Install engine

Raising the lifting table 

• Store the engine oil cooler (2)  on the front part of the lifting table.
• Release the coolant line with coolant pump (1)  .
• Carefully raise the lifting table.

  When raising, watch out for electrical lines, coolant hoses and colliding components. 

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• Hand-tighten the bolts (1)  .
• Hand-tighten the bolts (2)  .

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Install the ground strap 

• Install the ground strap (2)  .
• Tighten down screw (1)  .

Ground strap to transmission or body
M8	tightening torque	19 Nm

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• Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Transmission cross member to body
  M8	tightening torque	19 Nm

• Tighten down screws (2)  .

Transmission cross member to body
M8	tightening torque	19 Nm

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Tighten the bolts on the front axle support 

• Replace screws (1)  , (2)  and (3)  .

  Parts:  Screws

• Tighten down screws (3)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front axle carrier to body, front
  M12 Replace screws.	Joining torque	108 Nm
  	Angle of rotation	45°

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• Tighten down screws (2)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front axle support to center of body
  M12 Replace screws.	Joining torque	108 Nm
  	Angle of rotation	45°

• Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front axle carrier to body, rear
  M14 Replace screws.	Joining torque	108 Nm
  	Angle of rotation	45°

  NOTE: Perform the steps on the right and left side.
• Replace screws (1)  .

  Parts:  Screws

• Tighten down screws (1)  .

Bottom bumper bracket on the front subframe.
M8x100 Replace screws.	Tightening torque	19 Nm

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Securing the swivel bearing at the top left and right 

Secure the swivel bearing 

• Fix the swivel bearing (1)  to the body using special tool 2 413 317 in such a way as to prevent it from tipping outwards.

  Do not allow the swivel bearing (1)  to hang down from the brake hose!

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Removing the mobile lifting table 

• Release the lug bolts (2)  at the mount (1)  .

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• Empty the special tool 2 184 136 or 5 A16 8C6  and set aside.

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Attaching coolant hoses to front subframe 

• Attach all released coolant hoses back to their corresponding holders on the front subframe support.

Attaching the cable of the wheel RPM sensor on the left and right 

• Secure cable of wheel speed sensor to holder (3)  .
• Attach the connectors of the wheel speed sensor (2)  and lock.
• Close sealing cap (1)  .

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Securing cables on vertical acceleration sensor on right and left 

• Attach the cable (1)  on the holder (3)  .
• Attach the connector (2)  to the vertical acceleration sensor and lock it.

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Attaching the brake caliper on the left and right 

Securing the brake caliper 

• Release the special tool 2 413 317 from the brake caliper (1)  and remove.

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• Position the brake caliper and slide onto the stud bolts.
• Replace the nuts (1)  .

  Parts:  Nuts

• Tighten nuts (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Brake caliper on stud bolt of the front swivel bearing
  M12 Replace nuts.	Tightening torque	95 Nm

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• Secure the brake hose on the holders (1)  .
  NOTE: Only perform the operation on the left side.
• Attach the cable for the brake pad wear sensor to the holders (2)  .

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Installing the output shafts 

Replacing the left radial shaft seal 

• Pull out radial shaft seal with the aid of special tools 0 490 466 (00 5 010)  and 0 495 597 (24 2 354). 

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• Remove the assembly protection ring (1)  from the radial shaft sealing ring (2)  .

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• Replace radial shaft seal at front.

  Parts:  Radial shaft seal

• Coat the housing of the sheet metal flange of the radial shaft seal with the approved front differential fluid.
• Drive in the radial shaft seal to the stop using the special tool 0 493 539 (31 5 130)  .
• Remove the special tool 0 493 539 (31 5 130)  .

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• Reinstall installation protection ring (1)  in radial shaft seal (2)  .

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• Check the gearing of the output shaft for damage and replace damaged parts if necessary.
• Check the bellows for damage and replace damaged parts if necessary.
• If reusing the output shaft: 

  Replace the circlip (1)  .

  Parts:  Circlip

• Coat the contact surfaces (2)  using approved rear differential fluid.

Installing left output shaft 

• Fold open the assembly protection ring (1)  .

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• Feed the output shaft in the front axle transmission.
• Pull on the lug (1)  of the assembly protection ring until one of the two predetermined breaking points breaks.
• Pull out and dispose of the installation protection ring.

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• Thread in the output shaft (1)  and slide into front axle transmission up to the stop.

  Output shaft coupling must snap audibly into place.

• Position output shaft (1)  in the direction of arrow on wheel bearing.

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Replacing the radial shaft seal of the bearing bracket 

• Prepare the special tool 0 490 466 (00 5 010)  with the special tools 0 494 649 (21 2 230) (without the screw) and 0 493 384 (11 1 212)  .

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• Pull out and remove the radial shaft seal (1)  with the special tools 0 490 466 (00 5 010), 0 494 649 (21 2 230)  and 0 493 384 (11 1 212). 

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• Remove the assembly protection ring (1)  from the radial shaft sealing ring (2)  .

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• Replace radial shaft seal at front.

  Parts:  Radial shaft seal

• Coat the housing of the sheet metal flange of the radial shaft seal with the approved front differential fluid.
• Drive in the radial shaft seal to the stop using the special tool 0 493 539 (31 5 130)  .
• Remove the special tool 0 493 539 (31 5 130)  .

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• Reinstall installation protection ring (1)  in radial shaft seal (2)  .

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• Check the gearing of the output shaft for damage and replace damaged parts if necessary.
• Check the bellows for damage and replace damaged parts if necessary.
• If reusing the output shaft: 

  Replace the circlip (1)  .

  Parts:  Circlip

• Coat the contact surfaces (2)  using approved rear differential fluid.

Install right output shaft 

• Fold open the assembly protection ring (1)  .

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• Insert output shaft into the bearing support.
• Pull on the lug (1)  of the assembly protection ring until one of the two predetermined breaking points breaks.
• Pull out and dispose of the installation protection ring.

