Procedure steps

SAFETY INSTRUCTIONS: 

SPECIAL TOOLS AND TIGHTENING TORQUES: 

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

• OVERVIEW OF SPECIAL TOOLS 
• OVERVIEW OF TIGHTENING TORQUES 

PRE-PROCESSES: 

Prerequisite 

Switch off the ignition

1. Remove rear underbody protection 
   • Unscrew all bolts.
   • Remove underbody protection (1).
     Fig 1: Locating Underbody Protection Screws

     Courtesy of BMW OF NORTH AMERICA, INC.
2. Release exhaust system from catalytic converter 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   • Unscrew nuts (1).
     Fig 2: Identifying Exhaust System To Catalytic Converter Nuts

     Courtesy of BMW OF NORTH AMERICA, INC.
   • Unscrew nuts (1).
   • Slacken nuts (2).
   • Lower exhaust system slightly at front.
     Fig 3: Identifying Nuts

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3. Remove the acoustic cover 
   • Raise acoustic cover (1) and remove in direction of travel.
     Fig 4: Removing/Installing Acoustic Cover

     Courtesy of BMW OF NORTH AMERICA, INC.
4. 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.
   • 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 5: Removing Air Intake Filter Housing

     Courtesy of BMW OF NORTH AMERICA, INC.
5. Remove right charge-air line 
   • Unfasten clamp (1).
   • Unfasten clamp (2).
   • Remove right charge air line (3).
     Fig 6: Identifying Right Charge Air Line And Clamps

     Courtesy of BMW OF NORTH AMERICA, INC.
6. Remove right clean air pipe 
   NOTE: Description is for left component only. Procedure on the right side is identical.
   • Pull off hoses (1) from clean air pipe.
   • Release 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.
7. Remove left control sensor 
   • Unlock plug connection and disconnect.
   • Unclip control sensor cable at retaining clips.
   • Release control sensor using special tool 0 491 074 (11 7 020)  and a reversible ratchet (1).
     Fig 8: Removing Control Sensor

     Courtesy of BMW OF NORTH AMERICA, INC.
8. Remove left monitoring sensor 
   • Release retaining clip (1).
   • Remove heat shield wire ring (2) over oxygen sensor.
   • Disconnect connector from oxygen sensor.
   • Detach oxygen sensor cable from retaining clips (3).
     Fig 9: Identifying Retaining Clip And Wire Ring

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   • Release monitoring sensor (1) with special tool 0 491 074 (11 7 020)  .
     Fig 10: Releasing Monitoring Sensor

     Courtesy of BMW OF NORTH AMERICA, INC.
9. Remove right control sensor 
   • Unlock plug connection and detach.
   • Release control sensor cable from retaining clips.
   • Release control sensor with special tool 0 491 074 (11 7 020)  .
     Fig 11: Removing Control Sensor

     Courtesy of BMW OF NORTH AMERICA, INC.
10. Remove right monitoring sensor 
    • Release retaining clip (1).
    • Remove heat shield wire ring (2) over oxygen sensor.
    • Disconnect connector from oxygen sensor.
    • Detach oxygen sensor cable from retaining clips (3).
      Fig 12: Identifying Wire Ring And Retaining Clip

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Release monitoring sensor (1) with special tool 0 491 074 (11 7 020)  .
      Fig 13: Releasing Monitoring Sensor Using Special Tool (11 7 020)

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11. Remove upper heat shield 
    • Loosen screws (1).
    • Lift out holder.
      Fig 14: Identifying Holder Screws

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    • Release screw (1).
      Fig 15: Identifying Screw

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    • Release screw (1).
      Fig 16: Identifying Screw

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    • Loosen screws (1).
      Fig 17: Identifying Screws

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    • Loosen screws (1).
    • Lift out heat shield.
      Fig 18: Identifying Heat Shield Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
12. Remove heat shield at bottom 
    NOTE: For purposes of clarity: Illustration shows removed condition.
    • Release screw (1) from heat shield (2) and (3).
      Fig 19: Identifying Heat Shield Screws

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    • Loosen screws (1) on left heat shield.
      Fig 20: Identifying Screws On Left Heat Shield

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    • Release screw (1) on right heat shield.
      Fig 21: Loosening Screw On Right Heat Shield

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    • Release screw (1) on heat shield at bottom right.
    • Unclip heat shield and remove.
      Fig 22: Releasing Heat Shield Screw At Bottom Right

