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Home >> BMW >> 2011 >> 535i Automatic >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System - Repair >> Injection Nozzle And Lines >> 13 53 315 Removing and installing/replacing all injectors in fuel injection system

13 53 315 Removing and installing/replacing all injectors in fuel injection system

Overview of Activities 

Preprocesses 

  1. Remove luggage compartment floor trim panel. See  1
  2. Disconnect battery ground cable. See  2
  3. Draw off the air conditioning. See  3
  4. Remove acoustic cover. See  4
  5. Remove front strut brace on left and right. See  5
  6. Remove intake port on left and right. See  6
  7. Remove intake silencer housing on left and right. See  7
  8. Remove rear right strut brace. See  8
  9. Remove front underbody protection. See  9
  10. Remove rear underbody protection. See  10
  11. Removing stiffening plate (for four-wheel drive vehicles only). See  11
  12. Removing stiffening plate (for four-wheel drive vehicles only). See  12
  13. Removing coolant expansion tank partially. See  13
  14. Removing water valve for heater partially. See  14
  15. Remove all ignition coils (cylinders 1-8). See  15
  16. Removing transmission wiring harness partially. See  16
  17. Removing right bulkhead side section. See  17
  18. Removing the electronics box (auxiliary box) cover. See  18
  19. Removing the electronics box cover. See  19
  20. Removing electronics box partially. See  20
  21. Removing positive battery cable (alternator) partially. See  21
  22. Removing refrigerant line (intake pipe) partially. See  22
  23. Removing positive battery cable (battery) partially. See  23
  24. Remove left charge air line. See  24
  25. Remove right charge-air line. See  25
  26. Remove clean air pipe on left and right. See  26
  27. Partly remove wiring harness for injectors at cylinders 1-4. See  27
  28. Removing fuel delivery line at the pressure line. See  28
  29. Partly remove wiring harness for injectors at cylinders 5-8. See  29
  30. Remove the pressure line between the high pressure pump and rail. See  30
  31. Removing all pressure lines, cylinders 1-8 between injector and rail. See  31

    Keyprocesses 

  32. Removing all injectors at cylinders 1-8. See  32
  33. Renew Teflon ring (only when reusing injector). See  33
  34. Installing all injectors for cylinders 1-8. See  34

    Postprocesses 

  35. Install pressure line between high pressure pump and rail. See  35
  36. Installing all pressure lines, cylinders 1-8 between injector and rail. See  36
  37. Installing the wiring harness for injectors at cylinders 5-8. See  37
  38. Connecting fuel delivery line to the pressure line. See  38
  39. Installing wiring harness for injectors at cylinders 1-4. See  39
  40. Installing the clean air pipe on the left and right. See  40
  41. Install right charge air line. See  41
  42. Install left charge air line. See  42
  43. Installing positive battery cable (battery). See  43
  44. Installing refrigerant line (intake pipe). See  44
  45. Installing positive battery cable (alternator). See  45
  46. Install electronics box. See  46
  47. Installing the electronics box cover. See  47
  48. Installing the electronics box cover (auxiliary box). See  48
  49. Installing right bulkhead side section. See  49
  50. Installing transmission wiring harness. See  50
  51. Installing all ignition coils (cylinders 1-8). See  51
  52. Installing water valve for heater. See  52
  53. Install coolant expansion tank. See  53
  54. Installing stiffening plate (for four-wheel drive vehicles only). See  54
  55. Installing front stiffening plate (for four-wheel drive vehicles only). See  55
  56. Install front underbody protection. See  56
  57. Install underbody protection at rear. See  57
  58. Installing the rear right strut brace. See  58
  59. Install left and right intake silencer housing. See  59
  60. Installing the left and right intake port. See  60
  61. Installing the front left and right strut brace. See  61
  62. Install acoustic cover. See  62
  63. Evacuate and fill air conditioning. See  63
  64. Connecting the battery ground cable. See  64
  65. Install luggage compartment floor trim panel. See  65
  66. Perform injection quantity compensation. See  66

Additional Information 

Overview of Tightening Torques 

TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 32
Special tool 13 0 300 on special tool 13 0 301/13 0 302 and cylinder head cover 
Tightening torques  10 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 35
Pressure line to high pressure pump 
M14 Initial torque  10 Nm
Final torque (retorque twice)  30 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 35
Pressure line to rail 
M14 Initial torque  10 Nm
Final torque (retorque twice)  30 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 36
Injector hold-down device to cylinder head 
M7 14 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 36
Pressure line on injector 
M12 Initial torque  10 Nm
Final torque (retorque twice)  23 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 36
Pressure line to rail 
M12 Initial torque  10 Nm
Final torque (retorque twice)  23 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 37, 39
Engine wiring harness to engine 
M6 10 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 40
Clean air pipe to exhaust turbocharger 
M6 10 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 41, 42
Charge air line to charge air cooler 
Replace clamp 3.5 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 41, 42
Charge air line to exhaust turbocharger 
Replace clamp 3.5 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 43
Positive battery cable from battery to positive battery connection point 
M8 21 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 44
Refrigerant line to capacitor 
M6 8 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 45
Battery positive lead to battery positive terminal 
M8 15 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 46
Electronics box, lower section to body 
  8 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 46
Grounding cable to ground connection 
M8 21 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 53
Expansion tank to body 
M6 10 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 54, 55
Stiffening plate to front axle support 
M8 Jointing torque  15 Nm
Renew screws Angle of rotation  90 °
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 57
Rear underbody protection to body 
Screw 3 Nm
Nut 2.5 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 58
strut brace in engine compartment, rear 
M10 x 47 Jointing torque  30 Nm
Renew screws Angle of rotation  90 °
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 59
Clamp to air duct 
  3 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 61
Suspension cross-brace in engine compartment, front 
M10 x 25 Tightening torques  56 Nm
M10 x 47 Jointing torque  30 Nm
Renew screws Angle of rotation  90 °
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 64
Battery earth lead 
M6 5 Nm
TIGHTENING TORQUE SPECIFICATIONS

Use in Activity: 65
Luggage compartment floor trim panel to body 
  3 Nm

Overview Special Tool 

0 496 565 (13 5 160) Fastener 

SPECIAL TOOL DESCRIPTION

Use in Activity: 28, 38
Usage (Caps (2x)) To close off the fuel lines when removing and installing the engine.
Included in the tool or work  
Storage location A26
Replaced by  
In connection with  
SI-Number 01 22 08 (498)
SPECIAL TOOL DESCRIPTION

Pos BMW Order number Replaced by Designation In Connection with
1 0 496 567 (13 5 161)  Fastener 
(Cap (2 pieces)) To close the quick connectors deletion, can be ordered only via tool set		  
2 0 496 568 (13 5 162)  Fastener 
(Cap (2 x)) To close off the fuel lines. Discontinued, only available via complete tool		  
Fig 1: Identifying Fastener (13 5 160)
G06179502Courtesy of BMW OF NORTH AMERICA, INC.

