16 19 020 Remove and install/replace SCR active tank

Overview of Activities 

Preprocesses 

1. Remove front right wheel. See  1.
2. Remove trim on right wheel arch. See  2.
3. Remove front wheel arch cover on right. See  3.
4. Remove front right ornamental grille (until 03/2010). See  4.
5. Remove front right ornamental grille (from 03/2010). See  5.
6. Remove fuel tank underride protection. See  6.
7. Drawing off the SCR active tank. See  7.

   Keyprocesses 

8. Remove active tank. See  8.
9. Installing active tank. See  9.

   Postprocesses 

10. Fill SCR active tank. See  10.
11. Install fuel tank underride protection. See  11.
12. Install front right ornamental grille (until 03/2010). See  12.
13. Install front right ornamental grille (from 03/2010). See  13.
14. Install front right wheel arch cover. See  14.
15. Install trim on right wheel arch. See  15.
16. Clean contact surface of brake disc and hub. See  16.
17. Clean contact surface of wheel. See  17.
18. Grease wheel centering in wheel. See  18.
19. Install front right wheel. See  19.

Additional Information 

Overview of Tightening Torques 

Overview Special Tool 

0 492 518 (36 1 300) Adapter 

Fig 1: Identifying Adapter (36 1 300)

Courtesy of BMW OF NORTH AMERICA, INC.

0 496 521 (00 2 230) Pliers 

Fig 2: Moving Pliers (00 2 230)

Courtesy of BMW OF NORTH AMERICA, INC.

General information 

safety instructions 

Take care when loosening parts that contain AdBlue! AdBlue might come out when you loosen them.

• Have a collecting vessel ready.
• Ensure adequate ventilation in the workbay!
• Avoid contact with skin!
• Wear protective gloves.
• Avoid contact with eyes!
• Wear safety goggles.

Preprocesses 

1. Remove front right wheel 
   NOTE: Notify customers to regularly check the tire pressure (see Owner's Handbook) to prevent tire damage!
   NOTE: After adaptation of the tire pressure, the Run Flat Indicator must always be reinitialized.
   NOTE: Please refer to the Owner's Handbook of the vehicle for the initialization procedure.
   • To loosen the lockable wheel bolts, use a matching adapter from special tool 0 492 518 (36 1 300)  .
     Fig 3: Identifying Special Tool (36 1 300)

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Wheel is balanced electronically!
   • Observe the following procedure to prevent clamping errors and imbalance:
   • Position the wheel so that the valve (see illustration below) is at the bottom.
   • If several wheels are simultaneously removed, mark the position of the wheels on the vehicle with chalk on the wheels (e.g. "FL" for front left, etc.).
   • Mark wheel to wheel hub.
   • If applicable, mark lockable wheel bolts on the wheel.
   • Unscrew wheel bolts.
   • Remove wheel.
     Fig 4: Locating Wheel Bolts

     Courtesy of BMW OF NORTH AMERICA, INC.
2. Remove trim on right wheel arch 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   • Loosen blind rivet(1)  . Unclip the cover (2)  outwards.
     Fig 5: Identifying Wheel Arch Blind Rivet And Cover

     Courtesy of BMW OF NORTH AMERICA, INC.
3. Remove front wheel arch cover on right 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   • Loosen expanding rivets (1)  and screws (2)  and (3)  .
     Fig 6: Identifying Wheel Arch Rivet And Screw

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Release expanding rivet (1)  and nut (2)  .
   • Loosen screws (3)  and (4)  .
   • Feed wheel arch cover out downwards.
     Fig 7: Identifying Wheel Arch Cover Expanding Rivet And Nut

     Courtesy of BMW OF NORTH AMERICA, INC.
4. Remove front right ornamental grille (until 03/2010) 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   • Release side gill (1)  from latch mechanism (2)  in direction of arrow.
     Fig 8: Releasing Side Gill From Latch Mechanism

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Risk of damage!  Working with plastic wedges on painted surfaces can result in paint damage. Mask off the lever area for safety.
   • Press down latch mechanisms (1)  with special tool 00 9 323.
   • Remove ornamental grille (2)  towards the front.
     Fig 9: Identifying Latch Mechanisms And Ornamental Grille

     Courtesy of BMW OF NORTH AMERICA, INC.
5. Remove front right ornamental grille (from 03/2010) 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   NOTE: Risk of damage!  Working with plastic wedges on painted surfaces can result in paint damage. Mask off the lever area for safety.
   • Unclip latch mechanisms (1)  with special tool 00 9 325.
   • Remove ornamental grille (2)  towards the front.
     Fig 10: Identifying Latch Mechanisms And Ornamental Grille

     Courtesy of BMW OF NORTH AMERICA, INC.
6. Remove fuel tank underride protection 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   • Loosen clip (1)  .
   • Loosen screws/nuts (2)  and (3)  .
   • Thread out underride guard (4)  and remove downwards.
     Fig 11: Identifying Underride Guard, Screw And Clip

     Courtesy of BMW OF NORTH AMERICA, INC.
7. Drawing off the SCR active tank 
   CAUTION: Risk of acid burns! Skin and eye irritation/redness!