      Courtesy of BMW OF NORTH AMERICA, INC.
13. Remove holder for left monitoring sensor 
    • Loosen screws (1).
    • Remove holder for monitoring sensor (2).
      Fig 23: Identifying Monitoring Sensor Holder And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
14. Remove catalytic converter for cylinders 5-8 
    • Release screw (1) on catalytic converter.
    • Release clamp (2) on catalytic converter.
      Fig 24: Identifying Catalytic Converter Clamp And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1).
    • Pull crankcase ventilation (2) from cylinder head cover.
    • Loosen screws (3) on holder.
      Fig 25: Identifying Crankcase Ventilation And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1) for rear catalytic converter for cylinders 5-8 from cylinder head.
    • Remove catalytic converter for cylinders 5-8.
      Fig 26: Identifying Rear Catalytic Converter Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
15. Remove holder for right monitoring sensor 
    • Loosen screws (1).
    • Remove holder for monitoring sensor (2).
      Fig 27: Identifying Monitoring Sensor Holder And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
16. Remove catalytic converter for cylinders 1-4 
    • Release screw (1) on catalytic converter.
    • Release clamp (2) on catalytic converter.
      Fig 28: Identifying Catalytic Converter Clamp And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1).
    • Pull hose (2) from cylinder head cover.
    • Loosen screws (3) on holder.
      Fig 29: Identifying Crankcase Ventilation And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Loosen screws (1) on rear catalytic converter for cylinders 1-4 from cylinder head.
    • Remove catalytic converter for cylinders 1-4.
      Fig 30: Identifying Rear Catalytic Converter Screws

      Courtesy of BMW OF NORTH AMERICA, INC.

    KEY PROCESSES: 

17. Remove vacuum pump 

    Prerequisite 

    Low pressure in brake servo must be removed. For that, press brake pedal several times.

    NOTE: Vacuum pump is fitted on cylinder head 1 to 4 at rear on intake camshaft.
    • Loosen screws (1).
    • Remove heat shield (2).
    • Remove vacuum hose.
      Fig 31: Identifying Heat Shield Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Bolts (1) are secured against falling out.
    • Loosen screws (1).
    • Release screw (2).
    • Remove vacuum pump (3).
      Fig 32: Identifying Vacuum Pump Bolts And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
18. Install vacuum pump 
    • Turn drive (1) in the right position before installation.
    • Renew sealing ring (2) and coat with grease to facilitate installation.
      Fig 33: Identifying Vacuum Pump Drive And Sealing Ring

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Align vacuum pump drive to groove (1) of intake camshaft.

      Vacuum pump can best be installed when groove (1) is vertically aligned.

      Fig 34: Aligning Vacuum Pump Drive To Groove Of Intake Camshaft

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Install vacuum pump (3).
    • Tighten screw (2).
    • Tighten screws (1).
      Fig 35: Identifying Vacuum Pump Bolts And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Mount heat shield (2).
    • Tighten screws (1).
    • Connect vacuum hose.
      Fig 36: Identifying Heat Shield Screws

      Courtesy of BMW OF NORTH AMERICA, INC.

    POST PROCESSES: 

19. Install catalytic converter for cylinders 1-4 
    • Position catalytic converter for cylinders 1-4.
    • Tighten screws (1) on rear catalytic converter for cylinders 1-4 to cylinder head.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Catalytic converter to cylinder head
      M8	21 Nm

      Fig 37: Identifying Rear Catalytic Converter Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screws (3) on holder.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder of catalytic converter to cylinder head
      M8	21 Nm

    • Position hose (2) on cylinder head cover.
    • Tighten down screws (1).
      Fig 38: Identifying Crankcase Ventilation And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Crankcase ventilation to cylinder head cover
      M6	10 Nm

      NOTE: Clamp (2) must be installed with screw pointing inwards. Otherwise, heat shield can no longer be installed on top.
    • Tighten new clamp (2) on catalytic converter.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Catalytic converter to turbocharger
      Replace clamp	13 Nm

    • Tighten screw (1) on catalytic converter.
      Fig 39: Identifying Catalytic Converter Clamp And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder of catalytic converter to catalytic converter
      M8	21 Nm

      » Ends of clamp must rest parallel to each other.

      Fig 40: Identifying Correct Position Of V-Band Clamp Ends

      Courtesy of BMW OF NORTH AMERICA, INC.

    If there is a gap between ends of clamp, bolted connection must be loosened and repeated.

    Fig 41: Identifying Improper Screw Connection Of V-Band Clamp - Too Loose

    Courtesy of BMW OF NORTH AMERICA, INC.

    » If ends of clamp are positioned beneath each other, bolted connection must be released and repeated.