0 496 568 (13 5 162) Fastener 

SPECIAL TOOL DESCRIPTION

Use in Activity: 28, 38
Usage (Cap (2 x)) To close off the fuel lines. Discontinued, only available via complete tool
Included in the tool or work 0 496 565 
Storage location  
Replaced by  
In connection with  
SI-Number  
Fig 2: Identifying Fastener (13 5 160)
G06179502Courtesy of BMW OF NORTH AMERICA, INC.

0 496 481 (00 1 440) Socket wrench 

SPECIAL TOOL DESCRIPTION

Use in Activity: 31, 35, 36
Usage (socket wrench SW15) For releasing and tightening down screw connection of fuel line on injector.
Included in the tool or work  
Storage location A25
Replaced by  
In connection with  
SI-Number 01 20 08 (490)
Fig 3: Identifying Socket Wrench (00 1 440)
G06215165Courtesy of BMW OF NORTH AMERICA, INC.

0 496 480 (13 0 162) Adapter 

SPECIAL TOOL DESCRIPTION

Use in Activity: 31, 36
Usage (Adapter SW15) --> only available in set under 13 0 160 (0496371).
Included in the tool or work 0 496 371 
Storage location  
Replaced by  
In connection with  
SI-Number  
Fig 4: Identifying Adapter (13 0 162)
G06215235Courtesy of BMW OF NORTH AMERICA, INC.

0 496 479 (13 0 161) Socket wrench 

SPECIAL TOOL DESCRIPTION

Use in Activity: 31, 36
Usage (Socket wrench SW14 open) --> only available in set under 13 0 160 (0496371).
Included in the tool or work 0 496 371 
Storage location  
Replaced by  
In connection with  
SI-Number  
Fig 5: Identifying Adapter (13 0 162)
G06215235Courtesy of BMW OF NORTH AMERICA, INC.

0 496 752 (13 0 300) Tool 

SPECIAL TOOL DESCRIPTION

Use in Activity: 32
Usage (Dismantling tool) For dismantling seized injectors. Engine S63, N63, N43 note for N43: in combination with 13 5 250
Included in the tool or work  
Storage location B34
Replaced by  
In connection with  
SI-Number 01 16 12 (847)
Fig 6: Identifying Tool (13 0 300)
G08464504Courtesy of BMW OF NORTH AMERICA, INC.

0 495 757 (13 0 191) Pliers 

SPECIAL TOOL DESCRIPTION

Use in Activity: 33
Usage  
Included in the tool or work 0 495 756 
Storage location C19
Replaced by  
In connection with  
SI-Number 01 20 06 (299)
Fig 7: Identifying Pliers (13 0 191)
G08464488Courtesy of BMW OF NORTH AMERICA, INC.

0 495 761 (13 0 195) Fitting aid 

SPECIAL TOOL DESCRIPTION

Use in Activity: 33
Usage (Mounting cone)
Included in the tool or work 0 495 756 
Storage location C19
Replaced by  
In connection with  
SI-Number 01 20 06 (299)
Fig 8: Identifying Fitting Aid (13 0 195)
G08464466Courtesy of BMW OF NORTH AMERICA, INC.

0 495 758 (13 0 192) Holding sleeve 

SPECIAL TOOL DESCRIPTION

Use in Activity: 33
Usage (Assembly sleeve 1)
Included in the tool or work 0 495 756 
Storage location C19
Replaced by  
In connection with  
SI-Number 01 20 06 (299)
Fig 9: Identifying Holding Sleeve (13 0 192)
G08464472Courtesy of BMW OF NORTH AMERICA, INC.

0 495 759 (13 0 193) Holding sleeve

Use in Activity: 33

0 495 760 (13 0 194) Holding sleeve 

SPECIAL TOOL DESCRIPTION

Use in Activity: 33
Usage (Assembly sleeve 3)
Included in the tool or work 0 495 756 
Storage location C19
Replaced by  
In connection with  
SI-Number 01 20 06 (299)
Fig 10: Identifying Holding Sleeve (13 0 194)
G08464470Courtesy of BMW OF NORTH AMERICA, INC.

0 495 280 (13 0 140) Socket wrench 

SPECIAL TOOL DESCRIPTION

Use in Activity: 35
Usage For releasing and tightening fuel lines on piezo injector.
Included in the tool or work  
Storage location C52
Replaced by  
In connection with  
SI-Number 01 06 05 (181)
Fig 11: Identifying Socket Wrench (13 0 140)
G06876030Courtesy of BMW OF NORTH AMERICA, INC.

0 490 504 (00 9 120) Torque angle measuring dial 

SPECIAL TOOL DESCRIPTION

Use in Activity: 61
Usage For torsion angle adjustment of cylinder head bolts (all engines) And reinforcement plate front axle support E46
Included in the tool or work  
Storage location A5
Replaced by  
In connection with  
SI-Number  
Fig 12: Identifying Torque Angle Measuring Dial (00 9 120)
G08524196Courtesy of BMW OF NORTH AMERICA, INC.

General information 

safety instructions 

NOTE: Risk of damage!  Carry out engine wash with acoustic cover mounted only. No water must enter injector shafts. Corrosion between injectors and cylinder head must be avoided.
NOTE: Risk of damage!  Do not allow any dirt particles or foreign bodies to get into the system. Remove all traces of contamination before removing lines or separate components. Use only lint-free cloths. Seal all fuel system openings with protective caps or plugs. Before removing the injectors, clean or vacuum off injector shafts. Introduced contaminants can cause malfunctions in the system.