   Take care when loosening parts that contain AdBlue! AdBlue might come out when you loosen them.

   • Have a collecting vessel ready.
   • Ensure adequate ventilation in the workbay!
   • Avoid contact with skin!
   • Wear protective gloves.
   • Avoid contact with eyes!
   • Wear safety goggles.
   NOTE: Clean connections and covers of lines carrying AdBlue thoroughly with water after each disassembly or before each installation.
   NOTE: After repair work, thoroughly clean special tool and working area with water!
   NOTE: Use only lint-free cloths for cleaning.
   NOTE: Close connections and AdBlue leading lines.
   • Remove screw cap (1)  of filler connection.
     Fig 12: Identifying Filler Connection Screw Cap

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Read the manufacturer's operating instructions and safety regulations before starting up the AdBlue filling and extractor unit!
   • Pull off sealing cap (1)  suction hose.
     Fig 13: Identifying Suction Hose Sealing Cap

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Do not reuse extracted AdBlue!
   • Connect AdBlue suction pump (1)  .
   • Extract AdBlue.
     Fig 14: Identifying Adblue Suction Pump

     Courtesy of BMW OF NORTH AMERICA, INC.

   Keyprocesses 

8. Remove active tank 
   NOTE: For purposes of clarity, schematic diagram shows bumper panel removed.
   • Loosen mounting(1)  . Release plastic nuts (2)  .
   • Release plastic nuts (2)  .
   • Pivot brake air duct (4)  outwards.
     Fig 15: Identifying Brake Air Duct, Nut And Mounting

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Disconnect plug connection (1)  .
   • Turn plug connections (2)  90° and remove.
     Fig 16: Identifying Plug Connections

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Disconnect the hose pipe of the passive tank (1)  .
   • Disconnect metering line (2)  .
     Fig 17: Identifying Passive Tank Hose Pipe And Metering Line

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Disconnect filler channel (1)  and ventilation line (2)  .
   • Unclip filler channel and ventilation line from bracket (3)  .
     Fig 18: Identifying Ventilation Line Bracket And Filler Channel

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Loosen screws (1)  .
     Fig 19: Identifying Ventilation Line Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Loosen nuts (2)  .
   • Remove active tank (1)  and feed out filler channel.
     Fig 20: Identifying Active Tank Nuts

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Undo nuts (1)  loosen and remove active tank (2)  from holder.
     Fig 21: Identifying Active Tank Nuts

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Pull insulation (1)  off active tank (2)  downwards.
     Fig 22: Pulling Active Tank Insulation

     Courtesy of BMW OF NORTH AMERICA, INC.
9. Installing active tank 
   NOTE: For purposes of clarity, schematic diagram shows bumper panel removed.
   • Slide insulation (1)  onto the active tank (2)  from below.
     Fig 23: Sliding Insulation Onto Active Tank

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Fit holder on active tank and tighten nuts (1)  .
     TIGHTENING TORQUES SPECIFICATION
     
     

     Active tank on holder
     M8	6 Nm

     Fig 24: Identifying Active Tank Nuts

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Install active tank.
   • Feed in filler channel.
   • Tighten nuts (2)  .
     TIGHTENING TORQUES SPECIFICATION
     
     

     Holder, active tank to body (nut)
     M8	19 Nm

     Fig 25: Identifying Active Tank Nuts

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Tighten down screws (1)  .
     TIGHTENING TORQUES SPECIFICATION
     
     

     Holder active tank (screw)
     M6	4 Nm

     Fig 26: Identifying Active Tank Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Check for correct latch mechanism of AdBlue leading lines (1)  and (2)  by pulling on lines.
   • Connect filler channel (1)  and ventilation line (2)  .
   • Clip in filler channel and ventilation line in bracket (3)  .
     Fig 27: Identifying Ventilation Line Bracket And Filler Channel

     Courtesy of BMW OF NORTH AMERICA, INC.
     NOTE: Check for correct latch mechanism of AdBlue leading lines (1)  and (2)  by pulling on lines.
   • Disconnect the hose pipe of the passive tank (1)  .
   • Connect metering line (2)  .
     Fig 28: Identifying Passive Tank Hose Pipe And Metering Line

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Lock plug connection (2)  in holder by turning 90°.
   • Connect plug connections (1)  .
     Fig 29: Identifying Plug Connections

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Install holder (3)  with brake air duct (4)  .
   • Secure bracket (1)  .
   • Tighten plastic nuts (2)  .
     TIGHTENING TORQUES SPECIFICATION
     
     

     Holder active tank/brake air duct to body
     Plastic nut	3.5 Nm

     Fig 30: Identifying Brake Air Duct, Holder And Nut

     Courtesy of BMW OF NORTH AMERICA, INC.

