11 15 001 Replacing All Engine Ventilation Lines and Connection Lines

Overview of Activities 

Additional Information 

Overview of Tightening Torques 

Overview Special Tool 

0 490 504 (00 9 120) Torque Angle Measuring Dial 

Fig 1: Identifying Torque Angle Measuring Dial

Courtesy of BMW OF NORTH AMERICA, INC.

Preprocesses: 

1. Remove Spare Wheel Well Trim Panel At Rear 
   • Lift Luggage Compartment Floor Panel (1)  .
   • Release Expanding Rivets (2)  and Remove.
   • Remove Spare Wheel Well Trim Panel (3)  .
     Fig 2: Identifying Luggage Compartment Floor Panel, Expanding Rivets, and Spare Wheel Well Trim Panel

     Courtesy of BMW OF NORTH AMERICA, INC.
2. Disconnect Battery Negative Lead 

   Prerequisite 

   Ignition Switched Off.

   NOTE: for More Information Refer To Service Information Pertaining To BATTERY .
   • 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 3: Identifying Nut

     Courtesy of BMW OF NORTH AMERICA, INC.
3. Remove Acoustic Cover 
   • Raise Acoustic Cover (1)  .
   • Remove Acoustic Cover (1)  In The Direction of Travel.
     Fig 4: Identifying Acoustic Cover

     Courtesy of BMW OF NORTH AMERICA, INC.
4. Remove Front Strut Tower 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 Suspension Cross-Brace Is Not Permitted!
   • Release Screws (1)  .
   • Remove Strut Brace (2)  .
     Fig 5: Identifying Strut Brace and Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
5. 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 6: Identifying Latch and Intake Port

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   • Push In Latch Mechanism (1)  .
   • Detach Intake Port (2)  Towards Rear and Remove.
     Fig 7: Identifying Latch and Intake Port

     Courtesy of BMW OF NORTH AMERICA, INC.
6. 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 Filter Housing.
   • Detach The Intake Air Filter Housing From The Intake Port and Pull Off Upwards.
     Fig 8: Identifying Clamps and Connector

     Courtesy of BMW OF NORTH AMERICA, INC.
7. Removing The Electronics Box Cover 
   • Release Screws (1)  .
   • Remove Electronics Box Cover (2)  .
     Fig 9: Identifying Electronics Box Cover and Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
8. 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 The Side.
     Fig 10: Identifying Grommet Hold-Down Device, Rubber Grommets, and Connectors

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Unfasten Nut (1)  .
   • Detach Grounding Cable (2)  .
     Fig 11: Identifying Earth Lead and Nut

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Release Screw (1)  .
   • Lay Filler Neck (2)  for Windscreen Washer Fluid To One Side.
     Fig 12: Identifying Filler Neck and Screw

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Release Screws (1)  .
   • Unclip Coolant Lines From Clamp (2)  On The Electronics Box.
     Fig 13: 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 14: Identifying Electronics Box and Coolant Lines

     Courtesy of BMW OF NORTH AMERICA, INC.
9. Releasing Left Charge Air Hose On Exhaust Turbocharger 
   • Unfasten Clamp (1)  .
   • Bend Charge Air Pipe (2)  Slightly To The Side.
     Fig 15: Identifying Charge Air Pipe and Clamp

     Courtesy of BMW OF NORTH AMERICA, INC.
10. Releasing Right Charge Air Hose On Exhaust Turbocharger 
    • Unfasten Clamp (1)  .
    • Bend Charge Air Pipe (2)  Slightly To The Side.
      Fig 16: Identifying Charge Air Pipe and Clamp

      Courtesy of BMW OF NORTH AMERICA, INC.
11. 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 17: 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 18: Removing Left Clean Air Pipe (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Release Screw (1)  .
    • Pull Clean Air Pipe (2)  From Exhaust Turbocharger.
      Fig 19: Identifying Clean Air Pipe and Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
12. 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 20: 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 21: Removing Right Clean Air Pipe (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Release Screw (1)  .
    • Pull Clean Air Pipe (2)  From Exhaust Turbocharger.
      Fig 22: Identifying Clean Air Pipe and Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
13. 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 23: Identifying Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
14. 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 24: Identifying Pliers

