head cover.
WARNING:
Danger of injury on releasing high pressure line!
On releasing high pressure line, fuel may emerge at high speed.
- Observe warning on cylinder head cover! Carry out installation work on fuel system only at a coolant temperature below 40°C! Wear full face guard and protective gloves.
NOTE: Risk of damage! Attention must be paid to extreme cleanliness when working on the fuel system. Do not allow any dirt particles or foreign bodies to get into the system. Remove contamination prior to disassembly of components. Use only fluff-free cloths. Before removing the injectors, clean or vacuum off injector slots. Introduced contaminants can cause malfunctions in the system.

NOTE: Recycling: Fuel escapes when fuel lines are detached. Catch and dispose of escaping fuel in a suitable container. Observe country-specific waste disposal regulations.

NOTE: The following description applies to all pressure lines. First release pressure lines on rail to dissipate any available fuel pressure. Fuel must not get into the spark plug slot. Then disconnect the pressure line from the injector.
- Unscrew nuts (1).
- Unscrew nuts (1).
- Disconnect pressure line (2).
  
  Fig 22: Identifying Pressure Line And Nuts
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  NOTE: Important! If several pressure lines are removed, ensure that each pressure line is reinstalled in its original location (cylinder).
- Mark pressure lines.
- Seal pressure line (1) with a matching plug from set of special tools 2 0 494 179 (32 1 270) .
  
  Fig 23: Identifying Pressure Line And Nuts
  Courtesy of BMW OF NORTH AMERICA, INC.
- Seal rail and injector with a matching plug (1) from set of special tools 1 0 494 179 (32 1 270) .
  
  Fig 24: Identifying Seal Rail And Injector And Matching Plug
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove fan cowl with electric fan
NOTE: Only automatic or twin-clutch gearbox:
- Release screw (arrow).
- Detach radiator (1) for automatic transmission from fan cowl (2).
  
  Fig 25: Identifying Radiator For Automatic Transmission
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release connector (1) and remove.
- Unclip line (2) from fan cowl.
- Cut open cable strap (3).
- Release screw.
  
  Fig 26: Identifying Cable Strap And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release charge air duct (1) from rubber mount (2) on fan cowl.
  
  Fig 27: Identifying Charge Air Duct And Rubber Mount
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unlock catch in direction of arrow.
- Remove fan cowl towards top.
  
  Fig 28: Removing Fan Cowl
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove wiring harness section for ignition and injectors
- Unlock rear connector (1) from the control unit and disconnect.
- Release rear wiring harness from intake plenum.
  
  Fig 29: Identifying Rear Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release bolt (1) at rear of cable channel.
  
  Fig 30: Identifying Bolt At Rear Of Cable Channel
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release nuts (1) and remove earth cable.
- Unlock all connectors from ignition coils and injectors and detach.
- Unclip, feed out and remove wiring harness (2).
  
  Fig 31: Identifying Wiring Harness Nuts
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove cylinder head cover
- Release screws (1).
- Remove flange (2).
  
  Fig 32: Identifying Flange And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
- 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.
  
  Fig 33: Detaching Vacuum Line
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release screws of cylinder head cover from outside inwards in 1/2 turns.
- Remove cylinder head cover.
  
  Fig 34: Cylinder Head Cover BoltsTightening/Loosening Sequence
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove front underbody protection
- Release screws (1).
- Pull out underbody protection (2) under bumper trim panel (3).
  
  Fig 35: Pulling Out Underbody Protection Under Bumper Trim Panel
  Courtesy of BMW OF NORTH AMERICA, INC.
Hold engine at TDC setting (N55)
NOTE: When the engine is shut down, the intake and exhaust camshaft adjusters are normally locked in their initial setting. To prevent incorrect timing setting, proceed as follows:
- Check exhaust camshaft adjuster and intake adjuster lock and, if necessary, lock by turning camshafts.
  NOTE: When positioning special tool 0495005 (11 4 281) on mounting flats of intake camshaft, collision can occur at return spring of cylinder 1. Rework special tool 0495005 (11 4 281) as per following description.
- Check for freedom of movement of throttle return spring at intermediate lever cylinder 1.
- Recondition special tool 0 495 005 (11 4 281) .
- Rework phase on special tool 0 495 005 (11 4 281) as shown in area of 50 mm length and 8.5 mm width.
  
  Fig 36: Checking For Freedom Of Movement Of Throttle Return Spring
  Courtesy of BMW OF NORTH AMERICA, INC.
- Rework phase to 8.5 mm on special tool 0 495 005 (11 4 281) (see illustration).
  