Preprocesses 

  1. Remove luggage compartment floor trim panel 
    • Fold up luggage compartment floor trim panel (1)  .
    • Release plastic nuts (2)  .
    • Remove luggage compartment floor trim panel (1)  in direction of arrow.
      Fig 13: Removing Luggage Compartment Floor Trim Panel
      G06890037Courtesy of BMW OF NORTH AMERICA, INC.
  2. Disconnect battery ground cable 

    Prerequisite 

    Ignition switched off.

    NOTE: For more information see: 61 20... Safety information for handling the battery, 00... Notes on disconnecting and connecting the battery, 61 12... Notes on the intelligent battery sensor (IBS)
    • Slacken nut (1)  .
      NOTE: Risk of damage! Do not under any circumstances use force to pull off negative terminal.
    • Pull off battery ground cable with IBS towards the top, put to one side and secure.
      Fig 14: Identifying Battery Nut
      G06894996Courtesy of BMW OF NORTH AMERICA, INC.
  3. Draw off the air conditioning 
    NOTE: Drawing off the air conditioning: See "64 50 010 DRAWING OFF, EVACUATING AND FILLING HEATING AND AIR CONDITIONING SYSTEM (R134A) ".
  4. Remove acoustic cover 
    • Raise acoustic cover (1)  .
    • Remove acoustic cover (1)  in the direction of travel.
      Fig 15: Identifying Acoustic Cover
      G09873698Courtesy of BMW OF NORTH AMERICA, INC.
  5. Remove front strut brace on left and right 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    NOTE: Risk of damage to the body! Driving without the strut brace is not permitted!
    • Loosen screws (1)  .
    • Remove strut brace (2)  .
      Fig 16: Identifying Strut Brace Screws
      G06885997Courtesy of BMW OF NORTH AMERICA, INC.
  6. Remove intake port on left and right 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Push in latch mechanism (1)  .
    • Remove intake port (2)  towards the top.
      Fig 17: Removing Intake Port
      G09873700Courtesy of BMW OF NORTH AMERICA, INC.
    • Push in latch mechanism (1)  .
    • Detach intake port (2)  towards rear and remove.
      Fig 18: Detaching Intake Port
      G09873701Courtesy of BMW OF NORTH AMERICA, INC.
  7. Remove intake silencer housing on left and right 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Unfasten clamp (1)  .
    • Disconnect connector (2)  at the hot film air mass meter.
    • Release clamp (3)  .
    • Unclip oxygen sensor cable from intake silencer housing.
    • Detach the intake air filter housing from the intake port and pull off upwards.
      Fig 19: Identifying Clamps and Connector
      G09873702Courtesy of BMW OF NORTH AMERICA, INC.
  8. Remove rear right strut brace 
    NOTE: Risk of damage to the body! Driving without the strut brace is not permitted!
    • Loosen expanding rivets (1)  .
    • Remove cover (2)  .
      Fig 20: Identifying Rear Right Strut Brace Cover And Rivets
      G06889587Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1)  .
    • Remove strut brace (2)  .
      Fig 21: Identifying Strut Brace And Screws
      G06889588Courtesy of BMW OF NORTH AMERICA, INC.
  9. Remove front underbody protection 
    • Unscrew all bolts.
    • Remove underbody protection (1)  from bumper panel (2)  .
      Fig 22: Locating Front Underbody Protection Bolts
      G09921027Courtesy of BMW OF NORTH AMERICA, INC.
  10. Remove rear underbody protection 
    • Unscrew all bolts.
    • Remove underbody protection (1)  .
      Fig 23: Locating Rear Underbody Protection Bolts
      G06889547Courtesy of BMW OF NORTH AMERICA, INC.
  11. Removing stiffening plate (for four-wheel drive vehicles only) 
    NOTE: Risk of damage!  Driving without stiffening plate is not permissible.
    • Loosen screws (1)  .
    • Remove stiffening plate (2)  .
      Fig 24: Identifying Stiffening Plate Screws
      G09921029Courtesy of BMW OF NORTH AMERICA, INC.
  12. Removing stiffening plate (for four-wheel drive vehicles only) 
    NOTE: Risk of damage!  Driving without stiffening plate is not permissible.
    • Loosen screws (1)  .
    • Remove stiffening plate (2)  .
      Fig 25: Identifying Stiffening Plate Screws
      G06889545Courtesy of BMW OF NORTH AMERICA, INC.
  13. Removing coolant expansion tank partially 
    • Release screw (1)  .
    • Lift expansion tank (2)  upwards and secure to side.
      Fig 26: Identifying Coolant Expansion Tank Screws
      G09921031Courtesy of BMW OF NORTH AMERICA, INC.
  14. Removing water valve for heater partially 
    • Disconnect plug connection (1)  .
    • Pull water valve (2)  upwards out of holders.
      Fig 27: Identifying Water Valve And Plug Connection
      G09873721Courtesy of BMW OF NORTH AMERICA, INC.
  15. Remove all ignition coils (cylinders 1-8) 
    NOTE: Description is for one component only. Procedure is identical for all further components.
    NOTE: Risk of damage! Ignition coils must not be contaminated by fuel. The durability of the silicone material is greatly reduced by contact with fuel, which can lead to failure of the ignition coil. 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 failure of the ignition coil.
    • Unlock connector lock (1)  on the ignition coil (2)  and pull off the connector.
      NOTE: Risk of damage! Pulling ignition coil out jerkily may cause silicone hose to tear.
    • Pull ignition coil (2)  out slowly.
      Fig 28: Pulling Connector Lock On Ignition Coil
      G09875348Courtesy of BMW OF NORTH AMERICA, INC.
  16. Removing transmission wiring harness partially 
    • Unlock plug connections (1)  and (2)  and disconnect.
    • Remove transmission wiring harness (3)  from clamps.
      Fig 29: Locating Transmission Wiring Harness
      G09875540Courtesy of BMW OF NORTH AMERICA, INC.
    • Unlock plug connection (1)  and disconnect.
    • Slide transmission wiring harness as far as possible in an upward direction.
      Fig 30: Identifying Plug Connection
      G09875541Courtesy of BMW OF NORTH AMERICA, INC.
    • Unclip grommet hold-down device (1)  .
    • Release wiring harness (2)  from bulkhead.
    • Unlock connector (3)  and remove.
      Fig 31: Identifying Grommet Hold-Down Device, Wiring Harness And Connector
      G06889017Courtesy of BMW OF NORTH AMERICA, INC.
  17. Removing right bulkhead side section 
    • Pull gasket (1)  in the operating range off in an upward direction.
    • Loosen screws (2)  .
    • Loosen screws (3)  .
    • Remove right bulkhead side section (4)  upwards.