    Fig 42: Identifying Improper Screw Connection Of V-Band Clamp - Too Tight

    Courtesy of BMW OF NORTH AMERICA, INC.
20. Install holder for right monitoring sensor 
    • Position holder for monitoring sensor (2).
    • Tighten down screws (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder for monitoring sensor to cylinder head cover
      M6	10 Nm

      Fig 43: Identifying Monitoring Sensor Holder And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
21. Install catalytic converter for cylinders 5-8 
    • Position catalytic converter for cylinders 5-8.
    • Tighten screws (1) on rear catalytic converter for cylinders 5-8 to cylinder head.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Catalytic converter to cylinder head
      M8	21 Nm

      Fig 44: Identifying Rear Catalytic Converter Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screws (3) on holder.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder of catalytic converter to cylinder head
      M8	21 Nm

    • Position crankcase ventilation (2) on cylinder head cover.
    • Tighten down screws (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Crankcase ventilation to cylinder head cover
      M6	10 Nm

      Fig 45: Identifying Crankcase Ventilation And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
      NOTE: Clamp (2) must be installed with screw pointing inwards. Otherwise, heat shield can no longer be installed on top.
    • Tighten new clamp (2) on catalytic converter.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Catalytic converter to turbocharger
      Replace clamp	13 Nm

      Fig 46: Identifying Catalytic Converter Clamp And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screw (1) on catalytic converter.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder of catalytic converter to catalytic converter
      M8	21 Nm

      Ends of clamp must rest parallel to each other.

      Fig 47: Identifying Correct Position Of V-Band Clamp Ends

      Courtesy of BMW OF NORTH AMERICA, INC.

      » If there is a gap between ends of clamp, bolted connection must be released and repeated.

      Fig 48: Identifying Improper Screw Connection Of V-Band Clamp - Too Loose

      Courtesy of BMW OF NORTH AMERICA, INC.

      If ends of clamp are positioned beneath each other, bolted connection must be released and repeated.

      Fig 49: Identifying Improper Screw Connection Of V-Band Clamp - Too Tight

      Courtesy of BMW OF NORTH AMERICA, INC.
22. Install holder for left monitoring sensor 
    • Position holder for monitoring sensor (2).
    • Tighten down screws (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder for monitoring sensor to cylinder head cover
      M6	10 Nm

      Fig 50: Identifying Monitoring Sensor Holder And Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
23. Install heat shield on the bottom 
    NOTE: For purposes of clarity: Illustration shows removed condition.
    • Position heat shield and clip it in.
    • Tighten screw (1) on heat shield at bottom right.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 51: Releasing Heat Shield Screw At Bottom Right

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screw (1) on right heat shield.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 52: Loosening Screw On Right Heat Shield

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screws (1) on left heat shield.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 53: Identifying Screws On Left Heat Shield

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screw (1) from heat shield (2) and (3).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 54: Identifying Heat Shield Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
24. Install heat shield, top 
    • Position heat shield.
    • Tighten down screws (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 55: Identifying Heat Shield Screws

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

      Heat shield to heat shield
      M6	10 Nm

      Fig 56: Identifying Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screw (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 57: Identifying Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten screw (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Heat shield to heat shield
      M6	10 Nm

      Fig 58: Identifying Screw

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

      Holder for acoustic cover to cylinder head cover
      M6	10 Nm

      Fig 59: Identifying Holder Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
25. Install right monitoring sensor 
    NOTE: Risk of damage! Part of oxygen sensor that projects into exhaust branch (sensor ceramics) must not be cleaned or coated with lubricant.
    • Coat thread of control sensor thinly and evenly with NEVER-SEEZ COMPOUND .
    • Tighten monitoring sensor (1) with special tool 0 491 074 (11 7 020)  .
      TIGHTENING TORQUE SPECIFICATION
      
      

      Monitoring sensor to engine
      M18 x 1, 5	50 Nm

      Fig 60: Releasing Monitoring Sensor Using Special Tool (11 7 020)

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Position heat shield wire ring (2) over oxygen sensor.
    • Lock retaining clip (1).
    • Connect connector of oxygen sensor.
      NOTE: Risk of damage! Make sure cables are routed correctly and without abrasion.
    • Lock oxygen sensor cable in retaining clips (3).
      Fig 61: Identifying Wire Ring And Retaining Clip

      Courtesy of BMW OF NORTH AMERICA, INC.
26. Install right control sensor 
    NOTE: Risk of damage! Part of oxygen sensor that projects into exhaust branch (sensor ceramics) must not be cleaned or coated with lubricant.
    • Coat thread of control sensor thinly and evenly with NEVER-SEEZ COMPOUND .
    • Tighten control sensor using special tool 0 491 074 (11 7 020)  and a torque wrench (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Control sensor to engine
      M18 x 1, 5	50 Nm