   Postprocesses 

10. Fill SCR active tank 
    CAUTION: Risk of acid burns! Skin and eye irritation/redness!

    Take care when loosening parts that contain AdBlue! AdBlue might come out when you loosen them.

    • Have a collecting vessel ready.
    • Ensure adequate ventilation in the workbay!
    • Avoid contact with skin!
    • Wear protective gloves.
    • Avoid contact with eyes!
    • Wear safety goggles.
      NOTE: Read the manufacturer's operating instructions and safety regulations before starting up the AdBlue filling and extractor unit!
      NOTE: After repair work, thoroughly clean special tool and working area with water!
    • Connect filling hose (1)  with filler connection (2)  .
    • Connect ventilation line (4)  with connector (3)  .
      Fig 31: Identifying Filler Hose, Connection And Tank Ventilation Line

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect filler connection of filler device(1)  with filler connection of active tank.
      NOTE: Stop cock is positioned at right angles to flow direction when valve is closed.
    • Close shutoff tap (2)  .
      Fig 32: Identifying Filler Device And Shutoff Tap

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect filler connection (1)  with AdBlue fluid tank (2)  .
      NOTE: Stop cock is positioned at right angles to flow direction when valve is closed.
    • Close shutoff tap (3)  .
      Fig 33: Identifying Adblue Fluid Tank, Filler Connection And Shutoff Tap

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Create a difference in height (A) between AdBlue fluid tank and filler connection.
      NOTE: Shutoff tap is positioned lengthways to flow direction when valve is open.
    • Open shut off taps (1)  .

      » Active tank is filled up.

      Fig 34: Identifying Adblue Fluid Tank And Filler Connection Height

      Courtesy of BMW OF NORTH AMERICA, INC.
    • As soon as the AdBlue rises to the same level in the ventilation line (2)  as in the filling hose (1)  , the active tank is overfilled.
      Fig 35: Identifying Ventilation Line And Filling Hose

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Place AdBlue fluid tank (1)  on the floor.
    • The AdBlue flows back through the ventilation line (3)  and filling hose (2)  into the fluid tank (1)  .
      NOTE: Stop cock is positioned at right angles to flow direction when valve is closed.
    • Close shutoff taps when no more fluid flows through the filling hose (2)  and (3)  .
    • Disconnect filler unit from filler connection.
      Fig 36: Identifying Adblue Fluid Tank, Ventilation Line And Filling Hose

      Courtesy of BMW OF NORTH AMERICA, INC.
11. Install fuel tank underride protection 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    NOTE: Renew damaged expanding rivet.
    • Feed in underride protection (4)  .
    • Install clips (1)  .
    • Tighten nuts/bolts (2)  and (3)  .
      TIGHTENING TORQUES SPECIFICATION
      
      

      Underbody panelling on body
      Screw	3 Nm
      Nut	2.5 Nm

      Fig 37: Identifying Underride Protection, Clips And Bolts

      Courtesy of BMW OF NORTH AMERICA, INC.
12. Install front right ornamental grille (until 03/2010) 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Clip ornamental grille (2)  into bumper panel until retaining lugs (1)  noticeably engage.
      Fig 38: Installing Ornamental Grille Into Bumper Panel

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Press in side gill (1)  in direction of arrow.
      Fig 39: Pressing Side Gill

      Courtesy of BMW OF NORTH AMERICA, INC.
13. Install front right ornamental grille (from 03/2010) 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Clip ornamental grille (2)  into bumper panel until retaining lugs (1)  noticeably engage.
      Fig 40: Identifying Ornamental Grille And Retaining Lugs

      Courtesy of BMW OF NORTH AMERICA, INC.
14. Install front right wheel arch cover 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    NOTE: Make sure all covers in wheel arch are correctly fitted in relation to each other!
    • Rear cover (1)  covers front cover (2)  .
    • Cover (4)  covers rear cover(1)  .
    • Cover (3)  covers cover (2) (4)  and rear cover (1)  in area (B).
      Fig 41: Identifying Wheel Arch Cover Area