      Fig 32: Identifying Bulkhead Side Section, Gasket And Screws
      G09875542Courtesy of BMW OF NORTH AMERICA, INC.
  18. Removing the electronics box (auxiliary box) cover 
    • Loosen screws (1)  .
    • Open clamp (2)  .
    • Remove electronics box cover (2)  .
      Fig 33: Identifying Electronics Box Clamp And Screws
      G06888952Courtesy of BMW OF NORTH AMERICA, INC.
  19. Removing the electronics box cover 
    • Loosen screws (1)  .
    • Remove electronics box cover (2)  .
      Fig 34: Identifying Electronics Box Cover And Screws
      G06888959Courtesy of BMW OF NORTH AMERICA, INC.
  20. Removing electronics box partially 
    • Unlock and remove all connectors (1)  from control unit.
    • Unclip grommet hold-down device (2)  and remove.
    • Detach rubber grommets (3)  from electronics box. Place wiring harnesses to one side.
      Fig 35: Identifying Rubber Grommets, Grommet Hold-Down Device And Connectors
      G06888960Courtesy of BMW OF NORTH AMERICA, INC.
    • Unfasten nut (1)  .
    • Detach grounding cable (2)  .
      Fig 36: Identifying Grounding Cable And Nut
      G06888409Courtesy of BMW OF NORTH AMERICA, INC.
    • Release screw (1)  .
    • Lay filler neck (2)  for windscreen washer fluid to one side.
      Fig 37: Identifying Windscreen Washer Fluid Filler Neck And Screw
      G06888958Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1)  .
    • Unclip coolant lines from clamp (2)  on the electronics box.
      Fig 38: Identifying Electronics Box, Clamp And Screws
      G06888949Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Risk of damage! Do not under any circumstances kink or bend coolant lines.
    • Feed out complete electronics box (1)  along with control unit and coolant lines (2)  carefully upwards and put to one side.
      Fig 39: Identifying Electronics Box And Coolant Lines
      G09873708Courtesy of BMW OF NORTH AMERICA, INC.
  21. Removing positive battery cable (alternator) partially 
    • Open cover.
    • Release screw (1)  .
    • Remove positive battery cable (2)  from battery positive terminal.
    • Remove positive battery cable (2)  from clamps (3)  .
      Fig 40: Identifying Positive Battery Cable, Clamp And Screws
      G06888993Courtesy of BMW OF NORTH AMERICA, INC.
  22. Removing refrigerant line (intake pipe) partially 
    • Release screw (1)  .
    • Disconnect refrigerant line (2)  and place to one side.
      Fig 41: Identifying Refrigerant Line And Screws
      G06888411Courtesy of BMW OF NORTH AMERICA, INC.
  23. Removing positive battery cable (battery) partially 
    • Release screw (1)  .
    • Remove positive battery cable (2)  and place to one side.
      Fig 42: Identifying Positive Battery Cable And Screw
      G06889046Courtesy of BMW OF NORTH AMERICA, INC.
  24. Remove left charge air line 
    • Unfasten clamp (1)  .
    • Unfasten clamp (2)  .
    • Remove left charge air duct (3)  .
      Fig 43: Identifying Left Charge Air Duct And Clamp
      G06178906Courtesy of BMW OF NORTH AMERICA, INC.
  25. Remove right charge-air line 
    • Unfasten clamp (1)  .
    • Unfasten clamp (2)  .
    • Remove right charge air line (3)  .
      Fig 44: Identifying Right Charge Air Duct And Clamp
      G06179227Courtesy of BMW OF NORTH AMERICA, INC.
  26. Remove clean air pipe on left and right 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Pull off hoses (1)  from clean air pipe.
    • Release screw (2)  .
    • Pull off clean air pipe (3)  in direction of travel from turbocharger.
      Fig 45: Identifying Clean-Air Pipe, Hoses And Screw
      G06178877Courtesy of BMW OF NORTH AMERICA, INC.
  27. Partly remove wiring harness for injectors at cylinders 1-4 
    • Release screw (1)  .
      Fig 46: Identifying Injectors Wiring Harness Screws
      G06178917Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1)  .
    • Remove wiring harness (2)  and put away.
    • Remove wiring harness (3)  and put away.
      Fig 47: Identifying Wiring Harness And Screws
      G06178918Courtesy of BMW OF NORTH AMERICA, INC.
    • Release screw (1)  .
    • Lift cable channel (2)  .
    • Stow wiring harness to the front.
      Fig 48: Identifying Cable Channel And Screw
      G06178919Courtesy of BMW OF NORTH AMERICA, INC.
  28. Removing fuel delivery line at the pressure line 
    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.
    • Disconnect fuel delivery line (1)  .
    • Seal fuel lines with special tools 0 496 565 (13 5 160)  and 0 496 568 (13 5 162)  .
    • Catch and dispose of escaping fuel.
      Fig 49: Identifying Fuel Delivery Line
      G09921054Courtesy of BMW OF NORTH AMERICA, INC.
  29. Partly remove wiring harness for injectors at cylinders 5-8 
    • Loosen screws (1)  .
    • Lift cable channel (2)  .
      Fig 50: Identifying Cable Channel And Screws
      G06178921Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1)  .
    • Release screw (2)  .
    • Place wiring harness (4)  to one side.
    • Remove wiring harness (3)  and put away.
      Fig 51: Identifying Pressure Line Wiring Harness And Screw
      G06889026Courtesy of BMW OF NORTH AMERICA, INC.
  30. Remove the pressure line between the high pressure pump and rail 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    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.
    • Release union nuts (1)  .
    • Remove pressure line (2)  .
      Fig 52: Identifying Pressure Line And Union Nut
      G06178955Courtesy of BMW OF NORTH AMERICA, INC.
  31. Removing all pressure lines, cylinders 1-8 between injector and rail 
    NOTE: Description is for one component only. Procedure is identical for all further components.
    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.
    • Remove the pressure line along with the reversible ratchet (1)  and special tools 0 496 481 (00 1 440)  , 0 496 480 (13 0 162)  and 0 496 479 (13 0 161)  at the rail.
      Fig 53: Removing Pressure Line
      G09921058Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Important! If several pressure lines are removed, ensure that each pressure line is reinstalled in its original installation location (cylinder).
    • If required, mark the pressure line.
    • Secure the injector from turning by using a spanner (2)  and remove the union nuts (1)  .
    • Remove pressure line.
      Fig 54: Releasing Union Nut
      G06178950Courtesy of BMW OF NORTH AMERICA, INC.