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• Insert output shaft (1)  and slide in to the limit position in the bearing support.

  Output shaft coupling must snap audibly into place.

• Position output shaft (1)  in the direction of arrow on wheel bearing.

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Install the left and right spring strut holder 

Install spring suspension strut 

• Expand spring strut holder (1) with special tool 2 414 636. 
• Protecting the output shaft from damage with a towel is mandatory (2)  .
• Align spring strut holder (1)  using the gap on the reference mark on the spring strut.
• Insert and position spring strut holder (1)  on spring strut.

  The spring strut holder (1)  must be pushed up to the limit position on the spring strut!

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• Remove the special tool 2 414 636  .
• Remove towel (2)  .
• Replace the screw (2)  .

  Parts:  Screw

• Screw the screw (2)  into the spring strut holder (1)  and tighten it.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Spring strut holder on front spring strut
  M10 Replace screw.	Joining torque	42 Nm
  	Angle of rotation	90°

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  NOTE: TECHNICAL INFORMATION 
  Tighten the screw connection in the normal position.
  For additional information see: 31 00 GENERAL FRONT AXLE TECHNICAL DATA .
• Position spring strut holder on wishbone.
• Replace the screw (2)  and the nut (1)  .

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  Parts:  Screw, nut

• Install the screw (2)  and tighten the nut (1)  in the normal position.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Bottom wishbone on spring strut holder
  M14 Replace screw and nut. Tighten screw connection in normal position!	Joining torque  Angle of rotation	165 Nm 90°

• Position the stabilizer anti-roll bar link (2)  to the spring strut holder.
• Replace nut (1)  .

  Parts:  Nut

• Tighten nut (1)  .
  NOTE: Counter-hold at the Torx socket.

Anti-roll bar link on anti-roll bar/spring strut (air suspension)
M12 Replace nuts.	tightening torque	100 Nm

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Removing the top swivel bearing attachment 

• Loosen and remove special tool 2 413 317 from the swivel bearing (1)  .

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Fastening the wishbone to the top of the swivel bearing 

• Position the wishbone pin (4)  in the bore of the swivel bearing (3)  .
• Replace the screw (2)  and the nut (1)  .

  Parts:  Screw, nut

• Install the bolt (2)  .
• Tighten the screw connection using the nut (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Upper wishbone to swivel bearing
  M10 Replace screw and nut. Tightening via nut.	Tightening torque	56 Nm

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  Fasten the output shaft on the wheel bearing 

  NOTE: TECHNICAL INFORMATION 
  The installation note for front gearing must be observed at all times.
  • Replace the collar screw (1)  and compression spring (2)  .

    Parts:  Collar screw and compression spring

  • Note installation position of compression spring (2)  .
  • Keep the collar screw (1)  and the front gearings of the wheel bearing and the output shaft clean and free of grease.

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  • Hand-tighten the collar screw (1)  with the compression spring.

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    NOTE: TECHNICAL INFORMATION 
    The front gearing of the wheel bearing and output shaft must be installed in an interlocking position (tooth-in-tooth).
  • Ensure positive locking by mutual twisting of the wheel bearing (1)  and the output shaft (2)  .
  • Press brake pedal.

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  • Tighten the collar screw.
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Output shaft to wheel bearing
    M16 Replace collar screw and spring.	Joining torque	210 Nm
    	Angle of rotation	90°

    Installing the complete prop shaft 

    NOTE: RISK OF DAMAGE 
    Damage to the prop shaft during installation. 
    Non-observance of the installation guidelines for the prop shaft on the rear axle differential may cause severe damage. 

    • Always replace the recessed nut on the rear axle differential. Screw lock must be available.
    • Strictly observe a minimum hardening time of three hours after having screwed in the recessed nut. The hardening time may be longer at lower temperatures.
    • Check the centering (arrow) for damage and, if necessary, replace it.

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    • Apply a thin coat of grease to the soft centering (1)  , if necessary.
      CONSUMABLE DESCRIPTION
      
      

      Lubricating grease Olistamoly 2 LN 584 LO

      100 g, Tube

      83 19 0 447 919

    • Do not  grease the hard centering (2)  .

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    • Clean all residue from the recessed collar (1)  of the twelve-edge flange nut, the gearing on the bevel drive pinion (2)  and the taper (3)  and degrease.

      Remove adhesive residue.

    • Top up the collar insert (1)  with grease.

      When greasing the recessed collar (1)  , it is imperative  that absolutely no grease gets on the gearing of the bevel drive pinion (2)  .

      CONSUMABLE DESCRIPTION
      
      

      Lubricating grease Optitemp HT 1 LF

      50 g, Tube

      83230417754

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    • Use thread file (1)  to remove any adhesive residue on the thread.
    • The thread pitch must be correct! 

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      NOTE: RISK OF DAMAGE 
      Damage to the output flange. 
      Failure to observe the greasing specifications may lead to damage on the output flange. 

      • Do not contaminate the thread of the output flange with grease.
    • Clean adhesive residue from the thread (1)  of the propeller shaft hub.

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      Remove adhesive residue.

    • Clean shaft gearing (2)  and taper (3)  .

      Remove adhesive residue.

    • Replace the seal, recessed nut (1)  and retaining ring (2)  .

      Parts:  Seal, recessed nut, retaining ring

    • Insert the recessed nut (1)  with the seal into the recessed collar of the twelve-edge flange nut.
    • Mount retaining ring (2)  .

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    • Observe following installation sequence:
      • Position prop shaft on transmission.
      • Position the prop shaft at the rear axle differential.
      • Position central mount.
    • Observe the following screwing sequence:
      • recessed nut
      • Flexible disc to transmission
      • Central mount
    • Apply an even bead of Loctite 648 (BMW part number 9 067 732) approx. 10 mm (1)  all round from the edge in an area (2)  approx. 10 mm wide.

