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

Overview of Activities Preprocesses 

1. Remove battery cover. See  1.
2. Disconnect battery earth lead. See  2.
3. Remove acoustic cover. See  3.
4. Remove left microfilter housing cover. See  4.
5. Remove right microfilter housing cover. See  5.
6. Remove microfilter housing. See  6.
7. Installing the complete engine bulkhead. See  7.
8. Remove left and right tension struts on spring strut dome. See  8.
9. Remove intake port on left and right. See  9.
10. Remove intake silencer housing on left and right. See  10.
11. Remove front underbody protection. See  11.
12. Drain coolant. See  12.
13. Remove coolant expansion tank. See  13.
14. Remove heater valve for heating and air-conditioning unit. See  14.
15. Partly remove oil reservoir for hydraulic steering. See  15.
16. Remove lower section of steering shaft. See  16.
17. Remove all ignition coils (cylinders 1-8). See  17.
18. Remove fuel low-pressure sensor. See  18.
19. Removing engine ventilation line for cylinders 1-4. See  19.
20. Removing engine ventilation line for cylinders 5-8. See  20.
21. Removing right fresh-air duct. See  21.
22. Removing the electronics box cover. See  22.
23. Partly remove wiring harness for injectors at cylinders 1-4. See  23.
24. Removing fuel delivery line at the pressure line. See  24.
25. Partly remove wiring harness for injectors at cylinders 5-8. See  25.
26. Remove the pressure line between the high pressure pump and rail. See  26.
27. Removing all pressure lines, cylinders 1-8 between injector and rail. See  27.

    Keyprocesses 

28. Removing all injectors at cylinders 1-8. See  28.
29. Renew Teflon ring (only when reusing injector). See  29.
30. Installing all injectors for cylinders 1-8. See  30.

    Postprocesses 

31. Install pressure line between high pressure pump and rail. See  31.
32. Installing all pressure lines, cylinders 1-8 between injector and rail. See  32.
33. Installing the wiring harness for injectors at cylinders 5-8. See  33.
34. Connecting fuel delivery line to the pressure line. See  34.
35. Installing wiring harness for injectors at cylinders 1-4. See  35.
36. Installing the electronics box cover. See  36.
37. Installing the right fresh-air duct. See  37.
38. Installing engine ventilation line for cylinders 1-4. See  38.
39. Installing engine ventilation line for cylinders 5-8. See  39.
40. Installing fuel low-pressure sensor. See  40.
41. Installing all ignition coils (cylinders 1-8). See  41.
42. Installing steering shaft, bottom. See  42.
43. Installing oil reservoir for hydraulic steering. See  43.
44. Installing water valve for heater. See  44.
45. Install coolant expansion tank. See  45.
46. Install left and right intake silencer housing. See  46.
47. Installing the left and right intake port. See  47.
48. Installing left and right tension struts on spring strut dome. See  48.
49. Installing the complete engine bulkhead. See  49.
50. Remove right microfilter housing cover. See  50.
51. Installing left microfilter housing cover. See  51.
52. Install acoustic cover. See  52.
53. Connect battery earth lead. See  53.
54. Remove battery cover. See  54.
55. Add coolant. See  55.
56. Perform injection quantity compensation. See  56.
57. Alignment for active steering. See  57.
58. Carrying out steering angle sensor adjustment. See  58.

Additional Information 

Overview of Tightening Torques 

Overview Special Tool 

0 490 133 (00 2 030) Device 

Fig 1: Identifying Device (00 2 030)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 565 (13 5 160) Fastener 

Fig 2: Identifying Fastener (13 5 160)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 568 (13 5 162) Fastener 

Fig 3: Identifying Fastener (13 5 162)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 481 (00 1 440) Socket wrench 

Fig 4: Identifying Socket Wrench (00 1 440)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 480 (13 0 162) Adapter 

Fig 5: Identifying Adapter (13 0 162)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 479 (13 0 161) Socket wrench 

Fig 6: Identifying Socket Wrench (13 0 161)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 752 (13 0 300) Tool 

Fig 7: Identifying Special Tool (13 0 300)

Courtesy of BMW OF NORTH AMERICA, INC.

0 495 757 (13 0 191) Pliers 

Fig 8: Identifying Pliers (13 0 191)

Courtesy of BMW OF NORTH AMERICA, INC.

