11 15 001 Replacing all engine ventilation lines and actuating wires (N63)

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Preprocesses

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 1: Identifying Luggage Compartment Floor Trim Panel And Plastic Nuts
  Courtesy of BMW OF NORTH AMERICA, INC.
Disconnect battery ground cable
Prerequisite

Ignition switched off.

NOTE: Observe instructions pertaining to the vehicle battery: see SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY , NOTES FOR DISCONNECTING/CONNECTING BATTERY , and INFORMATION ON 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 2: Identifying Battery Ground Cable Nut
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove acoustic cover
- Raise acoustic cover (1) .
- Remove acoustic cover (1) in the direction of travel.
  
  Fig 3: Identifying Acoustic Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
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 4: Identifying Strut Brace And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
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 5: Pushing Intake Port Towards Top
  Courtesy of BMW OF NORTH AMERICA, INC.
- Push in latch mechanism (1) .
- Detach intake port (2) towards rear and remove.
  
  Fig 6: Removing Intake Port Towards Rear
  Courtesy of BMW OF NORTH AMERICA, INC.
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 7: Removing Intake Air Filter Housing
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing the electronics box cover
- Loosen screws (1) .
- Remove electronics box cover (2) .
  
  Fig 8: Identifying Electronics Box Cover And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
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 9: Identifying Grommet Hold-Down Device, Rubber Grommets, And Connectors
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unfasten nut (1) .
- Detach grounding cable (2) .
  
  Fig 10: Identifying Grounding Cable And Nut
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release screw (1) .
- Lay filler neck (2) for windscreen washer fluid to one side.
  
  Fig 11: Identifying Washer Fluid Filler Neck And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
- Loosen screws (1) .
- Unclip coolant lines from clamp (2) on the electronics box.
  
  Fig 12: Identifying Clamp And Screws
  Courtesy 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 13: Identifying Electronics Box And Coolant Lines
  Courtesy of BMW OF NORTH AMERICA, INC.
Releasing left charge air hose on exhaust turbocharger
- Unfasten clamp (1) .
- Bend charge air pipe (2) slightly to the side.
  
  Fig 14: Identifying Left Charge Air Hose And Clamp
  Courtesy of BMW OF NORTH AMERICA, INC.
Releasing right charge air hose on exhaust turbocharger
- Unfasten clamp (1) .
- Bend charge air pipe (2) slightly to the side.
  
  Fig 15: Identifying Right Charge Air Hose And Clamp
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove left clean air pipe .
- Version 1:
- 1. Unlock the retainer.
  2. At the same time, pull off connecting line from clean air pipe.
    
    Fig 16: Removing Left Clean Air Pipe
    Courtesy of BMW OF NORTH AMERICA, INC.
- Version 2:
- Lightly pull line (1) in the direction of the arrow.
  Simultaneously, unlock the latch mechanisms (2) one after the other using a screwdriver (3) .
  
  Pull off connecting line from clean air pipe.
  
  Fig 17: Pulling Connecting Line Off Clean Air Pipe And Engine Crankcase Ventilation Line
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release screw (1) .
- Pull clean air pipe (2) from exhaust turbocharger.
  
  Fig 18: Identifying Clean Air Pipe And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove right clean air pipe
- Version 1:
- 1. Unlock the retainer.
  2. At the same time, pull off connecting line from clean air pipe.
    
    Fig 19: Removing Right Clean Air Pipe
    Courtesy of BMW OF NORTH AMERICA, INC.
- Version 2:
- Lightly pull line (1) in the direction of the arrow.
  Simultaneously, unlock the latch mechanisms (2) one after the other using a screwdriver (3) .
  
  Pull off connecting line from clean air pipe.
  
  Fig 20: Pulling Off Connecting Line From Clean Air Pipe
  Courtesy of BMW OF NORTH AMERICA, INC.
- Release screw (1) .
- Pull clean air pipe (2) from exhaust turbocharger.
  
  Fig 21: Identifying Clean Air Pipe And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
Partly remove oil reservoir for hydraulic steering
- Remove screw (1) on wheel arch.
- Release screw (2) on expansion tank.
- Remove washers.
- Carefully lift oil reservoir and place to one side.
  
  Fig 22: Identifying Screws
  Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect coolant hoses on expansion tank .

Disconnect coolant hoses on expansion tank using generally available disconnecting tools.

E.g. HAZET disconnect pliers (see table).