    Keyprocesses 

  32. Removing all injectors at cylinders 1-8 
    NOTE: Description is for one component only. Procedure is identical for all further components.
    • Release screw (1)  .
    • Remove hold-down device (2)  .
      Fig 55: Identifying Holding-Down Device And Bolt
      G08494482Courtesy of BMW OF NORTH AMERICA, INC.
    • Pull out injector (1)  .
      NOTE: If several injectors are removed, ensure that each injector is reinstalled in its original installation location (cylinder). Mark injectors.
    • If required, mark injector (1)  .

      » If injector (1)  is jammed, perform following operations.

      Fig 56: Pulling Injector
      G08494483Courtesy of BMW OF NORTH AMERICA, INC.
    • Mount special tool 13 0 301 or 13 0 302 from set of special tools 0 496 752 (13 0 300)  on the jammed injector.
    • Attach special tool below to the injector and on the top with the knurled screw to the injector feed.
      Fig 57: Installing Special Tool (13 0 301) On Injector
      G08494484Courtesy of BMW OF NORTH AMERICA, INC.
    • Attach special tool 0 496 752 (13 0 300)  on special tool 13 0 301 or 13 0 302.
    • Mount screws (1)  on the dedicated holes and tighten.
      TIGHTENING TORQUE SPECIFICATIONS

      Special tool 13 0 300 on special tool 13 0 301/13 0 302 and cylinder head cover 
      Tightening torque  10 Nm
      Fig 58: Identifying Special Tool (13 0 300)
      G08494485Courtesy of BMW OF NORTH AMERICA, INC.
    • Screw in screw (1)  through special tool 0 496 752 (13 0 300)  in special tool 13 0 301 or 13 0 302 on the jammed injector. Tighten screw (1)  so far that the jammed injector is pulled out.
      Fig 59: Identifying Injector Screws
      G08494486Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Protective caps for the injectors are available from BMW Parts Service.
    • After removing, seal the injector tip and fuel line connection using protective caps (1)  and (3)  .
      Fig 60: Identifying Injector Protective Caps
      G05502024Courtesy of BMW OF NORTH AMERICA, INC.
  33. Renew Teflon ring (only when reusing injector) 
    NOTE: Risk of damage! When exchanging Teflon ring, hands and work surface must be clean and free of oil. Avoid mechanical contact with injector tip.
    • Remove Teflon ring (1)  by using special tool 0 495 757 (13 0 191)  from injector (2)  .
      NOTE: Risk of damage! Do not clean injector tip. Do not use ultrasonic sound or other auxiliary materials.
      Fig 61: Removing Teflon Ring Using Special Tool (13 0 191) From Injector
      G04789983Courtesy of BMW OF NORTH AMERICA, INC.
    • Use a lint-free cloth to remove combustion residues from cylindrical part of injector tip.
    • Slide new Teflon ring (1)  onto special tool 0 495 761 (13 0 195)  .
      Fig 62: Identifying Teflon Ring And Cone
      G04789984Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Risk of damage! Do not use fingernails to slide Teflon ring on. Do not use any lubricating agents. The sealing ring is expanded when slid on.
    • Slide Teflon ring (1)  with the help of your fingers and the special tool 0 495 761 (13 0 195)  on injector (2)  .
      Fig 63: Pushing Teflon Ring On Injector
      G04789985Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: To bring the expanded Teflon ring to its installation dimension, slide three assembly sleeves with decreasing diameters onto the injector. Do not use any lubricating agents.
    • Slide assembly sleeve (1)  with large opening first onto injector (1)  .
      Fig 64: Sliding Assembly Sleeve On Injector
      G04789986Courtesy of BMW OF NORTH AMERICA, INC.
    • Slide special tool 0 495 758 (13 0 192)  on the injector (1)  .
    • Then slide special tool 0 495 759 (13 0 193)  on the injector (1)  .
      Fig 65: Sliding Assembly Sleeve (13 0 192) Onto Injector
      G04789987Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Teflon ring swells up. Install injector within 10 minutes or push on protective cap.
    • Finally, push the injector (1)  in the special tool 0 495 760 (13 0 194)  .
      Fig 66: Pushing Injector Into Assembly Sleeve (13 0 194)
      G04789988Courtesy of BMW OF NORTH AMERICA, INC.
  34. Installing all injectors for cylinders 1-8 
    NOTE: Description is for one component only. Procedure is identical for all further components.

    Check 

    • Check injector bore for contamination.

    desired state 

    Result 

    » Injector bore is dirty.

    Measure 

    • Clean injector bore. To do this, slide existing injector without decoupling element but with new Teflon ring in and out of injector bore several times. Then replace Teflon ring.
    • Read off the adjustment value for the injection quantity compensation on the new injector.
      Fig 67: Identifying Injector Adjustment Value
      G04755092Courtesy of BMW OF NORTH AMERICA, INC.
    • Install new decoupling element (2)  .
      NOTE: Teflon ring swells up. Install injector within 10 minutes or push on protective cap.
    • Pull off protective cap (1)  from injector (3)  .
      Fig 68: Identifying Injector Protective Caps
      G05502024Courtesy of BMW OF NORTH AMERICA, INC.
    • Clean contact surface of decoupling element in the injector bore.
    • Install injector (1)  .
      NOTE: Ensure correct fit!
    • Position hold-down device (2)  with the bulge pointing downwards.
    • Tighten screw (3)  hand-tight only so that hold-down device (2)  is slack and if necessary injector (1)  can still be turned.
      Fig 69: Identifying Injector, Hold-Down Device And Screws
      G06178995Courtesy of BMW OF NORTH AMERICA, INC.