0 495 761 (13 0 195) Fitting aid 

Fig 9: Identifying Fitting Aid (13 0 195)

Courtesy of BMW OF NORTH AMERICA, INC.

0 495 758 (13 0 192) Holding sleeve 

Fig 10: Identifying Holding Sleeve (13 0 192)

Courtesy of BMW OF NORTH AMERICA, INC.

0 495 759 (13 0 193) Holding sleeve 

Fig 11: Identifying Holding Sleeve (13 0 193)

Courtesy of BMW OF NORTH AMERICA, INC.

0 495 760 (13 0 194) Holding sleeve 

Fig 12: Identifying Holding Sleeve (13 0 194)

Courtesy of BMW OF NORTH AMERICA, INC.

0 495 280 (13 0 140) Socket wrench 

Fig 13: Identifying Socket Wrench (13 0 140)

Courtesy of BMW OF NORTH AMERICA, INC.

General information 

safety instructions 

Preprocesses 

1. Remove battery cover 
   • Open the luggage compartment floor trim panel.
   • Loosen screws (1)  .
   • Remove battery cover upwards.
     Fig 14: Identifying Battery Cover Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
2. Disconnect battery earth lead 

   Prerequisite 

   Ignition switched off.

   • Slacken nut (1)  .
     NOTE: Risk of damage!  Do not under any circumstances pull or lever off intelligent battery sensor from battery by force.
   • Remove intelligent battery sensor (2) from battery and secure to side.
     Fig 15: Identifying Intelligent Battery Sensor And 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 16: Identifying Acoustic Cover

     Courtesy of BMW OF NORTH AMERICA, INC.
4. Remove left microfilter housing cover 
   • Pull off edge protection (1)  in working area.
   • Unlock screw caps (2)  and remove microfilter housing cover.
     Fig 17: Identifying Microfilter Housing Cover And Screw Caps

     Courtesy of BMW OF NORTH AMERICA, INC.
5. Remove right microfilter housing cover 
   • Pull off edge protection (1)  in working area.
   • Unlock screw caps (2)  and remove microfilter housing cover (3)  .
     Fig 18: Identifying Microfilter Housing Cover And Screw Caps

     Courtesy of BMW OF NORTH AMERICA, INC.
6. Remove microfilter housing 
   • Disconnect plug connection (1)  .
   • Unlock screw caps (2)  and remove microfilter housing.
     Fig 19: Identifying Microfilter Housing Screw Caps

     Courtesy of BMW OF NORTH AMERICA, INC.
7. Installing the complete engine bulkhead 
   NOTE: Ensure correct fit!
   NOTE: Renew damaged expanding rivet.
   • Feed in the right engine bulkhead (3)  .
     NOTE: Risk of damage!  Observe different screw lengths.
   • Tighten down screws (2)  .
   • Install expanding rivet (1)  .
     Fig 20: Identifying Right Engine Bulkhead And Down Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Feed in left engine bulkhead (5)  .
   • Clip in connecting line (3)  .
     NOTE: Risk of damage!  Observe different screw lengths.
   • Tighten down screws (2)  and (4)  .
   • Install expanding rivet (1)  .
     Fig 21: Identifying Left Engine Bulkhead And Down Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Feed in center engine bulkhead (3)  .
   • Tighten down screws (2)  and (4)  .
   • Install gasket (1)  for engine compartment lid.
     Fig 22: Identifying Engine Compartment Lid Gasket

     Courtesy of BMW OF NORTH AMERICA, INC.
8. Remove left and right tension struts on spring strut dome 
   NOTE: Description is for right component only. The procedure on the left component is identical.
   • Loosen screws (1)  .
   • Remove tension strut (2)  .
     Fig 23: Identifying Tension Strut And Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
9. Remove intake port on left and right 
   • Remove expanding rivet (1)  .
   • Remove air intake hose (2)  upwards.
     Fig 24: Removing Air Intake Hose

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Description is for left component only. Procedure on the right side is identical.
   • Push in latch mechanism (1)  .
   • Pull off air intake hose (2)  in direction of travel.
     Fig 25: Pushing Latch Mechanism