HAZET no.:	Designation
4590-1	Length of disconnect pliers (mm): 150
4590-2	Length of disconnect pliers (mm): 180
4590-3	Length of disconnect pliers (mm): 253
4590/2	Disconnect pliers set
4590/3	Disconnect pliers set

Fig 23: Identifying Pliers

Courtesy of BMW OF NORTH AMERICA, INC.

Remove coolant expansion tank
- Release screw (1).
- Release and disconnect coolant hoses (2).
- Raise expansion tank (3)
  
  Fig 24: Identifying Expansion Tank, Coolant Hoses, And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unlock connector (1) on coolant level sensor and disconnect.
- Remove expansion tank (2).
  
  Fig 25: Identifying Expansion Tank And Coolant Level Sensor Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing water valve for heater partially
- Disconnect plug connection (1) .
- Pull water valve (2) upwards out of holders.
  
  Fig 26: Identifying Water Valve And Plug Connection
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing oxygen sensor connector holder/left high pressure pump connector
- Unclip connector (1) and (2) from holder.
- Unlock and disconnect connectors (1) and (2) .
  
  Fig 27: Identifying Left High Pressure Pump Connectors
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unlock and disconnect connector (1) .
- Unlock holder (2) and feed out upwards.
  
  Fig 28: Identifying Holder And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove holder of oxygen sensor connector/high pressure pump connector, right
- Unclip connector (1) and (2) from holder.
- Unlock and disconnect connectors (1) and (2) .
  
  Fig 29: Identifying Right High Pressure Pump Connectors
  Courtesy of BMW OF NORTH AMERICA, INC.
- Unlock and disconnect connector (1) .
- Unlock holder (2) and feed out upwards.
  
  Fig 30: Identifying Holder And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing carrier plate
- Loosen screws (1) and (2) .
- Remove carrier plate (3) upwards.
  
  Fig 31: Identifying Carrier Plate And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing left carrier plate holder
- Loosen screws (1) .
- Feed out left carrier plate holder (2) upwards.
  
  Fig 32: Identifying Left Carrier Plate Holder And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing right carrier plate holder
- Loosen screws (1) .
- Feed out right carrier plate holder (2) upwards.
  
  Fig 33: Identifying Right Carrier Plate Holder And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing oil filler neck
- Loosen screws (1) .
- Remove oil filler neck (2) .
  
  Fig 34: Identifying Oil Filler Neck And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Key processes:
Removing right connecting line
- Version 1:
- 1. Unlock the retainer.
  2. Simultaneously pull off the engine ventilation line from the actuating wire.
    
    Fig 35: Unlocking Retainer And Pulling-Off Engine Ventilation Line From Actuating Wire
    Courtesy of BMW OF NORTH AMERICA, INC.
- Version 2:
- Lightly pull line (1) in the direction of the arrow.
  Simultaneously, unlock the latch mechanisms (2) one after the other using a screwdriver (3) .
  
  Pull off the engine ventilation line from the connecting line.
  
  Fig 36: Unlocking Latch Mechanisms And Pulling-Off Engine Ventilation Line From Connecting Line
  Courtesy of BMW OF NORTH AMERICA, INC.
- Loosen screws (2) .
- Detach the connecting line (1) from the cylinder head cover by pulling it upward.
  
  Fig 37: Detaching Connecting Line From Cylinder Head Cove
  Courtesy of BMW OF NORTH AMERICA, INC.
Visual inspection for loose parts in the cylinder head cover
- Conduct visual inspection in marked area (1) to check for loose parts.
- Remove any loose parts that may be on the oil separator.
  
  Fig 38: Identifying Engine Oil Filler Hole
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing engine ventilation line for cylinders 1-4 partially
- 1. Unlock the retainer.
  2. Simultaneously pull off the ventilation line from the intake system.
    
    Fig 39: Unlocking Retainer And Pulling Off Ventilation Line From Intake System
    Courtesy of BMW OF NORTH AMERICA, INC.
- Loosen screws (1) .
- Lift the engine wiring harness (2) slightly and remove the engine ventilation line.
  
  Fig 40: Identifying Engine Wiring Harness And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing left connecting line
- Version 1:
- 1. Unlock the retainer.
  2. Simultaneously pull off the engine ventilation line from the intake system.
    
    Fig 41: Unlocking Retainer And Pulling-Off Engine Ventilation Line From Actuating Wire
    Courtesy of BMW OF NORTH AMERICA, INC.
- Version 2:
- Lightly pull line (1) in the direction of the arrow.
  Simultaneously, unlock the latch mechanisms (2) one after the other using a screwdriver (3) .
  
