Procedure steps

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SPECIAL TOOLS AND TIGHTENING TORQUES:

For additional information on special tools and tightening torques pertaining to this procedure, refer to the following:

PRE-PROCESSES:

Remove luggage compartment floor trim panel
- Remove luggage compartment floor trim panel (1) in direction of arrow.
  
  Fig 1: Removing Luggage Compartment Floor Trim Panel
  Courtesy of BMW OF NORTH AMERICA, INC.
Disconnect battery ground cable
Prerequisite

Ignition switched off.

NOTE: For more information see NOTES FOR DISCONNECTING AND CONNECTING BATTERY .
- Slacken nut (1).
  NOTE: Risk of damage! Do not under any circumstances use force to pull off negative terminal.
- Pull off battery ground cable with IBS towards the top, put to one side and secure.
  
  Fig 2: Identifying Battery Ground Cable Nut
  Courtesy of BMW OF NORTH AMERICA, INC.
Removing the acoustic cover
- Raise acoustic cover (1).
- Remove acoustic cover (1) in the direction of travel.
  
  Fig 3: Identifying Acoustic Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove left intake silencer housing
- Unfasten clamp (1).
- Disconnect connector (2) at the hot film air mass meter.
- Loosen 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 4: Removing Intake Air Filter Housing
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove left charge air line
- Unfasten clamp (1).
- Unfasten clamp (2).
- Remove left charge air line (3).
  
  Fig 5: Identifying Left Charge Air Line And Clamps
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove right charge-air line
- Unfasten clamp (1).
- Unfasten clamp (2).
- Remove right charge air line (3).
  
  Fig 6: Identifying Right Charge-Air Duct And Clamps
  Courtesy of BMW OF NORTH AMERICA, INC.
Remove clean air pipe on left and right
NOTE: Description is for left component only. Procedure on the right side is identical.
- Pull off hoses (1) from clean air pipe.
- Loosen screw (2).
- Pull off clean air pipe (3) in direction of travel from turbocharger.
  
  Fig 7: Identifying Clean Air Pipe, Hoses, And Screw
  Courtesy of BMW OF NORTH AMERICA, INC.
KEY PROCESSES:
Remove fuel delivery 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.
NOTE: Risk of damage! Do not allow any dirt particles or foreign bodies to get into the system. Remove all traces of contamination before removing lines or separate components. Use only lint-free cloths. Seal all fuel system openings with protective caps or plugs. Introduced contaminants can cause malfunctions in the system.
- Unlock and disconnect fuel delivery line (1).
- Unlock connector (2) on fuel low-pressure sensor and disconnect.
- Loosen fuel delivery line (3) on high pressure pump.
- Unfasten screws (4).
- Catch and dispose of escaping fuel.
  
  Fig 8: Identifying Fuel Delivery Lines, Connector, And Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
- Seal fuel lines (1) and (2) with special tool (1) 0 496 565 (13 5 160) .
  
  Fig 9: Sealing Fuel Lines With Special Tools
  Courtesy of BMW OF NORTH AMERICA, INC.
- Loosen fuel delivery line (1) on high pressure pump.
- Catch and dispose of escaping fuel.
  
  Fig 10: Identifying Fuel Delivery Line At High Pressure Pump
  Courtesy of BMW OF NORTH AMERICA, INC.
- Loosen nuts (1) on retaining clips.
- Feed out and remove fuel feed line (2).
  
  Fig 11: Identifying Fuel Feed Line And Retaining Clip Nuts
  Courtesy of BMW OF NORTH AMERICA, INC.

Installing fuel delivery line

Feed in and position fuel delivery line (2).
Manually tighten nuts (1) on the retaining clips.

Fig 12: Identifying Fuel Feed Line And Retaining Clip Nuts
Courtesy of BMW OF NORTH AMERICA, INC.
Remove special tool (1) and (2) 0 496 565 (13 5 160) .

Fig 13: Sealing Fuel Lines With Special Tools
Courtesy of BMW OF NORTH AMERICA, INC.
Connect and lock fuel delivery line (1).
Connect connector (2) to fuel low-pressure sensor.
Manually tighten screws (4) on cylinder head.
Manually tighten fuel delivery line (3) to high pressure pump.

Fig 14: Identifying Fuel Delivery Lines, Connector, And Screws
Courtesy of BMW OF NORTH AMERICA, INC.
Manually tighten fuel delivery line (1) to high pressure pump.