  Fig 37: Checking Chamfer On Special Tool
  Courtesy of BMW OF NORTH AMERICA, INC.
- Remove fastener (1) in direction of arrow.
  
  Fig 38: Removing Fastener
  Courtesy of BMW OF NORTH AMERICA, INC.
- Rotate crankshaft at central bolt into TDC setting.
- Fix crankshaft. Slide in special tool 0 495 070 (11 0 300) in direction of arrow into the dowel hole.
  >> If the flywheel is secured in the correct dowel hole with special tool 0 495 070 (11 0 300) , the engine can no longer be moved at the central bolt.
  
  Fig 39: Sliding In Special Tool 0 495 070 (11 0 300)
  Courtesy of BMW OF NORTH AMERICA, INC.
- Vehicles with automatic transmission can only be secured to the specified position on flywheel (1) (see arrow in illustration).
  
  Fig 40: Locating Specified Securing Position On Flywheel
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  >> In TDC firing position on cylinder 1, cams of intake camshaft (1) point obliquely upwards.
  
  Fig 41: Identifying TDC Firing Position/Intake Camshaft
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  >> In TDC firing position on cylinder 1, cams of exhaust camshaft (1) point obliquely upwards.
  
  Fig 42: Identifying 1st Cylinder In TDC Firing Position Cams Of Exhaust Camshaft
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  >> The timings are correct when part numbers or read code (1) on intake and exhaust camshafts point towards top.
  
  Fig 43: Identifying Part Numbers On Intake And Exhaust Camshafts
  Courtesy of BMW OF NORTH AMERICA, INC.
- Secure special tool 0 496 673 (11 4 285) with bolts (1) to cylinder head.
- Fit special tool 0 495 006 (11 4 282) underneath on side of intake camshaft.
- Mount reworked special tool 0 495 005 (11 4 281) on the intake camshaft.
- Mount special tool 0 495 005 (11 4 281) on the exhaust camshaft.
  
  Fig 44: Fitting Special Tool 11 4 282 Underneath On Side Of Intake Camshaft
  Courtesy of BMW OF NORTH AMERICA, INC.
Keyprocesses
Remove intake and exhaust camshaft adjusters
NOTE: Release central bolts (1) and (2) of VANOS unit with special tool 0495004 (11 4 280) only. Remount special tool 0495004 (11 4 280) on N55 engine.
- Release central bolts (1) and (2).
  
  Fig 45: Removing Intake And Exhaust Camshaft Adjusters
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  NOTE: 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.
- Release chain tensioner (1).
  
  Fig 46: Locating Chain Tensioner
  Courtesy of BMW OF NORTH AMERICA, INC.
- Slightly lift timing chain (1) and remove exhaust camshaft adjuster (2) from exhaust camshaft.
- Slightly tilt exhaust camshaft adjuster (2) and remove upward.
  
  Fig 47: Removing Exhaust Camshaft Adjuster
  Courtesy of BMW OF NORTH AMERICA, INC.
- Slightly lift timing chain (1) and remove intake adjuster (2) from intake camshaft.
- Slightly tilt intake adjuster (2) and remove upward.
  
  Fig 48: Removing Intake Adjuster From Intake Camshaft
  Courtesy of BMW OF NORTH AMERICA, INC.

Install intake and exhaust camshaft adjuster

NOTE: Risk of damage! Intake and exhaust camshaft adjusters are different. Engine may be damaged if interchanged. Pay attention to markings.

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.

Fig 49: Identifying Marks On Intake And Exhaust Camshaft Adjuster
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The variable camshaft timing control is marked with EIN/IN for the intake camshaft.
Replace central bolt.
Place intake adjuster onto intake camshaft.
Place exhaust camshaft adjuster onto exhaust camshaft.
Insert central bolts (1) and tighten until they make contact.
Release central bolts (1) again by a 90° turn.

Fig 50: Releasing Central Bolts
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Incorrect assembly possible!

NOTE: Schematic representation of removed timing chain module.
Press tensioning rail (1) by hand against guide rail and make sure timing chain is guided in tensioning rail (1).

Fig 51: Pressing Tensioning Rail
Courtesy of BMW OF NORTH AMERICA, INC.
Turn increment wheel (2) in direction of arrow until retaining pins (1) on special tool 0 495 008 (11 4 290) match up.
0 495 008 (11 4 290) Slide on special tool in direction of arrow.