     Courtesy of BMW OF NORTH AMERICA, INC.
10. 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 26: Disconnecting Connector On Hot Film Air Mass Meter

      Courtesy of BMW OF NORTH AMERICA, INC.
11. Remove front underbody protection 
    • Loosen screws (1)  .
    • Pull out and remove underbody protection (2)  under the bumper panel (3)  .
      Fig 27: Identifying Underbody Protection Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
12. Drain coolant 
    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.
    • Open sealing cap (1)  on coolant expansion tank.
      Fig 28: Locating Sealing Cap On Coolant Expansion Tank

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Keep drip pan (1)  and special tool 0 490 133 (00 2 030)  ready.
      Fig 29: Identifying Drip Pan And Special Tool (00 2 030)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • If fitted, open coolant drain plug (1)  on radiator. For radiators without coolant drain plug, unlock and pull off coolant hose.
    • Drain coolant and collect with drip pan and special tool 0 490 133 (00 2 030)  (if necessary).
      NOTE: Observe country-specific waste disposal regulations.
    • Dispose of coolant.
      Fig 30: Identifying Coolant Drain Plug On Radiator

      Courtesy of BMW OF NORTH AMERICA, INC.
13. Remove coolant expansion tank 
    • Unlock coolant hose (1)  and detach.
    • Loosen screws.
    • Raise coolant expansion tank (2)  slightly until plug for coolant level switch and lower coolant hose are accessible. Unclip line on side of expansion tank.
      Fig 31: Identifying Coolant Expansion Tank

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Unlock connector (1)  and remove.
    • Unlock lower coolant hose (2)  and detach.
    • Remove coolant expansion tank (3)  .
      Fig 32: Identifying Coolant Expansion Tank And Lower Coolant Hose

      Courtesy of BMW OF NORTH AMERICA, INC.
14. Remove heater valve for heating and air-conditioning unit 
    NOTE: For purposes of clarity the graphic is shown without the engine.
    • Disconnect plug connection (1)  .
    • Release hose clamps (2)  and (3)  and detach coolant hoses.
      Fig 33: Identifying Coolant Hose Clamps

      Courtesy of BMW OF NORTH AMERICA, INC.
15. Partly remove oil reservoir for hydraulic steering 
    • Unscrew nuts.
    • Remove washers.
    • Attach the oil reservoir for hydraulic steering on the side.
      Fig 34: Locating Hydraulic Steering Oil Reservoir Nuts

      Courtesy of BMW OF NORTH AMERICA, INC.
16. Remove lower section of steering shaft 
    NOTE: Risk of damage! If the lower section of the steering shaft is separated from the steering gear/steering shaft middle section, the steering column switch cluster may be damaged when the steering wheel is turned.
    • Secure steering wheel from twisting.
    • Release clamping bolts (1)  .
    • Push steering shaft (2)  together and remove.
      Fig 35: Identifying Steering Shaft And Clamping Bolts

      Courtesy of BMW OF NORTH AMERICA, INC.
17. 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 36: Pulling Connector Lock On Ignition Coil

      Courtesy of BMW OF NORTH AMERICA, INC.
18. Remove fuel low-pressure sensor 
    CAUTION: Electric fuel pump starts up automatically when door is opened

    When the fuel system is open, fuel can escape at high pressure.

    • Before beginning work, disconnect negative battery terminal.
      CAUTION: Fuel escapes when the fuel system is open and hot

      At high coolant temperatures and with an open fuel system, sudden, high-pressure jets are possible. Fuel can escape at high pressure.

    • Carry out work on fuel system only with coolant temperature below 40°C.
      CAUTION: Disconnect negative battery terminal

      Danger of fire due to short circuits when dismantling.