Tighten fuel delivery line (1) to high pressure pump.

TIGHTENING TORQUES SPECIFICATION

Feed line to high pressure pump, cylinder head, retaining clip
M14, feed line to high pressure pump	Initial torque	10 Nm
Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque (retorque twice)	30 Nm
M6, feed line to cylinder head Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque	10 Nm
M6, feed line to retaining clip Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque	10 Nm

Fig 15: Identifying Fuel Delivery Line At High Pressure Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten fuel delivery line (3) to high pressure pump. Tighten screws (4) to cylinder head.

Fig 16: Identifying Fuel Delivery Lines, Connector, And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

TIGHTENING TORQUES SPECIFICATION

Feed line to high pressure pump, cylinder head, retaining clip
M14, feed line to high pressure pump	Initial torque	10 Nm
Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque (retorque twice)	30 Nm
M6, feed line to cylinder head Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque	10 Nm
M6, feed line to retaining clip Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque	10 Nm

Tighten nuts (1) to retaining clips of the feed line (2).

TIGHTENING TORQUES SPECIFICATION

Feed line to high pressure pump, cylinder head, retaining clip
M14, feed line to high pressure pump	Initial torque	10 Nm
Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque (retorque twice)	30 Nm
M6, feed line to cylinder head Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque	10 Nm
M6, feed line to retaining clip Manually tighten feed line to high pressure pump, cylinder head and retaining tab or loosen beforehand.	Final torque	10 Nm

Fig 17: Identifying Fuel Feed Line And Retaining Clip Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

POST PROCESSES:

Installing the clean air pipe on the left and right

NOTE: Description is for left component only. Procedure on the right side is identical.

Connect clean air pipe (3) to exhaust turbocharger.

Tighten down screw (2).

TIGHTENING TORQUES SPECIFICATION

Clean air pipe to exhaust turbocharger
M6	10 Nm

Connect hoses (1) of clean air pipe.

Fig 18: Identifying Clean Air Pipe, Hoses, And Screw
Courtesy of BMW OF NORTH AMERICA, INC.

Install left charge air line

Check gasket on exhaust turbocharger and renew if necessary.
Install left charge air line (3).

Tighten clamp (2).

TIGHTENING TORQUES SPECIFICATION

Charge air line to charge air cooler
Replace clamp	3, 5 Nm

Tighten clamp (1).

TIGHTENING TORQUES SPECIFICATION

Charge air line to exhaust turbocharger
Replace clamp	3, 5 Nm

Fig 19: Identifying Left Charge Air Line And Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

Install right charge air line

Check gasket on exhaust turbocharger and renew if necessary.
Install right charge air line (3).

Tighten clamp (2).

TIGHTENING TORQUES SPECIFICATION

Charge air line to charge air cooler
Replace clamp	3, 5 Nm

Tighten clamp (1).

Fig 20: Identifying Right Charge-Air Duct And Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

TIGHTENING TORQUES SPECIFICATION

Charge air line to exhaust turbocharger
Replace clamp	3, 5 Nm

Install left intake silencer housing

Connect intake silencer housing on intake port.
Clip oxygen sensor cable in on intake silencer housing.
Install clamp (3).
Connect connector (2) at the hot film air mass meter.

Tighten clamp (1).

TIGHTENING TORQUES SPECIFICATION

Clamp to air duct
	3 Nm

Fig 21: Identifying Clamps And Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Connecting the battery ground cable

NOTE: For more information see NOTES FOR DISCONNECTING AND CONNECTING BATTERY .

Position battery earth lead with IBS on negative terminal.

Tighten nut (1).

TIGHTENING TORQUES SPECIFICATION

Battery earth lead
M6	5 Nm

Fig 22: Identifying Battery Ground Cable Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Check function of DME.
Check fuel system for tightness
Check
- Check bolting points for tightness.
  desired state
- Result
  
  » leaks
  
  Measure
- Slacken all screw connections and perform tightening sequence again.
Install acoustic cover
- Insert acoustic cover (1) into existing rubber guides.
  
  Fig 23: Identifying Acoustic Cover
  Courtesy of BMW OF NORTH AMERICA, INC.
Install luggage compartment floor trim panel
- Place luggage compartment floor trim panel (1) in the direction opposite to arrow.
  
  Fig 24: Removing Luggage Compartment Floor Trim Panel
  Courtesy of BMW OF NORTH AMERICA, INC.