      The Loctite 648 must evenly fill all tooth gaps approx. 5 mm wide.

      The prop shaft (3)  must be connected with the output flange within  12 min.

      ADHESIVE DESCRIPTION
      
      

      Adhesive Loctite 648

      50 ml, Bottle

      07589067732

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    • In order to avoid a humming of the drivetrain after reinstalling the prop shaft: It is essential to reassemble the three-hole flange (3)  with the flexible disc (2)  in the same position.
    • Replace ZNS screws and self-locking nuts (1)  .

      Parts:  ZNS screws, self-locking nuts

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    • Position the screws and nuts (arrows).

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    • Push the prop shaft (1)  in arrow direction against the recessed nut (2)  up to the stop.
    • Unscrew the recessed nut (2)  by at least 2 threads manually on the prop shaft (1)  and fasten it.

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    • Central mount with the TOPPING designation: 
    • Central mount (1)  must be installed with the designation TOPPING at the top in the transmission tunnel.

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    • Position central mount.
    • Position screws (1)  .

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    • Variant with a narrow universal joint: 
    • Secure the prop shaft (1)  from twisting with the special tool 2 464 898 and a suitable tool (2)  on the center universal joint.

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    • Variant with a wide universal joint: 

      Secure the prop shaft from twisting with a suitable tool (1)  and on the center universal joint.

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      NOTE: RISK OF DAMAGE 
      Damage to the flange nut. 
      Failure to observe the installation specifications may lead to serious damage to the flange nut and the rear axle differential. 

      • Do not use the twelve-edge flange nut as counter support.
      • Screw in the recessed nut within 5 minutes.

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    • Secure juncture shaft against turning at center universal joint with a suitable tool.
    • Screw in the recessed nut counterclockwise in the arrow direction  with special tools 0 495 554 (33 5 070) and 0 496 959 (33 0 080). 

      The recessed nut must be screwed in within  5 min

      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Propeller shaft to rear axle differential
      recessed nut Replace recessed nut. It is imperative to observe the tightening sequence!	Joining torque	120 Nm
      	Release the screw connection by	90°
      	Final torque	45 Nm

    • After the propeller shaft is installed and the recessed nut is screwed in, strictly observe a hardening time of minimum 3 hours. 

      During this time the vehicle must not be moved or pushed! 

    • Hold down mounting bolts of the flexible disc on the nut and tighten via the screw.
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Rear flexible disc to three-hole flange
      M12 Replace screws. Joining torque and angle of rotation must be observed without fail. Tightening via screw.	Joining torque  Angle of rotation	55 Nm 90°

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    • Fasten the angle of rotation special tool  0 490 504 (00 9 120)  with the magnet special tool 0 495 108 (00 9 130) on the vehicle underbody and continue  to screw in according to angle of rotation.
    • Tighten down screws (1)  .
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Central mount to body
    M8	Tightening torque	19 Nm

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    Installing the heat shields 

    • Install heat shield (1)  .
    • Tighten nuts and screws (arrows).
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Heat shield to underbody
      Screws and nuts	Tightening torque	3 Nm

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    • Install heat shield (1)  .
    • Tighten nuts and screws (arrows).
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Heat shield to underbody
    Screws and nuts	Tightening torque	3 Nm

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    Install exhaust system 

    CAUTION: Component with heavy weight. 
    Injury hazard! 

    • Note component's center of gravity.
    • Support component using a jack.
    • Secure component against falling off the jack.
    CAUTION: Heavy component. 
    Heavy components can lead to injury or damage. 

    • Remove and install heavy components with the aid of another person/other persons.
    NOTE: TECHNICAL INFORMATION 
    Check the exhaust system for tightness after installation.
    NOTE: TECHNICAL INFORMATION 
    Mount the exhaust system in a de-energized state, following the tightening sequence from the rear silencer towards the exhaust manifold.
    NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
    • Check all rubber mounts (1)  of the exhaust system for damage and replace, if necessary.

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      NOTE: TECHNICAL INFORMATION 
      Conduct the following operation with the assistance of a second person.
    • Insert and install the exhaust system with the help of another person.
    • Replace nuts (1)  .

      Parts:  Nuts

    • Tighten nuts (1)  .

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      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Rear silencer on support
      Nut M8 Replace nut.	tightening torque	19 Nm

    • Position the holder of the exhaust system (2)  .
      NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
    • Position the ground strap.
      NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
    • Tighten down screw (1)  .

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      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust bracket
      M8 screw	Tightening torque	28 Nm

    • Tighten down screw (3)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust bracket
      M8 screw	Tightening torque	28 Nm

    • Position the holder of the exhaust system (2)  .
    • Tighten down screw (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust bracket
      M8 screw	Tightening torque	28 Nm

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    • Execution with RDE2: 

      Replace the seals (1)  .

      Parts:  Seals

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    • Position exhaust system.
    • Replace nut (1)  .

      Parts:  Nut

    • Tighten nut (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust bracket to transmission
      Nut M8 Replace nuts.	Tightening torque	19 Nm

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    • Replace nuts (2)  .

      Parts:  Nuts

    • Tighten nuts (2)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust system to catalytic converter
      Nut M8 Replace nuts.	Tightening torque	10 Nm
      	Tightening torque	28 Nm

    • Replace nut (1)  .

      Parts:  Nut

    • Tighten nut (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust bracket to transmission
      Nut M8 Replace nuts.	Tightening torque	19 Nm

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    • Replace nuts (2)  .

      Parts:  Nuts

    • Tighten nuts (2)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust system to catalytic converter
      Nut M8 Replace nuts.	Tightening torque	10 Nm
      	Tightening torque	28 Nm

    • Execution without RDE2: 

      Position exhaust system.

    • If necessary, replace clamp (2)  .