      Fig 62: Removing Control Sensor

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect connector of control sensor.
      NOTE: Risk of damage! Make sure cables are routed correctly and without abrasion.
    • Lock control sensor cable in retaining clips.
27. Install left monitoring sensor 
    NOTE: Risk of damage! Part of oxygen sensor that projects into exhaust branch (sensor ceramics) must not be cleaned or coated with lubricant.
    • Coat thread of monitoring sensor thinly and evenly with NEVER-SEEZ COMPOUND .
    • Tighten monitoring sensor (1) with special tool 0 491 074 (11 7 020)  .
      TIGHTENING TORQUE SPECIFICATION
      
      

      Monitoring sensor to engine
      M18 x 1, 5	50 Nm

      Fig 63: Releasing Monitoring Sensor

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Position heat shield wire ring (2) over monitoring sensor.
    • Lock retaining clip (1).
    • Connect connector of monitoring sensor.
      NOTE: Risk of damage! Make sure cables are routed correctly and without abrasion.
    • Lock monitoring sensor cable in retaining clips (3).
      Fig 64: Identifying Retaining Clip And Wire Ring

      Courtesy of BMW OF NORTH AMERICA, INC.
28. Install left control sensor 
    NOTE: Risk of damage! Part of oxygen sensor that projects into exhaust branch (sensor ceramics) must not be cleaned or coated with lubricant.
    • Coat thread of control sensor thinly and evenly with NEVER-SEEZ COMPOUND .
    • Tighten control sensor using special tool 0 491 074 (11 7 020)  and a torque wrench (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Control sensor to engine
      M18 x 1, 5	50 Nm

      Fig 65: Removing Control Sensor

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Connect connector of control sensor.
      NOTE: Risk of damage! Make sure cables are routed correctly and without abrasion.
    • Lock control sensor cable in retaining clips.
29. Install right clean air pipe 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Connect clean air pipe (3) to exhaust turbocharger.
    • Tighten screw (2).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Clean air pipe to exhaust turbocharger
      M6	10 Nm

    • Connect hoses (1) of clean air pipe.
      Fig 66: Identifying Clean Air Pipe, Hoses And Screw

      Courtesy of BMW OF NORTH AMERICA, INC.
30. Install right charge air line 
    • Check gasket on exhaust turbocharger and renew if necessary.
    • Install right charge air line (3).
    • Tighten clamp (2).
      TIGHTENING TORQUE SPECIFICATION
      
      

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

    • Tighten clamp (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

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

      Fig 67: Identifying Right Charge Air Line And Clamps

      Courtesy of BMW OF NORTH AMERICA, INC.
31. 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 SPECIFICATION
      
      

      Clamp to air duct
      3 Nm

      Fig 68: Identifying Connector And Clamps

      Courtesy of BMW OF NORTH AMERICA, INC.
32. Install acoustic cover 
    NOTE: Ensure correct fit!
    • Insert acoustic cover (1) into existing rubber guides.
      Fig 69: Identifying Acoustic Cover

      Courtesy of BMW OF NORTH AMERICA, INC.
33. Renew gasket for catalytic converter 1-4 and catalytic converter 5-8 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Clean sealing surfaces.
    • Replace gasket (1).
      Fig 70: Identifying Gasket

      Courtesy of BMW OF NORTH AMERICA, INC.
34. Connect exhaust system to catalytic converter 
    NOTE: Description is for left component only. Procedure on the right side is identical.
    • Position exhaust system on catalytic converter.
    • Tighten down nuts (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Exhaust system to catalytic converter
      M8	20 Nm
      Replace nuts

      Fig 71: Identifying Exhaust System To Catalytic Converter Nuts

      Courtesy of BMW OF NORTH AMERICA, INC.
    • Tighten down nuts (2).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder of exhaust system to exhaust system
      M8	22 Nm

    • Tighten down nuts (1).
      TIGHTENING TORQUE SPECIFICATION
      
      

      Holder of exhaust system to transmission
      M8	22 Nm

      Fig 72: Identifying Nuts

      Courtesy of BMW OF NORTH AMERICA, INC.
35. Install underbody protection at rear 
    NOTE: Ensure correct fit!
    • Position underbody protection (1).
    • Tighten down all screws.
      TIGHTENING TORQUE SPECIFICATION
      
      

      Rear underbody protection to body
      Screw	0 3 Nm
      Nut	2.5 Nm

      Fig 73: Locating Underbody Protection Screws

      Courtesy of BMW OF NORTH AMERICA, INC.
36. Check function of DME. 
37. Check vacuum pump for leaks and correct operation.