Fig 52: Turning Increment Wheel
Courtesy of BMW OF NORTH AMERICA, INC.
Special tool 0 495 004 (11 4 280) must be mounted for fastening the central bolts.
Use bolts to fasten special tool 0 495 008 (11 4 290) .
Screw special tool 0 493 971 (11 9 340) into cylinder head.

Fig 53: Screwing Special Tool 0 493 971 (11 9 340) Into Cylinder Head
Courtesy of BMW OF NORTH AMERICA, INC.

Pretension timing chain with special tool 0 493 971 (11 9 340) and 0 490 515 (00 9 250) .

TIGHTENING TORQUES SPECIFICATION

Special tool 0490515 (00 9 250)
Pre-tension timing chain.	0, 6 Nm

Fig 54: Pretensioning Timing Chain Using Special Tool 0 493 971 (11 9 340)

Courtesy of BMW OF NORTH AMERICA, INC.

Use special tool 0 490 504 (00 9 120) to tighten central bolts of intake adjuster.

TIGHTENING TORQUES SPECIFICATION

VANOS with camshaft sensor wheel to intake and exhaust camshafts
M10 x 94	Jointing torque	20 Nm
Replace screw.	Angle of rotation	180 °

Fig 55: Tightening Central Bolts Of Intake Adjuster

Courtesy of BMW OF NORTH AMERICA, INC.

Use special tool 0 490 504 (00 9 120) to tighten central bolts of exhaust camshaft adjuster.

TIGHTENING TORQUES SPECIFICATION

VANOS with camshaft sensor wheel to intake and exhaust camshafts
M10 x 94	Jointing torque	20 Nm
Replace screw.	Angle of rotation	180 °

Fig 56: Tightening Central Bolts Of Exhaust Camshaft Adjuster

Courtesy of BMW OF NORTH AMERICA, INC.

Postprocesses

Remove special tools

NOTE: Remove all special tools on completion of work . Nonobservance may lead to engine damage.

Unscrew special tool 0 493 971 (11 9 340) .

Fig 57: Removing Special Tools
Courtesy of BMW OF NORTH AMERICA, INC.

Install chain tensioner (1) and tighten.

TIGHTENING TORQUES SPECIFICATION

Chain tensioner to cylinder head
M22 x 1.5	55 Nm
Do not retighten chain tensioner. Replace sealing ring. Lightly oil thread.

Fig 58: Identifying Chain Tensioner

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws on special tool 0 495 008 (11 4 290) .
Remove special tool 0 495 008 (11 4 290) .

Fig 59: Removing Special Tool 0 495 008 (11 4 290)
Courtesy of BMW OF NORTH AMERICA, INC.
Release screws (1) and remove special tool 0 496 673 (11 4 285) .

Fig 60: Fitting Special Tool 11 4 282 Underneath On Side Of Intake Camshaft
Courtesy of BMW OF NORTH AMERICA, INC.
Pull out special tool 0 495 070 (11 0 300) backwards in direction of arrow out of dowel hole.
Crank engine 2x in direction of rotation at crankshaft.

Fig 61: Pulling Out Special Tool 0 495 070 (11 0 300)
Courtesy of BMW OF NORTH AMERICA, INC.

Check timing
- Fix crankshaft. Slide in special tool 0495070 in direction of arrow into the dowel hole.
  
  Fig 62: Sliding Special Tool 0495070
  Courtesy of BMW OF NORTH AMERICA, INC.
- Secure special tool 0 496 673 (11 4 285) with bolts (1) to cylinder head.
- Fit special tool 0 495 006 (11 4 282) underneath on side of intake camshaft.
- Mount reworked special tool 0 495 005 (11 4 281) on the intake camshaft.
- Mount special tool 0 495 005 (11 4 281) on the exhaust camshaft.
  
  Fig 63: Fitting Special Tool 11 4 282 Underneath On Side Of Intake Camshaft
  Courtesy of BMW OF NORTH AMERICA, INC.
- Only use special tool 0 495 004 (11 4 280) to loosen central bolts (1 and 2) of VANOS unit.
- Release central bolts (1 and 2).
  >> When all special tools can be mounted tension-free, the timing is OK.
  
  Fig 64: Releasing Central Bolts
  Courtesy of BMW OF NORTH AMERICA, INC.
Install front underbody protection
- Centre underbody protection (2) and insert in direction of arrow under bumper panel (3).
- Tighten screws (1).
  
  Fig 65: Locating Bumper Panel Screws
  Courtesy of BMW OF NORTH AMERICA, INC.