    Postprocesses 

  35. Install pressure line between high pressure pump and rail 
    • Tighten pressure line (1)  hand-tight on the rail and the injector.
    • Tighten pressure line (1)  first on the high-pressure pump using the torque wrench (2)  and the special tool 0 496 481 (00 1 440)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Pressure line to high pressure pump 
      M14 Initial torque  10 Nm
      Final torque (retorque twice)  30 Nm
      Fig 70: Tightening Pressure Line
      G09921075Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten pressure line to the rail using a torque wrench, a long spanner head and special tool 0 495 280 (13 0 140)  . When tightening the pressure line on the rail, ensure that the angle of rotation of special tool 0 495 280 (13 0 140) is restricted. Reapply the special tool if necessary.
      Fig 71: Tightening Pressure Line On Rail Using Torque Wrench
      G06178957Courtesy of BMW OF NORTH AMERICA, INC.
      TIGHTENING TORQUE SPECIFICATIONS

      Pressure line to rail 
      M14 Initial torque  10 Nm
      Final torque (retorque twice)  30 Nm
  36. Installing all pressure lines, cylinders 1-8 between injector and rail 
    NOTE: Description is for one component only. Procedure is identical for all further components.
    NOTE: Risk of damage! Only install pressure line free from distortion. 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 nuts cannot be screwed on easily by hand, the injector must if necessary be turned a little.
    • Tighten nuts (1)  on pressure (2)  line hand-tight.
      Fig 72: Identifying Pressure Line And Nuts
      G06178951Courtesy of BMW OF NORTH AMERICA, INC.
    • Turn injector (1)  in direction of arrow until nuts on pressure line can be easily screwed on by hand.
    • Tighten nuts (2)  of pressure line hand-tight.
    • Tighten screw for hold-down device (3)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Injector hold-down device to cylinder head 
      M7 14 Nm
      Fig 73: Turning Injector On Pressure Line
      G06178952Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten nut of pressure line on injector with torque wrench (1)  and special tool 0 496 479 (13 0 161)  . While doing so, hold the hexagon head of the injector against a spanner (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Pressure line on injector 
      M12 Initial torque  10 Nm
      Final torque (retorque twice)  23 Nm
      Fig 74: Tightening Pressure Line Nut On Injector Using Torque Wrench
      G09921079Courtesy of BMW OF NORTH AMERICA, INC.
    • For cylinder 4, tighten pressure line (1)  using torque wrench (2)  and a spanner head (3)  . In this process, counter-hold the hexagon head of the injector using a spanner.
      TIGHTENING TORQUE SPECIFICATIONS

      Pressure line on injector 
      M12 Initial torque  10 Nm
      Final torque (retorque twice)  23 Nm
      Fig 75: Tightening Pressure Line Using Crowfoot Wrench
      G06889052Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten the Pressure line to rail using torque wrench (1)  and special tools 0 496 481 (00 1 440)  , 0 496 480 (13 0 162)  and 0 496 479 (13 0 161)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Pressure line to rail 
      M12 Initial torque  10 Nm
      Final torque (retorque twice)  23 Nm
      Fig 76: Removing Pressure Line
      G09921058Courtesy of BMW OF NORTH AMERICA, INC.
  37. Installing the wiring harness for injectors at cylinders 5-8 
    NOTE: Tighten all cable channel screw points properly to torque. Some screw points are also ground points. If cable channels are not screwed properly, this may lead to malfunction and failure of the DME.
    • Position wiring harness (3)  and install.
    • Position wiring harness (4)  .
    • Tighten down screw (2)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Engine wiring harness to engine 
      M6 10 Nm
      Fig 77: Identifying Pressure Line Wiring Harness And Screw
      G06889026Courtesy of BMW OF NORTH AMERICA, INC.
    • Position cable channel (2)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Engine wiring harness to engine 
      M6 10 Nm
      Fig 78: Identifying Cable Channel And Screws
      G06178921Courtesy of BMW OF NORTH AMERICA, INC.
  38. Connecting fuel delivery line to the pressure line 
    • Remove fuel lines from special tools 0 496 565 (13 5 160)  and 0 496 568 (13 5 162)  .
    • Connect fuel delivery line (1)  .
      Fig 79: Identifying Fuel Delivery Line
      G09921054Courtesy of BMW OF NORTH AMERICA, INC.
  39. Installing wiring harness for injectors at cylinders 1-4 
    • Position wiring harness.
    • Position cable channel (2)  .
      NOTE: Tighten all cable channel screw points properly to torque. Some screw points are also ground points. If cable channels are not screwed properly, this may lead to malfunction and failure of the DME.
      Fig 80: Identifying Cable Channel And Screw
      G06178919Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten down screw (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Engine wiring harness to engine 
      M6 10 Nm
    • Position wiring harness (2)  and (3)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Engine wiring harness to engine 
      M6 10 Nm
    • Secure wiring harness (3)  .
    • Tighten down screw (1)  .
      Fig 81: Identifying Wiring Harness And Screws
      G06178918Courtesy of BMW OF NORTH AMERICA, INC.
      TIGHTENING TORQUE SPECIFICATIONS