    • Disconnect battery negative terminal before beginning work.
      NOTE: Ensure cleanliness when repairing the high-pressure fuel system. Dirt can lead to malfunctions and leakages. Use only lint-free cloths. Use protective caps or plugs to seal off openings.
      NOTE: Ignition coils must not be contaminated by fuel. Fuel can damage the silicone material and so impair the functioning of the ignition coils.
    • Unlock connector (1)  and remove.
    • Remove the low-pressure fuel sensor (2)  .
      Fig 37: Identifying Fuel Low-Pressure Sensor Connector

      Courtesy of BMW OF NORTH AMERICA, INC.
19. Removing engine ventilation line for cylinders 1-4 
    • 1. Unlock the retainer.
      2. Simultaneously pull off the engine ventilation line from the intake system.
         Fig 38: Removing Engine Ventilation Line From Intake System

         Courtesy of BMW OF NORTH AMERICA, INC.
    • Version 1:
    • 1. Unlock the retainer.
      2. Simultaneously pull off the engine ventilation line from the intake system.
         Fig 39: Pulling Engine Ventilation Line From Intake System

         Courtesy of BMW OF NORTH AMERICA, INC.
    • Version 2:
    • Pull the line (1) gently in the direction indicated by the arrow.

      At the same time, use a screwdriver (3) to unlock the latch mechanisms (2) one after the other.

      Pull off the engine ventilation line from the connecting line.

      Fig 40: Pulling Engine Ventilation Line

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen 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.
20. Removing engine ventilation line for cylinders 5-8 
    NOTE: The following graphics show banks 1-4.
    • 1. Unlock the retainer
      2. Simultaneously pull off the engine ventilation line from the intake system.
         Fig 42: Removing Engine Ventilation Line From Intake System

         Courtesy of BMW OF NORTH AMERICA, INC.
    • Version 1:
    • 1. Unlock the retainer.
      2. Simultaneously pull off the engine ventilation line from the intake system.
         Fig 43: Pulling Engine Ventilation Line From Intake System

         Courtesy of BMW OF NORTH AMERICA, INC.
    • Version 2:
    • Pull the line (1) gently in the direction indicated by the arrow.

      At the same time, use a screwdriver (3) to unlock the latch mechanisms (2) one after the other.

      Pull off the engine ventilation line from the actuating wire.

    • Feed out and remove engine ventilation line.
      Fig 44: Pulling Engine Ventilation Line

      Courtesy of BMW OF NORTH AMERICA, INC.
21. Removing right fresh-air duct 
    • Loosen expanding rivet.
    • Loosen locks in direction of arrow.
    • Feed out fresh-air duct (1)  .
      Fig 45: Removing Fresh-Air Duct And Locks

      Courtesy of BMW OF NORTH AMERICA, INC.
22. Removing the electronics box cover 
    • Open all the clamps.
    • Release lock (1)  in direction of arrow.
    • Remove cover for electronics box (2)  .
      Fig 46: Releasing Electronics Box Cover And Lock

      Courtesy of BMW OF NORTH AMERICA, INC.
23. Partly remove wiring harness for injectors at cylinders 1-4 
    • Unlock upper section (1)  of partition seal in direction of arrow and remove.
      Fig 47: Removing Upper Section Of Partition Seal

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1)  .
    • Unlock the holder (2)  , unclip and remove upwards.
    • Release grommets (3)  for wiring harness from lower section of partition seal and electronics box.
      Fig 48: Identifying Electronics Box Wiring Harness Grommets

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1)  .
    • Remove wiring harness (2)  and put away.
    • Remove wiring harness (3)  and put away.
      Fig 49: Identifying Wiring Harness And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Release screw (1)  .
    • Carefully lift cable channel (2)  .
    • Stow wiring harness to the front.
      Fig 50: Identifying Cable Duct And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
24. 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 51: Identifying Fuel Delivery Line

      Courtesy of BMW OF NORTH AMERICA, INC.
25. Partly remove wiring harness for injectors at cylinders 5-8 
    • Loosen screws (1)  .
    • Lift cable channel (2)  .
      Fig 52: Identifying Cable Channel And Screws

      Courtesy 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 53: Identifying Wiring Harness, Wiring Loom And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
26. 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 54: Identifying Pressure Line And Union Nuts

      Courtesy of BMW OF NORTH AMERICA, INC.
27. 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.
    Fig 55: Removing Pressure Line

    Courtesy of BMW OF NORTH AMERICA, INC.
    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.
      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 56: Removing Union Nut

      Courtesy of BMW OF NORTH AMERICA, INC.