      Courtesy of BMW OF NORTH AMERICA, INC.
15. Remove Coolant Expansion Tank 
    • Release Screw (1).
    • Release and Disconnect Coolant Hoses (2).
    • Raise Expansion Tank (3)
      Fig 25: Identifying Coolant Hoses, Expansion Tank and Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Unlock Connector (1) On Coolant Level Switch and Disconnect.
    • Remove Expansion Tank (2).
      Fig 26: Identifying Expansion Tank and Connector

      Courtesy of BMW OF NORTH AMERICA, INC.
16. 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

      Courtesy of BMW OF NORTH AMERICA, INC.
17. 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 28: Identifying Connectors

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Unlock and Disconnect Connector (1)  .
    • Unlock Holder (2)  and Feed Out Upwards.
      Fig 29: Identifying Connector and Holder

      Courtesy of BMW OF NORTH AMERICA, INC.
18. Removing Oxygen Sensor Connector Holder/Right High Pressure Pump Connector 
    • Unclip Connector (1)  and (2)  From Holder.
    • Unlock and Disconnect Connectors (1)  and (2)  .
      Fig 30: Identifying Connectors

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Unlock and Disconnect Connector (1)  .
    • Unlock Holder (2)  and Feed Out Upwards.
      Fig 31: Identifying Connector and Holder

      Courtesy of BMW OF NORTH AMERICA, INC.
19. Removing Carrier Plate 
    • Release Screws (1)  and (2)  .
    • Remove Carrier Plate (3)  Upwards.
      Fig 32: Identifying Carrier Plate and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
20. Removing Left Carrier Plate Holder 
    • Release Screws (1)  .
    • Feed Out Left Carrier Plate Holder (2)  Upwards.
      Fig 33: Identifying Carrier Plate Holder and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
21. Removing Right Carrier Plate Holder 
    • Release Screws (1)  .
    • Feed Out Right Carrier Plate Holder (2)  Upwards.
      Fig 34: Identifying Carrier Plate Holder and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
22. Removing Oil Filler Neck 
    • Release Screws (1)  .
    • Remove Oil Filler Neck (2)  .
      Fig 35: Identifying Oil Filler Neck and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
23. Removing Right Connecting Line 
    • Version 1: 
    • 1. Unlock The Retainer.
      2. Simultaneously Pull Off The Engine Ventilation Line From The Connecting Line.
         Fig 36: Removing Right Connecting Line

         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 37: Removing Right Connecting Line (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Release Screws (2)  .
    • Detach The Connecting Line (1)  From The Cylinder Head Cover By Pulling It Upward.
      Fig 38: Identifying Connecting Line and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
24. 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 39: Identifying Visual Inspection Area

      Courtesy of BMW OF NORTH AMERICA, INC.
25. 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 40: Removing Ventilation Line From Intake System

         Courtesy of BMW OF NORTH AMERICA, INC.
    • Release Screws (1)  .
    • Lift The Engine Wiring Harness (2)  Slightly and Remove The Engine Ventilation Line.
      Fig 41: Identifying Engine Wiring Harness and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
26. Removing Left Connecting Line 
    • Version 1: 
    • 1. Unlock The Retainer.
      2. Simultaneously Pull Off The Engine Ventilation Line From The Intake System.
         Fig 42: Removing Right Connecting Line

         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 43: Removing Right Connecting Line (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Release Screws (2)  .
    • Detach The Connecting Line (1)  From The Cylinder Head Cover By Pulling It Upward.
      Fig 44: Removing Connecting Line and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
27. 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 45: Identifying Visual Inspection Area

      Courtesy of BMW OF NORTH AMERICA, INC.
28. 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 Tank Ventilation Line.
      Fig 46: Removing Ventilation Line From Intake System

      Courtesy of BMW OF NORTH AMERICA, INC.
29. 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 47: Inserting Engine Ventilation Line Onto Intake System

      Courtesy of BMW OF NORTH AMERICA, INC.
30. Installing Left Connecting Line 
    • Push Connecting Line (1)  From Above Into Cylinder Head Cover.
    • Tighten Down Screws (2)  .
      Tightening Torques Specification
      
      

      Connecting Line On Cylinder Head Cover
      M6 X 18	10 Nm

      Fig 48: Identifying Connecting Line and Screws

      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 49: Inserting Connecting Line Onto Engine Ventilation Line (Version 1)