      Engine wiring harness to engine 
      M6 10 Nm
      Fig 82: Identifying Injectors Wiring Harness Screws
      G06178917Courtesy of BMW OF NORTH AMERICA, INC.
  40. Installing the clean air pipe on the left and right 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Connect clean air pipe (3)  to exhaust turbocharger.
    • Tighten down screw (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Clean air pipe to exhaust turbocharger 
      M6 10 Nm
    • Connect hoses (1)  of clean air pipe.
      Fig 83: Identifying Clean-Air Pipe, Hoses And Screw
      G06178877Courtesy of BMW OF NORTH AMERICA, INC.
  41. Install right charge air line 
    • Check gasket on exhaust turbocharger and renew if necessary.
    • Install right charge air line (3)  .
    • Tighten clamp (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Charge air line to charge air cooler 
      Replace clamp 3.5 Nm
    • Tighten clamp (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Charge air line to exhaust turbocharger 
      Replace clamp 3.5 Nm
      Fig 84: Identifying Right Charge Air Duct And Clamp
      G06179227Courtesy of BMW OF NORTH AMERICA, INC.
  42. Install left charge air line 
    • Check gasket on exhaust turbocharger and renew if necessary.
    • Install left charge air line (3)  .
    • Tighten clamp (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Charge air line to charge air cooler 
      Replace clamp 3.5 Nm
    • Tighten clamp (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Charge air line to exhaust turbocharger 
      Replace clamp 3.5 Nm
      Fig 85: Identifying Left Charge Air Duct And Clamp
      G06178906Courtesy of BMW OF NORTH AMERICA, INC.
  43. Installing positive battery cable (battery) 
    • Tighten screw (1)  of positive battery cable (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Positive battery cable from battery to positive battery connection point 
      M8 21 Nm
      Fig 86: Identifying Positive Battery Cable And Screw
      G06889046Courtesy of BMW OF NORTH AMERICA, INC.
  44. Installing refrigerant line (intake pipe) 
    • Install new gasket at refrigerant line (2)  .
    • Connect refrigerant line (2)  .
    • Tighten down screw (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Refrigerant line to capacitor 
      M6 8 Nm
      Fig 87: Identifying Refrigerant Line And Screws
      G06888411Courtesy of BMW OF NORTH AMERICA, INC.
  45. Installing positive battery cable (alternator) 
    • Tighten screw (1)  of positive battery cable (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Battery positive lead to battery positive terminal 
      M8 15 Nm
    • Fold down cover.
    • Secure positive battery cable (2)  in clamps (3)  .
      Fig 88: Identifying Positive Battery Cable, Clamp And Screws
      G06888993Courtesy of BMW OF NORTH AMERICA, INC.
  46. Install electronics box 
    NOTE: Risk of damage! Do not under any circumstances kink or bend coolant lines.
    • Carefully feed in electronics box (1)  with coolant lines (2)  .
    • Feed in the guide (3)  of the electronics box (1)  into the engine support.
      Fig 89: Identifying Electronics Box And Coolant Lines
      G09873771Courtesy of BMW OF NORTH AMERICA, INC.
    • Clip coolant lines to clamp (2)  on the electronics box.
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Electronics box, lower section to body 
        8 Nm
      Fig 90: Identifying Electronics Box, Clamp And Screws
      G06888949Courtesy of BMW OF NORTH AMERICA, INC.
    • Position filler neck (2)  for the windscreen washer fluid.
    • Tighten down screw (1)  .
      Fig 91: Identifying Windscreen Washer Fluid Filler Neck And Screw
      G06888958Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten nut (1)  of the grounding cable (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Grounding cable to ground connection 
      M8 21 Nm
      Fig 92: Identifying Grounding Cable And Nut
      G06888409Courtesy of BMW OF NORTH AMERICA, INC.
    • Attach rubber grommets (3)  in electronics box.
    • Connect all connectors (1)  on control unit and lock.
    • Clip grommet hold-down device (2)  .
      Fig 93: Identifying Rubber Grommets, Grommet Hold-Down Device And Connectors
      G06888960Courtesy of BMW OF NORTH AMERICA, INC.
  47. Installing the electronics box cover 
    • Position electronics box cover (2)  .
    • Tighten down screws (1)  .
      Fig 94: Identifying Electronics Box Cover And Screws
      G06888959Courtesy of BMW OF NORTH AMERICA, INC.
  48. Installing the electronics box cover (auxiliary box) 
    • Position electronics box cover (2)  .
    • Close clamps (2)  .
    • Tighten down screws (1)  .
      Fig 95: Identifying Electronics Box Clamp And Screws
      G06888952Courtesy of BMW OF NORTH AMERICA, INC.
  49. Installing right bulkhead side section 
    NOTE: Ensure correct fit!
    • Feed in right bulkhead side section (4)  and position.
    • Tighten down screws (3)  .
    • Tighten down screws (2)  .
    • Install new gasket (1)  .
      Fig 96: Identifying Bulkhead Side Section, Gasket And Screws
      G09875542Courtesy of BMW OF NORTH AMERICA, INC.
  50. Installing transmission wiring harness 
    • Connect connectors (3)  and lock.
    • Secure wiring harness (2)  to bulkhead.
    • Clip grommet hold-down device (1)  .
      Fig 97: Identifying Grommet Hold-Down Device, Wiring Harness And Connector
      G06889017Courtesy of BMW OF NORTH AMERICA, INC.
    • Feed in transmission wiring harness downwards.
    • Connect connectors (1)  and lock.
      Fig 98: Identifying Plug Connection
      G09875541Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect connectors (1)  and (2)  and lock.
    • Secure transmission wiring harness (3)  in clamps.
      Fig 99: Locating Transmission Wiring Harness
      G09875540Courtesy of BMW OF NORTH AMERICA, INC.
  51. Installing all ignition coils (cylinders 1-8) 
    NOTE: Description is for one component only. Procedure is identical for all further components.
    NOTE: Risk of damage! Ignition coils must not be contaminated by fuel. The durability of the silicone material is greatly reduced by contact with fuel, which can lead to failure of the ignition coil. 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 failure of the ignition coil.
    NOTE: The rubber cap must completely surround the sealing collar of the cylinder head cover. If rubber parts are squashed, the ignition coil can slip out again during engine operation.
    • Position the ignition coil (1)  and gently push it to the limit position, if necessary by twisting it back and forth slightly.
      Fig 100: Identifying Ignition Coil
      G06178846Courtesy of BMW OF NORTH AMERICA, INC.
      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). On closing locking lever, connector must lie on counter piece almost gap-free. In the process, the crank webs of the lever are positioned inside the counter piece.
    • Push connector (1)  onto the ignition coil with the connector latch mechanism (2)  open.
    • Carefully close the connector catch (2)  in the direction of the arrow.

      » The connector catch (2)  must snap into place without great effort.