  Pull off the engine ventilation line from the connecting line.
  
  Fig 42: Unlocking Latch Mechanisms And Pulling-Off Engine Ventilation Line From Connecting Line
  Courtesy of BMW OF NORTH AMERICA, INC.
- Loosen screws (2) .
- Detach the connecting line (1) from the cylinder head cover by pulling it upward.
  
  Fig 43: Detaching Connecting Line From Cylinder Head Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Visual inspection for loose parts in the cylinder head cover
- Conduct visual inspection in marked area (1) to check for loose parts.
- Remove any loose parts that may be on the oil separator.
  
  Fig 44: Identifying Engine Oil Filler Hole
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing engine ventilation line for cylinders 5-8 partially
- 1. Unlock the retainer.
  2. Simultaneously pull off the engine ventilation line from the intake system.
- Feed out and remove engine ventilation line.
  
  Fig 45: Unlocking Retainer And Pulling Off Ventilation Line From Intake System
  Courtesy of BMW OF NORTH AMERICA, INC.
Installing engine ventilation line for cylinders 5-8 partially
- Position engine ventilation line.
  NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
- Insert the engine ventilation line onto the intake system in the direction of the arrow.
  
  Fig 46: Inserting Engine Ventilation Line Onto Intake System
  Courtesy of BMW OF NORTH AMERICA, INC.

Installing left connecting line

Push connecting line (1) from above into cylinder head cover.

Tighten down screws (2) .

TIGHTENING TORQUES SPECIFICATIONS

Connecting line on cylinder head cover
M6 x 18	10 Nm

Fig 47: Installing Connecting Line

Courtesy of BMW OF NORTH AMERICA, INC.

Version 1:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Insert connecting line onto engine ventilation line.

Fig 48: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.
Version 2:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Insert connecting line onto engine ventilation line.

Fig 49: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.

Installing engine ventilation line for cylinders 1-4 partially

Slightly lift engine wiring harness.
Feed in engine ventilation line and position it properly.

NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.

Fig 50: Installing Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.
Insert the engine ventilation line onto the intake system in the direction of the arrow.
Position engine wiring harness (2) .

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATIONS

Engine wiring harness to engine
M8	10 Nm

Fig 51: Identifying Engine Wiring Harness And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installing right connecting line

Push connecting line (1) from above into cylinder head cover.

Tighten down screws (2) .

TIGHTENING TORQUES SPECIFICATIONS

Connecting line on cylinder head cover
M6 x 18	10 Nm

Fig 52: Installing Right Connecting Line

Courtesy of BMW OF NORTH AMERICA, INC.

Version 1:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Insert connecting line onto engine ventilation line.

Fig 53: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.
Version 2:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Insert connecting line onto engine ventilation line.

Fig 54: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.

Post processes:

Installing oil filler neck

Position oil filler neck (2) .

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATIONS

Oil filler neck on cylinder head cover
M6 x 20	8 Nm

Fig 55: Identifying Oil Filler Neck And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installing right carrier plate holder

Position right carrier plate holder (2) .

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATIONS

Carrier plate holder on cylinder head cover
M6 x 20	8 Nm

Fig 56: Identifying Right Carrier Plate Holder And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installing left carrier plate holder

Position left carrier plate holder (2) .

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATIONS

Carrier plate holder on cylinder head cover
M6 x 20	8 Nm

Fig 57: Identifying Left Carrier Plate Holder And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installing carrier plate
- Position carrier plate (3) .
- Tighten down screws (1) and (2) .
  
  Fig 58: Identifying Carrier Plate And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Installing oxygen sensor connector holder/right high pressure pump connector
- Connect holder (2) to carrier plate from above.
- Connect connector (1) .
  
  Fig 59: Identifying Holder And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Connect connectors (1) and (2) .
- Clip connectors (1) and (2) in the holder.
  
  Fig 60: Identifying Right High Pressure Pump Connectors
  Courtesy of BMW OF NORTH AMERICA, INC.
Installing oxygen sensor connector holder/left high pressure pump connector
- Connect holder (2) to carrier plate from above.
- Connect connector (1) .
  
  Fig 61: Identifying Holder And Connector
  Courtesy of BMW OF NORTH AMERICA, INC.
- Connect connectors (1) and (2) .
- Clip connectors (1) and (2) in the holder.
  
  Fig 62: Identifying Left High Pressure Pump Connectors
  Courtesy of BMW OF NORTH AMERICA, INC.
Installing water valve for heater
- Check that the rubber mount (1) and guide lug (2) are properly seated in holders (3) .
  