      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 50: Inserting Connecting Line Onto Engine Ventilation Line (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
31. 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.
    • Insert The Engine Ventilation Line Onto The Intake System In The Direction of The Arrow.
      Fig 51: Inserting Engine Ventilation Line Onto Intake System

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Position Engine Wiring Harness (2)  .
    • Tighten Down Screws (1)  .
      Tightening Torques Specification
      
      

      Engine Wiring Harness To Engine
      M8	10 Nm

      Fig 52: Identifying Engine Wiring Harness and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
32. Installing Right Connecting Line 
    • Push Connecting Line (1)  From Above Into Cylinder Head Cover.
    • Tighten Down Screws (2)  .
      Tightening Torques Specification
      
      

      Connecting Line On Cylinder Head Cover
      M6 X 18	10 Nm

      Fig 53: Identifying Connecting Line and Screws

      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 54: Inserting Connecting Line Onto Engine Ventilation Line (Version 1)

      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 55: Inserting Connecting Line Onto Engine Ventilation Line (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
33. Installing Oil Filler Neck 
    • Position Oil Filler Neck (2)  .
    • Tighten Down Screws (1)  .
      Tightening Torques Specification
      
      

      Oil Filler Neck On Cylinder Head Cover
      M6 X 20	8 Nm

      Fig 56: Identifying Oil Filler Neck and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
34. Installing Right Carrier Plate Holder 
    • Position Right Carrier Plate Holder (2)  .
    • Tighten Down Screws (1)  .
      Tightening Torques Specification
      
      

      Carrier Plate Holder On Cylinder Head Cover
      M6 X 20	8 Nm

      Fig 57: Identifying Carrier Plate Holder and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
35. Installing Left Carrier Plate Holder 
    • Position Left Carrier Plate Holder (2)  .
    • Tighten Down Screws (1)  .
      Tightening Torques Specification
      
      

      Carrier Plate Holder On Cylinder Head Cover
      M6 X 20	8 Nm

      Fig 58: Identifying Carrier Plate Holder and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
36. Installing Carrier Plate 
    • Position Carrier Plate (3)  .
    • Tighten Down Screws (1)  and (2)  .
      Fig 59: Identifying Carrier Plate and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
37. Installing Oxygen Sensor Connector Holder/Right High Pressure Pump Connector 
    • Connect Holder (2)  To Carrier Plate From Above.
    • Connect Connector (1)  .
      Fig 60: Identifying Connector and Holder

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect Connectors (1)  and (2)  .
    • Clip Connectors (1)  and (2)  In The Holder.
      Fig 61: Identifying Connectors

      Courtesy of BMW OF NORTH AMERICA, INC.
38. Installing Oxygen Sensor Connector Holder/Left High Pressure Pump Connector 
    • Connect Holder (2)  To Carrier Plate From Above.
    • Connect Connector (1)  .
      Fig 62: Identifying Connector and Holder

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect Connectors (1)  and (2)  .
    • Clip Connectors (1)  and (2)  In The Holder.
      Fig 63: Identifying Connectors

      Courtesy of BMW OF NORTH AMERICA, INC.
39. Installing Water Valve for Heater 
    • Check That The Rubber Mount (1)  and Guide Lug (2)  Are Properly Seated In Holders (3)  .
      Fig 64: 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 65: Identifying Water Valve and Plug Connection

      Courtesy of BMW OF NORTH AMERICA, INC.
40. Install Coolant Expansion Tank 
    • Position Expansion Tank (2)  In The Dedicated Area.
    • Connect Connector (1)  To Coolant Level Switch and Lock.
      Fig 66: Identifying Expansion Tank and 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 Specification
      
      

      Expansion Tank To Body
      M6	10 Nm

      Fig 67: Identifying Coolant Hoses, Expansion Tank and Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
41. Fastening Oil Reservoir for Hydraulic Steering 
    • Position Oil Reservoir.
    • Install Washers.
    • Release Screw 2 On Expansion Tank.
      Tightening Torques Specification
      
      

      Oil Reservoir On Coolant Expansion Tank/Holder
      M6	8 Nm

    • Tighten Screw 1 On Wheel Arch.
      Tightening Torques Specification
      
      