      Parts:  Circlip

    • Tighten nuts (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      cl.
      cl.	Tightening torque	55 Nm

    • Grease the thread on the exhaust system with high-temperature assembly paste.
      CONSUMABLE DESCRIPTION
      
      

      High-temperature assembly paste

      10 g, Tube

      83230309003

    • Clip the pressure line (2)  into the holder (1)  .
    • Tighten the union nuts (3)  .

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      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Pressure line union nut
      Pressure line union nut	Tightening torque	40 Nm

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    • Grease the thread on the exhaust system with high-temperature assembly paste.
      CONSUMABLE DESCRIPTION
      
      

      High-temperature assembly paste

      10 g, Tube

      83230309003

    • Clip the pressure line (2)  into the holder (1)  .
    • Tighten the union nuts (3)  .

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      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Pressure line union nut
      Pressure line union nut	Tightening torque	40 Nm

    • Connect connectors (2)  and lock.
    • Clip in connector (3)  on the holder.
    • Clip the oxygen sensor cable (1)  into the clamps.

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    • Connect connectors (2)  and lock.
    • Clip in connector (3)  on the holder.
    • Clip the oxygen sensor cable (1)  into the clamps.

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    • Variant with exhaust temperature sensors: 
    • Tighten exhaust temperature sensors upstream of the gasoline particulate filter (2)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust temperature sensor for gasoline particulate filter
      Coupling nut	Tightening torque	30 Nm

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    • Tighten exhaust temperature sensors downstream of the gasoline particulate filter (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Exhaust temperature sensor for gasoline particulate filter
      Coupling nut	Tightening torque	30 Nm

    • Connect connector (1)  .
    • Lock connector (1)  to exhaust flap (2)  .

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    • Connect connector (1)  .
    • Lock connector (1)  to exhaust flap (2)  .

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    Installing the rear tunnel connecting support 

    • Position the connecting support (3)  on the rear of the tunnel.
    • Tighten the screws (1)  .
      TIGHTENING TORQUE SPECIFICATIONS
      
      

      Rear tunnel connecting support on body
      M8x30 Apply Loctite.	tightening torque	30 Nm

    • Tighten screws (2)  .
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Undershield
    Hexagon screw Plastic nut	tightening torque  tightening torque	2.6 Nm 2.6 Nm

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    Installing the reinforcement strut 

  • Position the reinforcement strut (3)  .
  • Tighten nuts (2)  .
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Reinforcement strut on thrust arm
    M10 Apply Loctite.	Tightening torque	62 Nm

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  • Tighten down screws (1)  .
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Reinforcement strut on body
    M8x30 Apply Loctite.	tightening torque	30 Nm

    Installing undershield on the fuel tank on the right 

    • Position undershield on the fuel tank on the left (1)  .
    • Tighten down screws (2)  .
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Undershield
    Hexagon screw Plastic nut	tightening torque  tightening torque	2.6 Nm 2.6 Nm

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  • Tighten the screws (1)  .
    TIGHTENING TORQUE SPECIFICATIONS
    
    

    Undershield
    Hexagon screw Plastic nut	tightening torque	2.6 Nm
    	tightening torque	2.6 Nm

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    Removing the undershield on the left fuel tank 

  • Loosen screws (1)  .

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  • Loosen screws (2)  .
  • Remove the undershield (1)  at the fuel tank on the left.

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  Installing the rear diffuser 

• Thread in the rear diffuser (2)  and position.
• Tighten nuts (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Rear diffuser
  Plastic nut	Tightening torques	2.2 Nm

  • Tighten screws (arrows).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Undershield
  Hexagon screw Plastic nut	tightening torque	2.6 Nm
  	tightening torque	2.6 Nm

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  Installing low-temperature coolant pump left 

  Fastening electric coolant pump of feed line to holder 

• Position electric coolant pump (2)  .
• Turn electric coolant pump (2)  counter clockwise and engage at snap-in lug (1)  .

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• Connect plug connection (1)  and lock.

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• Connect and lock the coolant hoses (1)  .

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  Installing right coolant pump for low temperature 

  Fastening electric coolant pump of return line to holder 

• Position electric coolant pump (2)  .
• Turn electric coolant pump (2)  clockwise and engage at snap-in lug (1)  .

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• Connect and lock the plug connection (2)  .

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• Connect and lock the coolant hoses (2)  .
• Fix wiring harness mounting (1)  .

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• Connect plug connection (1)  and lock.

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• Replace the O-rings of the intake pipe (2)  .

  Parts:  O-rings

• Insert the intake pipe (2)  completely from the top and install.
• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Refrigerant line to air conditioning condenser/connecting piece
  M8	tightening torque	19 Nm

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• Insert the coolant line.
• Connect the coolant line to the retaining clip (1)  and audibly lock it in place.

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  Installing coolant hose between coolant radiator and engine 

• Position coolant hoses in area (2)  .
• Lock coolant hoses in area (2)  at the retaining clips (1)  .
• The retaining clips (1)  must lock audibly.

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• Replace the sealing ring in the coolant pump.

  Parts:  Seal

• Position the coolant hose (2)  .
• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant line on coolant pump
  M6x12 screw	tightening torque	8 Nm

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• Unlock and disconnect coolant lines (1)  .
• Place coolant lines to one side.

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  Connecting refrigerant lines 

• Replace the sealing rings (1)  .

  Parts:  Sealing ring

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• Position refrigerant lines (2)  .
• Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Refrigerant line to air conditioning condenser/connecting piece
  M8	tightening torque	19 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing the front bottom right wheel arch cover 

  NOTE: Description is for left component only. Procedure on the right side is identical.
  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Guide the wheel arch cover (2)  in.
• Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Wheel arch cover (screws)
  Thermoplastic hexagon screw	Tightening torque	3 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Connecting the transmission oil cooler line 

  NOTE: TECHNICAL INFORMATION 
  Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
• Position the transmission oil cooler line (1)  .
• Lock the transmission oil cooler line (1)  .