    Keyprocesses 

28. 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 57: Identifying Holding-Down Element And Screw

      Courtesy 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 58: Pulling Injector

      Courtesy 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 59: Identifying Special Tool (13 0 301) On Jammed Injector

      Courtesy 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 60: Identifying Special Tool (13 0 300) And Insert Screws

      Courtesy 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 61: Identifying Jammed Injector And Bolt

      Courtesy 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 62: Identifying Protective Caps

      Courtesy of BMW OF NORTH AMERICA, INC.
29. 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.
    • Use a lint-free cloth to remove combustion residues from cylindrical part of injector tip.
      Fig 63: Removing Teflon Ring With Special Tool (13 0 191) From Injector

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Slide new Teflon ring (1)  onto special tool 0 495 761 (13 0 195)  .
      Fig 64: Identifying Teflon Ring On Special Tool (13 0 195)

      Courtesy 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 65: Pushing Teflon Ring On Injector

      Courtesy 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 66: Sliding Assembly Sleeve On Injector

      Courtesy 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 67: Sliding Special Tool (13 0 192) On Injector

      Courtesy 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 68: Pushing Injector In Special Tool (13 0 194)

      Courtesy of BMW OF NORTH AMERICA, INC.
30. 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 69: Identifying Injector Adjustment Value

      Courtesy 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 70: Identifying Protective Cap

      Courtesy 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 71: Identifying Injector And Hold-Down Device Bolt

      Courtesy of BMW OF NORTH AMERICA, INC.

    Postprocesses 

31. 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 72: Tightening Pressure Line On High-Pressure Pump Using Torque Wrench

      Courtesy 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.
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Pressure line to rail
      M14	Initial torque	10 Nm
      	Final torque (retorque twice)	30 Nm

      Fig 73: Tightening Pressure Line On Rail

      Courtesy of BMW OF NORTH AMERICA, INC.
32. 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 74: Identifying Pressure Line And Union Nuts

      Courtesy 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 75: Turning Injector On Pressure Line

      Courtesy 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 76: Tightening Pressure Line Nut On Injector With Torque Wrench

      Courtesy 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 77: Tightening Pressure Line Using Torque Wrench

      Courtesy 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 78: Tightening Pressure Line To Rail Using Torque Wrench

      Courtesy of BMW OF NORTH AMERICA, INC.
33. 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 79: Identifying Wiring Harness, Wiring Loom And Screws

      Courtesy 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 80: Identifying Cable Channel And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
34. 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 81: Identifying Fuel Delivery Line

      Courtesy of BMW OF NORTH AMERICA, INC.
35. Installing wiring harness for injectors at cylinders 1-4 
    • Position wiring harness.
    • Position cable channel (2)  .
    • Tighten down screw (1)  .
      Fig 82: Identifying Cable Channel And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Position wiring harness (3)  .
    • Position wiring harness (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.
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Engine wiring harness to cylinder head cover
      M6	10 Nm

      Fig 83: Identifying Wiring Harness And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Fix grommets (3)  for the wiring harness in the lower section of the partition seal and the electronics box.
    • Clip in holder (2)  .
    • Tighten down screws (1)  .

      » The grommets must be correctly installed to be watertight.

      Fig 84: Identifying Electronics Box Wiring Harness Grommets

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Install the upper section (1)  of the partition seal (2)  and lock.
      Fig 85: Identifying Upper Section Of Partition Seal And Lock

      Courtesy of BMW OF NORTH AMERICA, INC.
36. Installing the electronics box cover 
    • Position the electronics box cover (2)  .
    • Lock the lock in direction of arrow (1)  .
    • Close all clamps.
      Fig 86: Installing Electronics Box Cover

      Courtesy of BMW OF NORTH AMERICA, INC.
37. Installing the right fresh-air duct 
    • Feed in fresh-air duct (1)  and latch.
    • Install expanding rivet.
      Fig 87: Identifying Fresh-Air Duct

      Courtesy of BMW OF NORTH AMERICA, INC.
38. Installing engine ventilation line for cylinders 1-4 
    • 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 88: Inserting Engine Ventilation Line Onto Intake System

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Position engine wiring harness (2).
    • Tighten down screws (1).
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Engine wiring harness to engine
      M8	10 Nm

      Fig 89: Identifying Engine Wiring Harness 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.
    • Connect the engine ventilation line to the actuating wire.
      Fig 90: Connecting Engine Ventilation Line To Actuating Wire

      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.
    • Connect the engine ventilation line to the actuating wire.
      Fig 91: Connecting Engine Ventilation Line To Actuating Wire