      Oil Reservoir To Wheel Arch
      M6 X 37	10 Nm

      Fig 68: Identifying Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
42. 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 Specification
      
      

      Clean-Air Pipe To Turbocharger
      M6	10 Nm

      Fig 69: 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 70: Inserting Connecting Line Onto Engine Ventilation Line (Version 1)

      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 71: Inserting Connecting Line Onto Engine Ventilation Line (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
43. 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 Specification
      
      

      Clean-Air Pipe To Turbocharger
      M6	10 Nm

      Fig 72: 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 73: Inserting Connecting Line Onto Engine Ventilation Line (Version 1)

      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 74: Inserting Connecting Line Onto Engine Ventilation Line (Version 2)

      Courtesy of BMW OF NORTH AMERICA, INC.
44. 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 Specification
      
      

      Charge Air Hose To Exhaust Turbocharger
      Screw Clamp	3, 5 Nm

      Fig 75: Identifying Charge Air Pipe and Clamp

      Courtesy of BMW OF NORTH AMERICA, INC.
45. 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 Specification
      
      

      Charge Air Hose To Exhaust Turbocharger
      Screw Clamp	3, 5 Nm

      Fig 76: Identifying Charge Air Pipe and Clamp

      Courtesy 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 77: Identifying Electronics Box, Guide, and Coolant Lines

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Clip Coolant Lines To Clamp (2)  On The Electronics Box.
    • Tighten Down Screws (1)  .
      Tightening Torques Specification
      
      

      Electronics Box, Lower Section On Body
      	8 Nm

      Fig 78: 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 79: Identifying Filler Neck and Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten Nut (1)  of The Grounding Cable (2)  .
      Tightening Torques Specification
      
      

      Grounding Cable To Ground Connection
      M8	21 Nm

      Fig 80: Identifying Earth Lead 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 81: Identifying Grommet Hold-Down Device, Rubber Grommets, and Connectors

      Courtesy of BMW OF NORTH AMERICA, INC.
47. Installing The Electronics Box Cover 
    • Position Electronics Box Cover (2)  .
    • Tighten Down Screws (1)  .
      Fig 82: Identifying Electronics Box Cover and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
48. 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 Specification
      
      

      Clamp To Air Duct
      	3 Nm

      Fig 83: Identifying Connector and Clamps

      Courtesy of BMW OF NORTH AMERICA, INC.
49. 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 84: Identifying 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 85: Identifying Intake Port and Latch Mechanism

      Courtesy of BMW OF NORTH AMERICA, INC.
50. 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 Torques Specification
      
      

      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 °

      Fig 86: Identifying Strut Brace and Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
51. Install Acoustic Cover 
    NOTE: Ensure Correct Fit!
    • Insert Acoustic Cover (1)  Into Existing Rubber Guides.
      Fig 87: Identifying Acoustic Cover

      Courtesy of BMW OF NORTH AMERICA, INC.
52. 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 Protective Goggles. Wear Protective Gloves.
    NOTE: for Dirt Contamination of The Cooling System (E.G. By Engine Oil), The Cooling System Must Be Rinsed with Water Until All Dirt Contamination Is Removed!
    NOTE: Never Reuse Used Coolant!
    NOTE: Observe COOLANT REQUIREMENTS AND MIXTURE RATIO .
    • Top Up Coolant Until Coolant Level Is At Maximum.
      NOTE: for More Information See: 17 00 039 Venting and Filling Cooling System with Vacuum Filling Unit
    • Vent Cooling System.
      Fig 88: Identifying Max Level

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    • 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 89: Identifying Sealing Cap

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53. Connecting The Battery Ground Cable 
    NOTE: for More Information Refer To Service Information Pertaining To BATTERY .
    • Position Battery Ground Cable with Ibs On Negative Terminal.
    • Tighten Nut (1)  .
      Tightening Torques Specification
      
      

      Battery Earth Lead
      M6	5 Nm

      Fig 90: Identifying Nut

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54. Installing Spare Wheel Well Trim Panel At Rear 
    • Insert Spare Wheel Well Trim Panel (3)  .
    • Secure Expanding Rivet (2)  .
    • Fold Down Luggage Compartment Floor Panel (1)  .
      Fig 91: Identifying Luggage Compartment Floor Panel, Expanding Rivets, and Spare Wheel Well Trim Panel

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