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  Engine oil cooler partial installation 

• Position the engine oil cooler (2)  with the crash pads.
• Snap the engine oil cooler (2)  upwards onto the retaining lugs (1)  on the crash pad.

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• Secure the engine oil cooler (2)  from falling down.
• Tighten the screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  upstream engine oil cooler
  M6x45 screw	Tightening torque	8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Connect the coolant line (2)  .
• Retaining clip (1)  must engage audibly.

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  Install the stiffening plate 

• Insert the thrust field (3)  on the covers of the steering assembly (2)  and position.
• Replace the bolts (arrows).
• Parts:  Screws
• Tighten screws (arrows).

  Courtesy of BMW OF NORTH AMERICA, INC.

  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Thrust field to front axle support
  M8 Replace screws.	Joining torque	25 Nm
  	Angle of rotation	70°

  • Tighten down screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Underbody protection
  Screw	Tightening torque	3 Nm

  Installing fan cowl with electric motor 

• Insert the fan cowl (1)  downwards to the coolant hoses.

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• Clip in the hose support (2)  to the fan cowl (1)  .

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• F90 only:  Insert the front underbody protection (1)  .
• Slide the front underbody protection (1)  slightly backwards and insert it under the thrust field (2)  .
• Tighten all bolts (arrows).

  Courtesy of BMW OF NORTH AMERICA, INC.

  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Underbody protection
  Screw	Tightening torque	3 Nm

  • F91, F92, F93 only: 
  • Insert the front underbody protection (1)  .
• Slide the front underbody protection (1)  slightly backwards and insert it under the thrust field (2)  .
• Tighten all bolts (arrows).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Underbody protection
  Screw	Tightening torque	3 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Fan cowl with electric motor
  Screw	Tightening torque	2.8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Courtesy of BMW OF NORTH AMERICA, INC.

  • Clip in and secure wiring harness mountings (1)  .
  • Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Fan cowl with electric motor
  screw	Tightening torque	2.8 Nm

• Connect plug connection (2)  and lock.

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  Install the rear top cross connection 

• Position the cross connection at the upper rear (4)  and guide in.
• Snap the cable clip (3)  into the cross connection at the upper rear (4)  .
• Tighten down screws (2)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Top rear cross connection center
  Tightening torque	M8x20 screw	28 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Tighten the screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Top rear cross connection center
  Tightening torque	M8x30 screw	19 Nm

  Install left intake silencer housing 

  Install intake filter housing left (version with refrigerant partition) 

• Position the intake filter housing (5)  .
• Lock the detents (4)  at the clean air tube (1)  .
• Carefully engage the centering pin (2)  on the intake filter housing (5)  downwards into the decoupling elements (3)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Insert wire in area (4)  upwards on the firewall.
• Position the bellows (3)  on the clean air tube.
• Clip in the line (2)  .
• Tighten the hose clamp (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Hose clamp
  Hose clamp	Tightening torque	3 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position the intake filter housing (5)  .
• Lock the detents (4)  at the clean air tube (1)  .
• Carefully engage the centering pin (2)  on the intake filter housing (5)  downwards into the decoupling elements (3)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position the bellows (3)  on the clean air tube.
• Clip in the line (2)  .
• Tighten the hose clamp (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Hose clamp
  Hose clamp	Tightening torque	3 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Install right intake silencer housing 

• Position the intake filter housing (5)  .
• Lock the detents (4)  on the clean air tube (1)  .
• Carefully engage the centering pin (2)  into place on the intake filter housing (5)  downwards into the decoupling elements (3)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position the bellows (3)  on the clean air tube.
• Clip in the line (2)  .
• Tighten the hose clamp (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Hose clamp
  Hose clamp	Tightening torque	3 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Install front cross connection 

• Feed in cross connection (2)  with holders (3)  .
• Attach the Bowden cable (1)  .

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  • Tighten the screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front cross connection
  Screw	Tightening torque	11.8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  Tighten the left front-end strut 

  NOTE: RISK OF DAMAGE 
  Use of an incorrect tool (impact screwdriver) to release and tighten the screws. 
  Damaged thread. 

  • Only use a standard tool (e.g. reversible ratchet) to release/tighten the screws.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Clean the thread at shock tower.
• Replace the screw (1)  .
• Parts:  Screw
• Tighten the bolt (1)  of the strut brace (3)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front-end strut, front
  Screw	Joining torque	28 Nm
  	Angle of rotation	90°

• Replace the screw (2)  .

  Parts:  Screw

• Tighten the bolt (2)  of the strut brace (3)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front-end strut, rear
  Screw	Joining torque	56 Nm
  	Angle of rotation	90°

• Repair the damaged thread on the shock tower with a Helicoil insert.
  CONSUMABLE DESCRIPTION
  
  

  Helicoil thread insert

  M10x30 mm

  07129909659

  Tighten the front-end strut on the right 

  NOTE: RISK OF DAMAGE 
  Use of an incorrect tool (impact screwdriver) to release and tighten the screws. 
  Damaged thread. 

  • Only use a standard tool (e.g. reversible ratchet) to release/tighten the screws.
• Clean the thread at shock tower.
• Replace the screw (1)  .
• Parts:  Screw
• Tighten the bolt (1)  of the strut brace (3)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front-end strut, front
  screw	Joining torque	28 Nm
  	Angle of rotation	90°

• Replace the screw (2)  .

  Parts:  Screw

• Tighten the bolt (2)  of the strut brace (3)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Front-end strut, front
  screw	Joining torque  Angle of rotation	56 Nm 90°

• Repair the damaged thread on the shock tower with a Helicoil insert.
  CONSUMABLE DESCRIPTION
  
  

  Helicoil thread insert

  M10x30 mm

  07129909659

  Installing the cover in the engine compartment on the left 

• Position the cover in the engine compartment on the left (2)  .
• Mount the expanding rivets (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing the cover in the engine compartment on the right 

• Position the cover in the engine compartment on the right (2)  .
• Mount the expanding rivets (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing holder of the DME control unit for cylinders 5 to 8 

• Carefully push the holder of the refrigerant line (3)  aside.
• Insert holder with the DME control unit of cylinders 5 to 8 (2)  and position.
• Engage the connector bracket (1)  .