Install cylinder head cover

Fit cylinder head cover.

TIGHTENING TORQUES SPECIFICATION

Cylinder head cover to cylinder head
M6	8, 5 Nm

Tighten fitting screws (1).
Tighten fitting screws (2).
Tighten remaining cylinder head cover screws in sequence (3 to 24).

Fig 66: Cylinder Head Cover Bolts Tightening/Loosening Sequence
Courtesy of BMW OF NORTH AMERICA, INC.
Position vacuum line (1) and press down.
>> Lock (arrows) of vacuum line (1) must engage audibly.

Fig 67: Identifying Vacuum Line
Courtesy of BMW OF NORTH AMERICA, INC.
Renew sealing flange.
Mount flange (2).
Tighten down screws (1).

Fig 68: Identifying Cylinder Head Cover Flange And Screw
Courtesy of BMW OF NORTH AMERICA, INC.

Installing the ignition coils
NOTE: Risk of damage: The rubber cap must completely surround the sealing collar of the cylinder head cover. If rubber part is squashed, ignition coil can slip out again during engine operation.
- Position ignition coil and gently push it to limit position, by twisting it back and forth slightly if necessary.
- Check anti-twist lock.
- Push connector (1) with connector catch (2) open onto ignition coil.
- Carefully close connector catch (2) in direction of arrow.
  
  Fig 69: Installing Ignition Coils
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  >> 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. The sides of the locking lever lie inside the counter piece.
- Position cable clip.
- Tighten screw (2).
- Clip oxygen sensor connector (1) in bracket.
  
  Fig 70: Identifying Connector And Catch
  Courtesy of BMW OF NORTH AMERICA, INC.

Installing pressure lines

NOTE: Risk of damage! 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. High pressure lines may be rescrewed a maximum of 10 times.

Copper gaskets that may be fitted (1) are no longer used and must be removed.
If reusing the pressure line, apply a light coating of transmission oil to the thread. New pressure lines are already coated.

Fig 71: Identifying Copper Gaskets
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Risk of damage! All pressure lines must be installed tension-free.

NOTE: 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!

Fig 72: Identifying Pressure Line And Nuts
Courtesy of BMW OF NORTH AMERICA, INC.
Insert pressure line (1).
Tighten nuts (2) hand-tight only.
Reinstall line damper (3).
Applies only to vehicles with Continental high pressure pump:
NOTE: Observe tightening sequence.
Tighten nut (1) on injector.
Tighten nut (2) on rail.

Tighten down nuts with special tool 3 0 496 479 (13 0 161) .

TIGHTENING TORQUES SPECIFICATION

High pressure lines to rail and injection system
M12	23±3 Nm
Coat screw connection with transmission oil.

Fig 73: Identifying Pressure Line, Damper And Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Applies only to vehicles with Bosch high pressure pump:
NOTE: If ball bush is not in center of sealing cone of rail with injector when pressure line is attached, pressure 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 Mount pressure lines hand-tight.

5 Tighten screws (1) on hold-down device.

Fig 74: Identifying Pressure Pump Union Nuts And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

TIGHTENING TORQUES SPECIFICATION

Hold-down device to cylinder head
M7	13±1 Nm

6 Tighten nuts (2) on injectors.

TIGHTENING TORQUES SPECIFICATION

High pressure lines to rail and injection system
M12	23±3 Nm

7 Tighten nuts (3) on rail.

TIGHTENING TORQUES SPECIFICATION

High pressure lines to rail and injection system
M12	23±3 Nm

Check fuel system for tightness.
Check function of DME.

Install rear ignition coil cover
- Thread in ignition coil cover (3), position and connect on rubber mount.
- Fasten wiring harnesses (2) on ignition coil cover (3).
- Lock clamp (1).
  
  Fig 75: Identifying Ignition Coil Cover And Lock Clamp
  Courtesy of BMW OF NORTH AMERICA, INC.

Install wiring harness section for ignition and injectors

Connect and lock all connectors from ignition coils and injectors.
Position wiring harness (2), thread in and clip in.

Position ground cable and tighten nuts (1).

TIGHTENING TORQUES SPECIFICATION

Earth cable for ignition coils
	5 Nm

Fig 76: Identifying Wiring Harness And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten rear screw (1) on cable channel.

TIGHTENING TORQUES SPECIFICATION

Cable channel to cylinder head cover
	8 Nm

Fig 77: Identifying Rear Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Connect control unit connector (1) and lock.

Fig 78: Identifying Control Unit Connector
Courtesy of BMW OF NORTH AMERICA, INC.