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Feed in wheel arch cover.
    • Install expanding rivet (1)  and tighten nuts (2)  .
    • Tighten down screws (3)  and (4)  .
      TIGHTENING TORQUES SPECIFICATION
      
      

      Underbody panelling on body
      Screw	3 Nm
      Nut	2.5 Nm

      Fig 42: Identifying Wheel Arch Cover Rivet And Nuts

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Install expanding rivets (1)  and tighten bolts (2)  and (3)  .
      TIGHTENING TORQUES SPECIFICATION
      
      

      Underbody panelling on body
      Screw	3 Nm
      Nut	2.5 Nm

      Fig 43: Identifying Expanding Rivets And Bolts

      Courtesy of BMW OF NORTH AMERICA, INC.
15. Install trim on right wheel arch 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Check latch mechanisms (1)  on cover (2)  for damage and replace cover if necessary.
      Fig 44: Identifying Wheel Arch Latch Mechanisms And Nut

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Install trim on wheel arch. Apply blind rivets (1)  with special tool 0 496 521 (00 2 230)  .
      Fig 45: Identifying Wheel Arch Blind Rivet And Cover

      Courtesy of BMW OF NORTH AMERICA, INC.
16. Clean contact surface of brake disc and hub 
    NOTE: Contact surfaces between brake disc/wheel and brake disc/wheel hub must be clean and free of grease.
    NOTE: Do not operate special tool with an impact screwdriver!
    • Remove dirt, grease and corrosion from contact surface with a drill and special tool 81 25 2 344 011.
    • Degrease contact surface with cleaning agent, refer to BMW Parts Department.
      Fig 46: Identifying Special Tool (81 25 2 344 011)

      Courtesy of BMW OF NORTH AMERICA, INC.
17. Clean contact surface of wheel 
    NOTE: Contact surfaces between brake disc/wheel and brake disc/wheel hub must be clean and free of grease.
    NOTE: Do not operate special tool with an impact screwdriver!
    • Remove dirt, grease and corrosion from contact surface with a drill and special tool 81 25 2 344 011.
    • Degrease contact surface with cleaning agent, refer to BMW Parts Department.
    • If grease is present in area of wheel bolt hole, remove brake disc and clean.
      Fig 47: Identifying Special Tool (81 25 2 344 011)

      Courtesy of BMW OF NORTH AMERICA, INC.
18. Grease wheel centering in wheel 
    • Grease wheel centering (1)  in wheel thinly. Refer to OPERATING FLUIDS .
      Fig 48: Identifying Wheel Centering

      Courtesy of BMW OF NORTH AMERICA, INC.
19. Install front right wheel 
    NOTE: Clean wheel bolts and check threads for damage, replace, if necessary. Replace corroded wheel bolts.
    • Check brake disc mounting bolt (1)  for tight fit!
      TIGHTENING TORQUES SPECIFICATION
      
      

      Front brake disc to wheel hub
      M8x14	16 Nm
      Replace screw.

      TIGHTENING TORQUES SPECIFICATION
      
      

      Rear brake disc to wheel hub
      M8x14	16 Nm
      Replace screw.

      » Mounting bolt (1)  may not under any circumstances protrude over contact surface (2)  between brake disc and wheel.

      Fig 49: Identifying Wheel Hub Contact Surface Mounting Surface

      Courtesy of BMW OF NORTH AMERICA, INC.
    • To tighten the lockable wheel bolts, use a matching adapter from special tool 0 492 518 (36 1 300)  .
      Fig 50: Identifying Special Tool (36 1 300)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Observe the following procedure to prevent clamping errors and imbalance:
    • Wheel positioned with valve facing down.
    • Align wheel marking with wheel hub marking.
    • Install lockable wheel bolt for marking on wheel.
      Fig 51: Locating Wheel Bolts

      Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Under no circumstances use pneumatic or electric screwdrivers to install and tighten the wheel bolts.
      NOTE: Wheel must rest uniformly against the brake disc. In case of non-original BMW wheel bolts/wheels, it may be necessary to retighten wheel bolts due to setting properties (pay attention to manufacturer data).
      Fig 52: Tightening Wheel Bolts

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Fit wheel bolts and evenly tighten crosswise by hand in order to center the disc wheel.
    • Tighten wheel bolts crosswise using a calibrated torque wrench to the specified tightening torque.
      TIGHTENING TORQUES SPECIFICATION
      
      

      Wheel bolt
      M14	140 Nm
      After installation, torque of all wheel bolts must be checked again. Wheel bolts must not be oiled!