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• Ensure that the centering pin (2)  is located in the lug (1)  on the left spring support.

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• Engage the cable bracket (1)  .
• Tighten down screw (2)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  DME control unit holder
  screw	Tightening torque	8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  • Tighten the screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  DME control unit holder
  screw	Tightening torque	8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Connect connectors (1)  and lock.
• Engage the cable bracket (2)  in the adapter plate.

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• Clip the transmission wiring harness downwards in the area (1)  and lock it.
• Clip the engine wiring harness onto the bracket (2)  .

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• Lock the clip of the vehicle wiring harness (1)  .

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• Connect and lock the plug connections (1)  .

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  Installing mount for DME master control module support 

• Position mount for DME master control module (2)  .
• Tighten the screws (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Mount for DME master control module
  M6x13 screw	Tightening torque	8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

  • Clip positive battery cable in at holders (1)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  Installing the fuel line 

• Position the fuel line (2)  .
• Connect the fuel line (2)  .
• The retaining clip (1)  on the fuel line (2)  should audibly lock.

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• Connect the fuel line.
• The fuel line should audible lock on the retaining clip (1)  .
• Remove rag.

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• Position the positive battery cables (2)  on the remote positive terminal.
• Tighten nuts (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Positive battery cable
  Positive pole screw	tightening torque	15 Nm

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• Feed in the cover (1)  in a downwards direction.
• Check the detents (2)  are seated correctly.

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• Connect and lock tank vent line (2)  .
• Connect plug connection (1)  and lock.

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Partially installing the vacuum pump 

• Position the vacuum line.
• Connect the vacuum line at the closure (1)  and lock.

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  Installing control unit holder for cylinders 1 to 4 

• Insert and position control unit holder (1)  with the control units.

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• Make sure that the centering pins (2)  are located in the rubber mounts (1)  .

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• Engage the cable bracket (1)  .

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• Connect connectors (1)  and lock.

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• Connect connectors (1)  and lock.

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• Engage the wires and connectors (1)  to the adapter plate.

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• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  DME control unit holder
  screw	Tightening torque	8 Nm

  Courtesy of BMW OF NORTH AMERICA, INC.

• Tighten down screw (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  DME control unit holder
  screw	Tightening torque	8 Nm

• Engage the cable bracket (2)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

  Install acoustic cover 

• Check the correct installation of all rubber mounts (1)  in the acoustic cover (2)  .

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position the acoustic cover (1)  .
• Clip the acoustic cover (1)  downwards onto the detents (2)  .

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  Install the cover panel of the master DME control unit 

• Position the cover of the master DME control unit (1)  .
• Engage the cover panel of the master DME control unit (1)  downwards with the clamps (2)  and the guide pins (3)  in the carrier plate of the DME.

  Courtesy of BMW OF NORTH AMERICA, INC.

  Install the cover panel of the slave DME control unit 

• Position the cover panel of the slave DME control unit (2)  .
• Engage the cover of the slave DME control unit (2)  downward with the clamps (1)  in the carrier plate of the DME.

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  Disconnect all negative battery leads 

• See additional information.

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  Evacuate and charge conditioning 

• See additional information.

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  Check the straight-ahead driving position of the steering wheel 

Check 

• For straight-ahead driving, check the correct straight-ahead driving position of the steering wheel.

Result 

» The steering wheel has an inclination during straight-ahead driving.

Measure 

• Lower the steering shaft on the steering column until the steering wheel is no longer inclined (repeat action if necessary).

Measure 

• If the steering wheel continues to have a minimal inclination: Carry out a toe adjustment at the front axle.

Checking the airbag for function 

Check 

• Turn steering wheel in both directions to the stop.

Result 

» The airbag checklight lights up.

Measure 

• Replace the coil spring cassette.

Topping up motor oil 

• Position sealing ring (1)  on the oil drain plug (2)  .
• Parts:  Sealing ring

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position the oil drain plug (1)  with sealing ring and let it engage it a few thread turns by hand.
• Tighten oil drain plug (1)  .

Oil drain plug
screw M18x1.5	Tightening torque	40 Nm

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• Position the cover panel of the oil drain plug (1)  , turn it clockwise and engage.

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• Turn the oil filler cap (1)  counterclockwise and open it.
• Pour in engine oil.

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Engine oil S63B44T4
Filling capacity, motor oil change with oil filter element		10L

• Turn the oil filler cap (1)  clockwise and shut it.

Check engine oil level Precondition 

Vehicle in horizontal position.

• Carry out an electronic oil measurement.
• Top up motor oil if necessary.

Filling the low-temperature cooling system with the vacuum filling equipment 

Vacuum filling equipment 

Vacuum filling equipment - connected to the coolant expansion tank

1. Vacuum filling equipment with pressure gauge and shutoff valves
2. Filling hose
3. Fluid tank with coolant
4. Venturi nozzle
5. Compressed air connection (7 bar)
6. Exhaust hose (route exhaust hose into a collecting vessel)

Precondition 

The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filling equipment must have a sufficient quantity of premixed coolant, 1 l to 2 l more than the specified capacity for the vehicle. The fluid tank of the vacuum filling equipment must be positioned at the same height as the coolant expansion tank. The compressed air connection must have a pressure of 7 bar. Ignition is switched off.

The vacuum filling equipment must be functional and free of dirt.

Not the type of coolant 

Coolant in the collecting vessel of vacuum filler device 

Courtesy of BMW OF NORTH AMERICA, INC.