Install fan cowl with electric fan
- Thread in fan cowl downwards in direction of arrow.
- Pay attention to latch mechanism of fan cowl (see small arrow in illustration).
  
  Fig 79: Installing Fan Cowl With Electric Fan
  Courtesy of BMW OF NORTH AMERICA, INC.
- Make sure fan cowl (1) and holder (2) are in correct installation position.
  
  Fig 80: Identifying Fan Cowl And Holder
  Courtesy of BMW OF NORTH AMERICA, INC.
- Mount charge air line (1) on rubber mount (2) on fan cowl.
  
  Fig 81: Identifying Charge Air Line And Rubber Mount
  Courtesy of BMW OF NORTH AMERICA, INC.
- Connect connector (1).
- Clip in line (2) of fan cowl.
- Replace cable straps (3).
- Tighten down screw.
  
  Fig 82: Identifying Cable Straps And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Only automatic or twin-clutch gearbox:
- Position radiator (1) for automatic transmission on fan cowl (2).
- Tighten screw (arrow).
  
  Fig 83: Identifying Radiator For Automatic Transmission On Fan Cowl
  Courtesy of BMW OF NORTH AMERICA, INC.

Install intake port

Position intake port (3).
Connect intake port to air filter housing and lock with clamps (2).

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Intake port to lock support
	2 Nm

Fig 84: Identifying Intake Port And Down Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Install clean air pipe

Position clean air pipe (1).
Clip vent hose in on clean air pipe!

Tighten screw (5).

TIGHTENING TORQUES SPECIFICATION

Lower clean air pipe to air duct
	3 Nm

Tighten screws (3) on clean air pipe (1).

Tighten screw (2).

TIGHTENING TORQUES SPECIFICATION

Clean-air duct to cylinder head cover
	3 Nm

Fig 85: Identifying Clean Air Pipe And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Connect connector (4) of heating element and lock.
Position upper section of intake filter housing (4) on clean air pipe.
Close clamps along line (1).
NOTE: Risk of damage! If hose clamp is tightened to a higher tightening torque, clean air pipe may be damaged!

Tighten clamp (2).

TIGHTENING TORQUES SPECIFICATION

Clean air pipe to intake silencer
Clamp	3 Nm

Connect connector (3) of hot film air mass meter and lock.

Fig 86: Positioning Upper Section Of Intake Filter Housing On Clean Air Pipe
Courtesy of BMW OF NORTH AMERICA, INC.

Install cowl panel cover
- Install sealing strip (1) (water ingress). If need be, retrofit the sealing strip (1).
  
  Fig 87: Identifying Sealing Strip
  Courtesy of BMW OF NORTH AMERICA, INC.
- Check grommets (1) for correct fit and damage.
  
  Fig 88: Identifying Grommets
  Courtesy of BMW OF NORTH AMERICA, INC.
- Cowl panel cover (1) must be correctly guided on the right and left under the cover for windscreen (2).
  
  Fig 89: Identifying Cowl Panel Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Install both wiper arms
NOTE: Wiper motor must be in its wiper park position. Note setting dimensions.
- Position wiper blades.
- Screw nuts on slightly.
  
  Fig 90: Locating Wiper Arms Nut
  Courtesy of BMW OF NORTH AMERICA, INC.

Adjust wiper arms

NOTE: Correctly adjusting the contact angle of the wiper arms on the windscreen increases wiping quality.

Adjust scale value of special tool 61-6100 MEASURING DEVICE according to the following values:

TECHNICAL DATA DESCRIPTION

Scale range
Scale range for left-hand drive vehicles	0... +10

Fig 91: Adjusting Scale Value Of Special Tool 0 495 346 (61 6 100)

Courtesy of BMW OF NORTH AMERICA, INC.

TECHNICAL DATA DESCRIPTION

Scale range
Scale range for right-hand drive vehicles	For right hand drive vehicles, change the preceding sign of the scale values.
	0... -10

Adjust distance between wiper blade (2) and trim panel on cowl panel (1) (A, B) to height of wiper arm mounting.

TECHNICAL DATA DESCRIPTION

Setting dimension (A, B) on windscreen wiper arm
	passenger's side
	88 mm ± 3 mm
	driver's side
	95 mm ± 3 mm

TECHNICAL DATA DESCRIPTION

C = contact angle between wiper blade center plane and windscreen.
	passenger's side
	86.7° ± 1°
	driver's side
	86.0° ± 1°

When setting with special tool 61-6100 MEASURING DEVICE , the scale value is adjusted in accordance with the following values:

TECHNICAL DATA DESCRIPTION

Scale value (left-hand drive vehicle) on special tool
	passenger's side
	-3
	driver's side
	-4

Tighten nut.