      Courtesy of BMW OF NORTH AMERICA, INC.
39. Installing engine ventilation line for cylinders 5-8 
    NOTE: The following graphics show banks 1-4.
    • 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 92: Inserting Engine Ventilation Line Onto Intake System

      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.
    • Connect the engine ventilation line to the actuating wire.
      Fig 93: Connecting Engine Ventilation Line To Actuating Wire

      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.
    • Connect the engine ventilation line to the actuating wire.
      Fig 94: Connecting Engine Ventilation Line To Actuating Wire

      Courtesy of BMW OF NORTH AMERICA, INC.
40. Installing fuel low-pressure sensor 
    NOTE: Ignition coils must not be contaminated by fuel. Fuel can damage the silicone material and so impair the functioning of the ignition coils.
    NOTE: Ensure cleanliness when repairing the high-pressure fuel system. Dirt can lead to malfunctions and leakages. Use only lint-free cloths. Use protective caps or plugs to seal off openings.
    • Replace sealing ring on fuel low-pressure sensor.
    • Screw in fuel low-pressure sensor (2)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Fuel low-pressure sensor
      	Tightening torque	20 Nm

    • Attach connector (1)  .
      Fig 95: Identifying Fuel Low-Pressure Sensor Connector

      Courtesy of BMW OF NORTH AMERICA, INC.
41. 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 96: Locating Ignition Coil

      Courtesy 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 97: Pushing Connector Onto Ignition Coil With Connector Latch Mechanism

      Courtesy of BMW OF NORTH AMERICA, INC.
42. Installing steering shaft, bottom 
    NOTE: Risk of damage! If the lower section of the steering shaft is separated from the steering gear/steering shaft middle section, the steering column switch cluster may be damaged when the steering wheel is turned.
    • Clean thread to remove all remnants of screw locking adhesive.
    • Connect steering shaft first to steering gear and then to steering shaft middle section. Clamping bolt must rest in steering gear groove or steering shaft middle section.
    • Tighten clamping bolts (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Lower steering shaft to steering gear
      M8 Recut screw thread, replace clamping bolt, retorquing not permitted	28 Nm

      Fig 98: Identifying Steering Shaft And Clamping Bolts

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Turn steering wheel in both directions to the limit position. The airbag indicator light must not light up in the process.
    • Check directional stability of car.
43. Installing oil reservoir for hydraulic steering 
    • Position oil reservoir for hydraulic steering.
    • Tighten nuts along with their washers.
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Oil reservoir for hydraulic steering on bracket
      M6	5.3 Nm

      Fig 99: Locating Hydraulic Steering Oil Reservoir Nuts

      Courtesy of BMW OF NORTH AMERICA, INC.
44. Installing water valve for heater 
    NOTE: For purposes of clarity the graphic is shown without the engine.
    • Attach heater valve (1)  in the bracket (2)  .

      » Check the correct position of the heater valve (1)  in the bracket (2)  .

      Fig 100: Identifying Heater Valve And Bracket

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect connector (1)  .
    • Connect coolant hoses and tighten hose clamps (2)  and (3)  .

      » The coolant hoses may not be interchanged.

      Fig 101: Identifying Coolant Hose Clamps

      Courtesy of BMW OF NORTH AMERICA, INC.
45. Install coolant expansion tank 
    • Connect connector (1)  .
    • Connect lower coolant hose (2)  and lock.
    • If required, remove disconnect pliers from the coolant hoses.
    • Position the coolant expansion tank (3)  .

      » Check the correct position of the coolant expansion tank (3)  .

      Fig 102: Identifying Coolant Expansion Tank And Lower Coolant Hose

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten down screws.
    • Connect coolant hose (1)  and lock.
    • If required, remove disconnect pliers from the coolant hoses.
      Fig 103: Locating Coolant Expansion Tank Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
46. 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 104: Identifying Hot Film Air Mass Meter Connector

      Courtesy of BMW OF NORTH AMERICA, INC.
47. Installing the left and right intake port 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Attach intake hose (1)  .

      » Intake hose (1)  must be correctly engaged.