Choose the correct coolant for filling.

In general, a vehicle has to be filled with the coolant with which it is delivered from the factory.

1. G48 (Blue) (BMW LC-87) 

   Must not  be mixed with i3 Coolant or G30 MINI Diesel W16.

2. i3 Coolant (Blue) (BMW LC-13) 

   Is used only for heater circuit i3. i3 Coolant must not be added to other coolant circuits or mixed with other coolants.

3. HT12 (Pink) (BMW LC-18) 

   Must not be mixed with i3 Coolant or G30 MINI Diesel W16.

4. HT12 (Green) (BMW LC-18) 

   Must not be mixed with i3 Coolant or G30 MINI Diesel W16.

5. G30 (Pink) (BMW LC-07) 

   May be W16 used exclusively for the MINI Diesel.  G30 must not be filled in the other coolant circuits or mixed with the other coolants.

• Connect special tool (2) 5 A31 EF2  to the vacuum filling equipment (1)  .
• Connect the special tool (2)  with the appropriate adapter (3) from the set of special tools  0 494 417 (17 0 100)  . 
• Cooling system capacity
• Select a suitable adapter (Y) from the set of special tools 0 494 417 (17 0 100) :

Type	Engine	Adapter (Y) from 17 0 100
F90	S63TU4	17 0 109

• Fill the fluid tank of the vacuum filling equipment with 1 l to 2 l more than the filling capacity of coolant specified for the vehicle.

Cooling system capacity
F90 S63TU4 (High-temperature coolant circuit)	11.5 L
F90 S63TU4 (Low-temperature coolant circuit)	4.5 L

• Connect the selected adapter (Y)  to the coolant expansion tank.
• Connect the vacuum filling equipment to the connection (X)  of the adapter.
• Check whether both shutoff valves (A)  and (B)  of the vacuum filling equipment (1)  are closed.
• Connect and lock connection (X)  to the coolant expansion tank.
• Connect Venturi nozzle (1)  to the vacuum filling equipment (2)  .
• (X)  is the connection on the coolant expansion tank.
• Connect compressed air (1)  .
• (X)  is the connection on the coolant expansion tank.
• Open shutoff valve (B)  .
• The venturi nozzle generates a flow noise.
• Open shutoff valve (A)  until the filling hose (1)  is full without bubbles.
• Close the shutoff valve (A)  again.
• » The filling hose (1)  has now been bled.
• Check the coolant hoses for porosity and, if necessary, replace them.

• After a vacuum of -0.8 to -0.95 bar is reached in the coolant circuit (approx. 2 min), close shutoff valve (B)  .
• Check whether shutoff valves (A)  and (B)  are closed.
• Disconnect the Venturi nozzle (1)  .
• Check 
• The vacuum in the coolant circuit must be maintained for at least 2 min.
• Result 
• » Vacuum drops.
• Measure
• Search for leaks, repair them, and start the filling procedure from the beginning.
• Check 
• The vacuum in the coolant circuit must be maintained for at least 2 min.
• Result 
• » Vacuum remains constant.
• Measure
• Continue with filling.
• Keep shutoff valve (B)  closed during the filling process.
• To fill the cooling system, open shutoff valve (A)  to the fluid tank of the vacuum filling equipment.
• Stop the filling procedure when the needle in the pressure tester is on 0 bar or it no longer drops.
• If necessary, reduce remaining vacuum. To do so, open the shutoff valve (B)  .
• Remove the vacuum filling equipment with the adapter from the coolant expansion tank.
• Adjust the coolant level to the maximum mark.
• After filling the engine cooling system with the vacuum filling equipment, also carry out the cooling system bleeding procedure.

Fill the high-temperature cooling system with the vacuum filling equipment 

High-temperature vacuum filling equipment 

Vacuum filling equipment - connected to the coolant expansion tank

1. Vacuum filling equipment with pressure gauge and shutoff valves
2. Filling hose
3. Fluid tank with coolant
4. Venturi nozzle
5. Compressed air connection (7 bar)
6. Exhaust hose (route exhaust hose into a collecting vessel)

Precondition 

The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filling equipment must have a sufficient quantity of premixed coolant, 1 l to 2 l more than the specified capacity for the vehicle. The fluid tank of the vacuum filling equipment must be positioned at the same height as the coolant expansion tank. The compressed air connection must have a pressure of 7 bar. Ignition is switched off.

The vacuum filling equipment must be functional and free of dirt.

• Connect the coolant line (2)  .
• Retaining clip (1)  must engage audibly.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Position coolant hose in area (2)  .
• Lock coolant hose in area (2)  on the retaining clip (1)  .
• The retaining clip (1)  must lock audibly.

Courtesy of BMW OF NORTH AMERICA, INC.

Not the type of coolant 

Coolant in the collecting vessel of vacuum filler device 

Courtesy of BMW OF NORTH AMERICA, INC.

Choose the correct coolant for filling. 

In general, a vehicle has to be filled with the coolant with which it is delivered from the factory.

1. G48 (Blue) (BMW LC-87) 

   Must not  be mixed with i3 Coolant or G30 MINI Diesel W16.

2. i3 Coolant (Blue) (BMW LC-13) 

   Is used only for heater circuit i3. i3 Coolant must not be added to other coolant circuits or mixed with other coolants.

3. HT12 (Pink) (BMW LC-18) 

   Must not be mixed with i3 Coolant or G30 MINI Diesel W16.

4. HT12 (Green) (BMW LC-18) 

   Must not be mixed with i3 Coolant or G30 MINI Diesel W16.

5. G30 (Pink) (BMW LC-07) 

   May be W16 used exclusively for the MINI Diesel. G30 must not be filled in the other coolant circuits or mixed with the other coolants.