TIGHTENING TORQUES SPECIFICATION

Wiper arm to engine
M10	30 Nm

Fig 92: Locating Wiper Arms Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Fit protective cap.

Fig 93: Fitting Protective Cap
Courtesy of BMW OF NORTH AMERICA, INC.
Remove wiper blade (1) from wiper arm (2). Journal (3) is the fixture point for special tool 61-6100 MEASURING DEVICE .

Fig 94: Identifying Wiper Blade And Wiper Arm
Courtesy of BMW OF NORTH AMERICA, INC.
Slide special tool 61-6100 MEASURING DEVICE onto journal (1).
Set special tool 61-6100 MEASURING DEVICE on windscreen (2). Read the number in degrees on the scale.
Scale range from 0 to -10 is relevant for left-hand drive vehicles and scale range from 0 to +10 for right-hand drive vehicles.

Fig 95: Sliding Special Tool 0 495 346 (61 6 100) Onto Journal
Courtesy of BMW OF NORTH AMERICA, INC.
If the specified number in degrees is not correct, the wiper arm (1) must be limited to the spot shown with the special tool 0 495 457 (61 6 110) .

Fig 96: Adjusting Wiper Arm
Courtesy of BMW OF NORTH AMERICA, INC.

Install microfilter housing lower section
- Gasket (2) of microfilter housing lower section (1) must be OK.
  
  Fig 97: Checking Gasket Of Microfilter Housing Lower Section
  Courtesy of BMW OF NORTH AMERICA, INC.
- Position microfilter housing lower section (1) and insert in direction of arrow.
- Make sure microfilter housing lower section (1) is correctly seated.
  
  Fig 98: Positioning Microfilter Housing Lower Section
  Courtesy of BMW OF NORTH AMERICA, INC.
- Tighten screw (1) on both sides of microfilter housing lower section (3).
- Fasten holder (2) on both sides.
  
  Fig 99: Adjusting Microfilter Housing Lower Section
  Courtesy of BMW OF NORTH AMERICA, INC.
- Slide in cable strip (1) in direction of arrow into the microfilter housing lower section (2).
  NOTE: Retaining lugs (3) must not be damaged or missing.
- Make sure retaining lugs (3) are fitted correctly.
  
  Fig 100: Sliding Cable Strip
  Courtesy of BMW OF NORTH AMERICA, INC.
- Insert connector (1), must engage audibly.
- Clip cable into guides (2).
  
  Fig 101: Identifying Guides And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Insert connector (1), must engage audibly.
- Clip cable into guides (2).
  
  Fig 102: Identifying Guides And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
  
  NOTE: Make sure cable clip (2) and hose (1) are correctly seated in recess (3).
- Fasten cable clip (2) and hose (1) on cover (4).
- Left cover (4) is installed in same way as right cover.
  
  Fig 103: Identifying Cable Clip And Hose
  Courtesy of BMW OF NORTH AMERICA, INC.
- Position right cover (2) and make sure it is fitted correctly.
- Engage cover on points (3).
- Fasten holder (1).
  
  Fig 104: Positioning Right Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Install microfilter housing upper section
- Insert microfilter housing upper section (4).
- Tighten down screws (2).
- Tighten down screws (3).
- Tighten down screws (1).
  
  Fig 105: Identifying Microfilter Housing Upper Section
  Courtesy of BMW OF NORTH AMERICA, INC.
Install ignition coil cover
- Position ignition coil cover (1) in direction of arrow and connect downwards on rubber mount.
  
  Fig 106: Installing Ignition Coil Cover
  Courtesy of BMW OF NORTH AMERICA, INC.

Connect battery earth lead

Position battery terminal (2) with battery earth lead (3) on negative battery terminal.

Tighten nut (1) of battery terminal.

TIGHTENING TORQUES SPECIFICATION

Battery earth lead to battery
M6	5 Nm

Fig 107: Identifying Battery Terminal And Battery Earth Lead

Courtesy of BMW OF NORTH AMERICA, INC.

Install flap in right luggage compartment trim panel
- Position flap (2) in luggage compartment trim panel and close.
- Turn lock (1) 90° to right.
  
  Fig 108: Identifying Luggage Compartment Trim Panel
  Courtesy of BMW OF NORTH AMERICA, INC.