  Fig 63: Identifying Rubber Mount, Guide Lug, And Holders
  Courtesy of BMW OF NORTH AMERICA, INC.
- Install water valve (2) in the holders.
- Connect connector (1) .
  
  Fig 64: Identifying Water Valve And Plug Connection
  Courtesy of BMW OF NORTH AMERICA, INC.

Install coolant expansion tank

Position expansion tank (2) in the dedicated area.
Connect connector (1) to coolant level switch and lock.

Fig 65: Identifying Expansion Tank And Coolant Level Sensor Connector
Courtesy of BMW OF NORTH AMERICA, INC.
Fully insert expansion tank (3) .
Connect and lock coolant hoses (2) .
If required, remove disconnect pliers from coolant hoses (2) .

Tighten down screw (1) .

TIGHTENING TORQUES SPECIFICATIONS

Expansion tank to body
M6	10 Nm

Fig 66: Identifying Expansion Tank, Coolant Hoses, And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Fastening oil reservoir for hydraulic steering

Position oil reservoir.
Install washers.

Release screw 2 on expansion tank.

TIGHTENING TORQUES SPECIFICATIONS

Oil reservoir to coolant expansion tank/holder
M6	8 Nm

Tighten screw 1 on wheel arch.

TIGHTENING TORQUES SPECIFICATIONS

Oil reservoir to wheel arch
M6 x 37	10 Nm

Fig 67: Identifying Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Install right clean air pipe

Check the gasket on the clean air pipe.
Replace faulty gasket.
Position clean air pipe (2) on exhaust turbocharger.

Tighten down screw (1) .

TIGHTENING TORQUES SPECIFICATIONS

Clean air pie to turbocharger
M6	10 Nm

Fig 68: Identifying Clean Air Pipe And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Version 1:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Attach connecting line to clean air pipe.

Fig 69: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.
Version 2:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Attach connecting line (1) with the latch mechanisms (2) to clean air pipe.

Fig 70: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.

Install left clean air pipe

Check the gasket on the clean air pipe.
Replace faulty gasket.
Position clean air pipe (2) on exhaust turbocharger.

Tighten down screw (1) .

TIGHTENING TORQUES SPECIFICATIONS

Clean air pie to turbocharger
M6	10 Nm

Fig 71: Identifying Clean Air Pipe And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Version 1:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Attach connecting line to clean air pipe.

Fig 72: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.
Version 2:
NOTE: Ensure correct locking of all the retaining lugs. Retaining lugs must audibly snap into place.
Attach connecting line (1) with the latch mechanisms (2) to clean air pipe.

Fig 73: Inserting Connecting Line Onto Engine Ventilation Line
Courtesy of BMW OF NORTH AMERICA, INC.

Fastening right charge air hose on exhaust turbocharger

Check gasket between charge air hose and exhaust turbocharger.
Replace faulty gasket.
Position charge air hose (2) on exhaust turbocharger.

Tighten clamp (1) .

TIGHTENING TORQUES SPECIFICATIONS

Charge air hose to exhaust turbocharger
Screw clamp	3.5 Nm

Fig 74: Identifying Right Charge Air Hose And Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

Fastening left charge air hose on exhaust turbocharger

Check gasket between charge air hose and exhaust turbocharger.
Replace faulty gasket.
Position charge air hose (2) on exhaust turbocharger.

Tighten clamp (1) .

TIGHTENING TORQUES SPECIFICATIONS

Charge air hose to exhaust turbocharger
Screw clamp	3.5 Nm

Fig 75: Identifying Left Charge Air Hose And Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

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 76: Identifying Electronics Box, Coolant Lines, And Guide
Courtesy of BMW OF NORTH AMERICA, INC.
Clip coolant lines to clamp (2) on the electronics box.

Tighten down screws (1) .

TIGHTENING TORQUES SPECIFICATIONS

Electronics box, lower section to body
	8 Nm

Fig 77: Identifying Clamp And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Position filler neck (2) for the windscreen washer fluid.
Tighten down screw (1) .

Fig 78: Identifying Washer Fluid Filler Neck And Screw
Courtesy of BMW OF NORTH AMERICA, INC.

Tighten nut (1) of the grounding cable (2) .

TIGHTENING TORQUES SPECIFICATIONS

Grounding cable to ground connection
M8	21 Nm

Fig 79: Identifying Grounding Cable And Nut

Courtesy 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 80: Identifying Grommet Hold-Down Device, Rubber Grommets, And Connectors
Courtesy of BMW OF NORTH AMERICA, INC.