      Fig 101: Closing Connector Catch
      G09875349Courtesy of BMW OF NORTH AMERICA, INC.
  52. Installing water valve for heater 
    • Check that the rubber mount (1)  and guide lug (2)  are properly seated in holders (3)  .
      Fig 102: Identifying Holders, Guide Lug And Rubber Mount
      G06886260Courtesy of BMW OF NORTH AMERICA, INC.
    • Install water valve (2)  in the holders.
    • Connect connector (1)  .
      Fig 103: Identifying Water Valve Connector
      G09921108Courtesy of BMW OF NORTH AMERICA, INC.
  53. Install coolant expansion tank 
    • Position expansion tank (2)  .
    • Tighten down screw (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Expansion tank to body 
      M6 10 Nm
      Fig 104: Identifying Coolant Expansion Tank Screws
      G09921031Courtesy of BMW OF NORTH AMERICA, INC.
  54. Installing stiffening plate (for four-wheel drive vehicles only) 
    • Position stiffening plate (2)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Stiffening plate to front axle support 
      M8 Jointing torque  15 Nm
      Renew screws Angle of rotation  90 °
      Fig 105: Identifying Stiffening Plate Screws
      G06889545Courtesy of BMW OF NORTH AMERICA, INC.
  55. Installing front stiffening plate (for four-wheel drive vehicles only) 
    • Position stiffening plate (2)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Stiffening plate to front axle support 
      M8 Jointing torque  15 Nm
      Renew screws Angle of rotation  90 °
      Fig 106: Identifying Stiffening Plate Screws
      G09921111Courtesy of BMW OF NORTH AMERICA, INC.
  56. Install front underbody protection 
    • Feed in underbody protection (1)  in bumper panel (2)  .
    • Tighten down all bolts.
      Fig 107: Locating Front Underbody Protection Bolts
      G09921027Courtesy of BMW OF NORTH AMERICA, INC.
  57. Install underbody protection at rear 
    NOTE: Ensure correct fit!
    • Position underbody protection (1)  .
    • Tighten down all bolts.
      TIGHTENING TORQUE SPECIFICATIONS

      Rear underbody protection to body
      Screw 3 Nm
      Nut 2.5 Nm
      Fig 108: Locating Rear Underbody Protection Bolts
      G06889547Courtesy of BMW OF NORTH AMERICA, INC.
  58. Installing the rear right strut brace 
    • Position strut brace (2)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      strut brace in engine compartment, rear 
      M10 x 47 Jointing torque  30 Nm
      Renew screws Angle of rotation  90 °
      Fig 109: Identifying Strut Brace And Screws
      G06889588Courtesy of BMW OF NORTH AMERICA, INC.
    • Engage cover (2)  in strut brace.
      NOTE: Renew damaged expanding rivet.
    • Secure cover with expanding rivet (1)  .
      Fig 110: Identifying Rear Right Strut Brace Cover And Rivets
      G06889587Courtesy of BMW OF NORTH AMERICA, INC.
  59. Install left and right intake silencer housing 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Connect intake silencer housing on intake port.
    • Clip oxygen sensor cable in on intake silencer housing.
    • Install clamp (3)  .
    • Connect connector (2)  at the hot film air mass meter.
    • Tighten clamp (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Clamp to air duct 
        3 Nm
      Fig 111: Identifying Hot Film Air Mass Meter Connector And Clamp
      G09873777Courtesy of BMW OF NORTH AMERICA, INC.
  60. Installing the left and right intake port 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Insert intake port (2)  towards the front.

      » Latch mechanism (1)  is locked.

      Fig 112: Identifying Intake Port And Latch Mechanism
      G09873778Courtesy of BMW OF NORTH AMERICA, INC.
    • Feed in intake port (2)  towards the bottom.

      » Latch mechanism (1)  is locked.

      Fig 113: Identifying Intake Port And Latch Mechanism
      G09873779Courtesy of BMW OF NORTH AMERICA, INC.
  61. Installing the front left and right strut brace 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    NOTE: Ensure correct installation position of the strut brace. Screw with washer is fitted at connection, front top.
    • Position strut brace (2)  .
    • Tighten screws (1)  with torque and then tighten them using special tool 0 490 504 (00 9 120)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Suspension cross-brace in engine compartment, front 
      M10 x 25 Tightening torque  56 Nm
      M10 x 47 Jointing torque  30 Nm
      Renew screws Angle of rotation  90 °
      Fig 114: Identifying Strut Brace Screws
      G06885997Courtesy of BMW OF NORTH AMERICA, INC.
  62. Install acoustic cover 
    NOTE: Ensure correct fit!
    • Insert acoustic cover (1)  into existing rubber guides.
      Fig 115: Identifying Acoustic Cover
      G09873698Courtesy of BMW OF NORTH AMERICA, INC.
  63. Evacuate and fill air conditioning 
    NOTE: Fill air conditioning: See "64 50 010 DRAWING OFF, EVACUATING AND FILLING HEATING AND AIR CONDITIONING SYSTEM (R134A) ".
  64. Connecting the battery ground cable 
    NOTE: For more information see: 61 20... Safety information for handling the battery, 00... Notes on disconnecting and connecting the battery, 61 12... Notes on the intelligent battery sensor (IBS)
    • Position battery earth lead with IBS on negative terminal.
    • Tighten nut (1)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Battery earth lead 
      M6 5 Nm
      Fig 116: Identifying Battery Ground Cable Nut
      G09921121Courtesy of BMW OF NORTH AMERICA, INC.
  65. Install luggage compartment floor trim panel 
    • Place luggage compartment floor trim panel (1)  in the direction opposite to arrow.
    • Fold back luggage compartment floor trim panel (1)  as shown.
    • Tighten plastic nuts (2)  .
      TIGHTENING TORQUE SPECIFICATIONS

      Luggage compartment floor trim panel to body 
        3 Nm
    • Fold down luggage compartment floor trim panel (1)  .
    • Close tailgate.
      Fig 117: Removing Luggage Compartment Floor Trim Panel
      G06890037Courtesy of BMW OF NORTH AMERICA, INC.
  66. Perform injection quantity compensation 
    NOTE: An injection quantity compensation must be carried out if an injector is replaced or changed on the cylinder side. Injection 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!
    • Connect "Diagnosis system".
    • Select "Function selection".
    • Select "Service functions".
    • Select "Engine electrical system".
    • Select "Adjustment functions".
    • Select "Adjust injectors".
    • Select "Test schedule".
    • Enter adjustment value.

      » For each replaced injector, the adjustment value must be entered according to the installation location (cylinder).

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