• Connect special tool (2) 5 A31 EF2  to the vacuum filling equipment (1)  .
• Connect the special tool (2)  with the appropriate adapter (3) from the set of special tools  0 494 417 (17 0 100)  . 
• Select a suitable adapter (Y) from the set of special tools 0 494 417 (17 0 100) :

Type	Engine	Adapter (Y) from 17 0 100
F90	S63TU4	17 0 113

• Fill the fluid tank of the vacuum filling equipment with 1 l to 2 l more than the filling capacity of coolant specified for the vehicle.

Cooling system capacity
F90 S63TU4 (High-temperature coolant circuit)	11.5 L
F90 S63TU4 (Low-temperature coolant circuit)	4.5 L

• Connect the selected adapter (Y)  to the coolant expansion tank.
• Connect the vacuum filling equipment to the connection (X)  of the adapter.
• Check whether both shutoff valves (A)  and (B)  of the vacuum filling equipment (1)  are closed.
• Connect and lock connection (X)  to the coolant expansion tank.
• Connect Venturi nozzle (1)  to the vacuum filling equipment (2)  .
• Connect and lock connection (X)  to the coolant expansion tank.
• Connect compressed air (1)  .
• (X)  is the connection on the coolant expansion tank.
• Open shutoff valve (B)  .
• The venturi nozzle generates a flow noise.
• Open shutoff valve (A)  until the filling hose (1)  is full without bubbles.
• Close the shutoff valve (A)  again.
• » The filling hose (1)  has now been bled.
• Check the coolant hoses for porosity and, if necessary, replace them.

• After a vacuum of -0.8 to -0.95 bar is reached in the coolant circuit (approx. 2 minutes), close shutoff valve (B)  .
• Check whether the shutoff valves (A)  and (B)  are closed.
• Disconnect the Venturi nozzle (1)  .
• Check 
• The vacuum in the coolant circuit must be maintained for at least 2 min.
• Result 
• » Vacuum drops.
• Measure
• Look for the leak, repair it and start the filling procedure from the beginning.
• Check 
• The vacuum in the coolant circuit must be maintained for at least 2 min.
• Result 
• » Vacuum remains constant.
• Measure
• Continue with filling.
• Keep shutoff valve (B)  closed during the filling process.
• To fill the cooling system, open shutoff valve (A)  to the fluid tank of the vacuum filling equipment.
• Stop the filling procedure when the needle in the pressure tester is on 0 bar or it no longer drops.
• If necessary, reduce remaining vacuum. To do so, open shutoff valve (B)  .
• Remove the vacuum filling equipment with the adapter from the coolant expansion tank.
• Adjust the coolant level to the maximum mark.
• After filling the engine cooling system with the vacuum filling equipment, also carry out the cooling system bleeding procedure.

Venting the low-temperature cooling system 

• Remove the vacuum filling equipment from the coolant expansion tank of the low-temperature coolant circuit.
• Adjust the coolant level in the coolant expansion tank of the low-temperature coolant circuit to the maximum mark.
• Close the sealing cap (1)  on the coolant expansion tank of the low-temperature coolant circuit.
• Close the engine compartment lid.
• Activate testing-analysis-diagnosis (PAD) by quickly pressing the START-STOPPING button three times.
• Activate the low beams and the hazard-warning lights at the same time.
• If the low beams and the hazard-warning lights are not turned on, the ignition (terminal 15) turns off automatically after a while and interrupts the bleeding procedure.

• Set the heating to the maximum  temperature and the blower to the lowest  level.
• Depress the accelerator pedal and hold for 15 s.

  The automatic cooling system bleeding procedure is initiated.

  After about 11 min, the cooling system bleeding procedure is ended automatically.

• Start engine.

  The idle speed is automatically increased to 1200 RPM. 

• Allow the engine to cool down.
• Adjust the fill level in the coolant expansion tank of the low-temperature coolant circuit up to the maximum mark.

Vent the high-temperature coolant system 

• Remove the vacuum filling equipment from the coolant expansion tank of the high-temperature coolant system.
• Open the bleeder screw on the coolant expansion tank for the high-temperature coolant circuit and close it again after approx. 10 s.

  The bleeder screw can be closed before 10 s have elapsed if coolant escapes.

• Adjust the fill level in the coolant expansion tank of the high-temperature coolant circuit to the maximum mark.
• Close the sealing cap on the coolant expansion tank of the high-temperature cooling circuit.
• Ensure that the hood is closed. 
• Connect battery charger.
• Activate  testing-analysis-diagnosis (PAD) by quickly pressing the START-STOPPING button three times.
• Set heating to maximum  temperature.
• Set the fan to the lowest  level.
• Deactivate  the testing-analysis-diagnosis (PAD) by pressing the START-STOPPING button.
• Activate  testing-analysis-diagnosis (PAD) by quickly pressing the START-STOPPING button three times.
• Depress the accelerator pedal and maintain for 15 s;  do not press the brake pedal during this process.

  The automatic cooling system bleeding procedure is initiated.

  Depending on the equipment specification of the instrument cluster (KOMBI), ("Service function started") is displayed.

• Step off the accelerator pedal and press the brake pedal.
• Start engine.

  The engine speed and actuators in the cooling system are automatically  controlled in accordance with a cooling system bleeding procedure.

  The cooling system bleeding procedure is ended approx. 11 min after  the engine start.

  Observe the display in the instrument cluster (KOMBI). ("Service function ended")

  The engine speed drops to the idle speed.

  If the service function is canceled, the cooling system bleeding procedure must  be repeated.

• Switch off engine.
• Let the coolant temperature cool down to < 50°C.
  NOTE: TECHNICAL INFORMATION 
  After the cooling system bleeding procedure, the cooling system is topped up via the maximum mark.
  Overfilling the cooling system serves to balance the remaining air in the cooling system.
  The normal fill level of the coolant is reached during driving.
• Adjust fill level in coolant expansion tank of high-temperature coolant circuit to 200 ml over maximum mark.
• Close the sealing cap (1)  until the arrows align.