Installing the electronics box cover
- Position electronics box cover (2) .
- Tighten down screws (1) .
  
  Fig 81: Identifying Electronics Box Cover And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.

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 TORQUES SPECIFICATIONS

Clamp to air duct
	3 Nm

Fig 82: Identifying Connector And Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

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 83: Installing Intake Port And Latch Mechanism
  Courtesy of BMW OF NORTH AMERICA, INC.
- Feed in intake port (2) towards the bottom.
  « Latch mechanism (1) is locked.
  
  Fig 84: Installing Intake Port
  Courtesy of BMW OF NORTH AMERICA, INC.

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) .

Fig 85: Identifying Strut Brace And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

TIGHTENING TORQUES SPECIFICATIONS

Suspension cross-brace in engine compartment, front
M10 x 25	Tightening torque	56 Nm
M10 x 47	Joining torque	30 Nm
Replace screws	Angle of rotation	90 °

Install acoustic cover
NOTE: Ensure correct fit!
- Insert acoustic cover (1) into existing rubber guides.
  
  Fig 86: Identifying Acoustic Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Filling coolant in the expansion tank
CAUTION: Risk of acid burns from contact with coolant.

Acid burns may result in the event of coolant coming into contact with eyes or the skin.
- Wear safety goggles. Wear protective gloves.
  NOTE: For contamination of the cooling system (e.g. by engine oil), the cooling system must be rinsed with water until all contamination is removed!
  
  NOTE: Never reuse used coolant!
  
  NOTE: Use only RECOMMENDED COOLANT AND OBSERVE MIXTURE RATIO . Observe CAPACITIES .
- Top up coolant until coolant level is at maximum.
  NOTE: For more information see: COOLANT, CHECKING COOLING SYSTEM .
  
  Fig 87: Checking Coolant Level
  Courtesy of BMW OF NORTH AMERICA, INC.
- Vent cooling system.
- Screw sealing cap (1) to coolant expansion tank. In this process, close the sealing cap (1) until the arrows are aligned.
- Check function of cooling system.
- Visually inspect cooling system for tightness.
  
  Fig 88: Identifying Sealing Cap On Coolant Expansion Tank
  Courtesy of BMW OF NORTH AMERICA, INC.

Connecting the battery ground cable

NOTE: Observe instructions pertaining to the vehicle battery: see SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY , NOTES FOR DISCONNECTING/CONNECTING BATTERY , and INFORMATION ON INTELLIGENT BATTERY SENSOR (IBS) .

Position battery earth lead with IBS on negative terminal.

Tighten nut (1) .

TIGHTENING TORQUES SPECIFICATIONS

Battery earth lead
M6	5 Nm

Fig 89: Identifying Battery Ground Cable Nut

Courtesy of BMW OF NORTH AMERICA, INC.

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 TORQUES SPECIFICATIONS

Luggage compartment floor trim panel to body
	3 Nm

Fig 90: Identifying Luggage Compartment Floor Trim Panel And Plastic Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Fold down luggage compartment floor trim panel (1) .
Close tailgate.

Additional Information

Overview of Tightening Torques

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 30, 32
Connecting line on cylinder head cover
M6 x 18	10 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 31
Engine wiring harness to engine
M8	10 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 33
Oil filler neck on cylinder head cover
M6 x 20	8 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 34, 35
Carrier plate holder on cylinder head cover
M6 x 20	8 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 40
Expansion tank to body
M6	10 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 41
Oil reservoir to coolant expansion tank/holder
M6	8 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 41
Oil reservoir to wheel arch
M6 x 37	10 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 42, 43
Clean air pie to turbocharger
M6	10 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 44, 45
Charge air hose to exhaust turbocharger
Screw clamp	3.5 Nm

TIGHTENING TORQUES SPECIFICATIONS

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

TIGHTENING TORQUES SPECIFICATIONS

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

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 48
Clamp to air duct
	3 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 50
Suspension cross-brace in engine compartment, front
M10 x 25	Tightening torque	56 Nm
M10 x 47	Joining torque	30 Nm
Replace screws	Angle of rotation	90 °

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 53
Battery earth lead
M6	5 Nm

TIGHTENING TORQUES SPECIFICATIONS

Use in Activity: 54
Luggage compartment floor trim panel to body
	3 Nm

Overview Special Tool

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

SPECIAL TOOL DESCRIPTION

Use in Activity: 50
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 91: Identifying Torque Angle Measuring Dial

Courtesy of BMW OF NORTH AMERICA, INC.