      Fig 105: Attaching Intake Hose

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Attach air intake hose left and right (2)  .
    • Fasten expanding rivet (1)  .
      Fig 106: Attaching Air Intake Hose Left And Right

      Courtesy of BMW OF NORTH AMERICA, INC.
48. Installing left and right tension struts on spring strut dome 
    NOTE: Description is for right component only. The procedure on the left component is identical.
    • Position tension strut (2)  .
    • Tighten down screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Tension strut to spring strut dome
      Renew screws	Jointing torque	19 Nm
      	Angle of rotation	90 °

      Fig 107: Identifying Tension Strut And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
49. Installing the complete engine bulkhead 
    NOTE: Ensure correct fit!
    NOTE: Renew damaged expanding rivet.
    • Feed in the right engine bulkhead (3)  .
      NOTE: Risk of damage!  Observe different screw lengths.
    • Tighten down screws (2)  .
    • Install expanding rivet (1)  .
      Fig 108: Identifying Right Engine Bulkhead And Down Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Feed in left engine bulkhead (5)  .
    • Clip in connecting line (3)  .
      NOTE: Risk of damage!  Observe different screw lengths.
    • Tighten down screws (2)  and (4)  .
    • Install expanding rivet (1)  .
      Fig 109: Identifying Left Engine Bulkhead And Down Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Feed in center engine bulkhead (3)  .
    • Tighten down screws (2)  and (4)  .
    • Install gasket (1)  for engine compartment lid.
      Fig 110: Identifying Engine Compartment Lid Gasket

      Courtesy of BMW OF NORTH AMERICA, INC.
50. Remove right microfilter housing cover 
    • Pull off edge protection (1)  in working area.
    • Unlock screw caps (2)  and remove microfilter housing cover (3)  .
      Fig 111: Identifying Microfilter Housing Cover And Screw Caps

      Courtesy of BMW OF NORTH AMERICA, INC.
51. Installing left microfilter housing cover 
    • Check the correct position of water channel (1)  in guide (2)  .
    • Check flap (3)  for ease of movement, clean of major dirt, if required.
      Fig 112: Identifying Water Channel Correct Position

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Position microfilter housing cover and lock screw caps (2)  .
    • Install edge protection (1)  in working area.
      Fig 113: Identifying Microfilter Housing Cover And Screw Caps

      Courtesy of BMW OF NORTH AMERICA, INC.
52. Install acoustic cover 
    NOTE: Ensure correct fit!
    • Insert acoustic cover (1)  into existing rubber guides.
      Fig 114: Identifying Acoustic Cover

      Courtesy of BMW OF NORTH AMERICA, INC.
53. Connect battery earth lead 
    • Position intelligent battery sensor (2)  on the battery.
    • Tighten nut (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Battery earth lead to battery
      M6	5 Nm

      Fig 115: Identifying Intelligent Battery Sensor

      Courtesy of BMW OF NORTH AMERICA, INC.
54. Remove battery cover 
    • Open the luggage compartment floor trim panel.
    • Loosen screws (1)  .
    • Remove battery cover upwards.
      Fig 116: Identifying Battery Cover Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
55. Add coolant 
    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!
    • Tighten coolant drain plug (1)  with a new sealing ring to the radiator. For radiators without coolant drain plugs, connect coolant hose and lock.
      Fig 117: Identifying Coolant Drain Plug On Radiator

      Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Never reuse used coolant!
      NOTE: Use only recommended coolant. Observe mixture ratio. Observe capacities. Observe bleeding instructions! For this purpose, see RADIATOR -- OPERATING FLUIDS .
    • Top up coolant until coolant level is at maximum.
      NOTE: For more information see: 17 00 039 Bleeding and filling cooling system with vacuum filling unit
    • Vent cooling system.
      Fig 118: Locating Coolant Level (Max And Min)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Screw sealing cap (1)  to coolant expansion tank (2)  . 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 119: Locating Sealing Cap On Coolant Expansion Tank

      Courtesy of BMW OF NORTH AMERICA, INC.
56. 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).

57. Alignment for active steering 
    • Connect vehicle to BMW diagnosis system.
    • Select and carry out startup/alignment for active front steering under Service functions.
58. Carrying out steering angle sensor adjustment 
    • Connect vehicle to BMW diagnosis system.
    • Select and carry out steering angle sensor adjustment under Service functions.